BHARAT

ALUMINIUM COMPANY LTD.

KORBA-CG
GROWTH PROJECT

Vehicle Movement, Loading & Unloading Safe Procedure

BALCO-GP-HSES-SOP-002

Rev Date Revision List Prepared Checked Approved

This document confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of
BALCO. The copyright f this document is vested in Bharat Aluminium Company Ltd. All rights reserved. Neither the whole nor any part of this document
may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise)
without the prior written consent of the copyright owner.

1. INTRODUCTION

Purpose

This procedure identifies the measures to be taken to ensure safe procedure for movement of heavy
vehicle including loading, unloading and shifting that takes place are performed in accordance with
relevant legislation and safe working practices. The safety of all personnels such cases shall be
primary and mandate strict compliance with these procedure for Heavy vehicle movement including
loading unloading and shifting.

Scope
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This procedure applies to all employees, contractor employees, vehicle operators and other personnel
involved in the heavy vehicle operations of all type of vehicles involved in BALCO Growth project
activities.

2. REFRENCE
 BALCO HSE & SUSTAINIBILITY GUIDE
 BALCO VSS STANDARDS
 BALCO GUIDANCE NOTES
 BALCO VEHICLE ENTERING SOP

3. RESPONSIBILITIES

Supervisor/person in charge

It is the responsibility of the Supervisor or person in charge to:

 Ensure all the vehicles involved in the project activity shall be moved safely.
 Shall demonstrate the personal commitment of his engineers, workers towards implementation of
HSE targets.
 Shall implement the requirements of the client safety policy towards vehicle safety.
 Shall manage supervisory structure with in their respective sections to ensure that the detailed
requirements of the Client and Company.
 Shall ensure that pre-inspection checklist to be filled before starting of the vehicle.
 Shall continuously review Health and Safety performance with in his sections to ensure that
performance targets are being achieved.
 Shall ensure that Tool Box talks conducted at his site regularly.
 Shall participate in Risk Assessments / JSA before starting of job and control measures are
communicated to the persons responsible for supervising and executing the work.

Vehicle Operators

Vehicle Operator responsibilities include:

 all operators to comply with this procedure;

 to ensure a spotter is in place as set out in this SOP;
 to ensure that any specific loading requirements are passed on to the supervisor in charge
of loading;
 to follow mandatory PPE requirements including wearing gloves when undertaking
manual handling tasks including securing the load;
 to report any hazards or incidents to supervisor;
 Ensure loads are appropriately restrained when entering and exiting the project area.

4. VEHICLE GATE PASS PROCEDURE.

 Ensure all the vehicles entering to the plant must undergoes the screening procedure as per
BALCO policy.
 All the vehicles & Equipment must comply to BALCO HSES standard.
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 Vehicle gate procedure must be followed as per SOP shared by road safety wing.
 No any technological vehicle shall be allowed to enter in to plant in one day gate pass
procedure.
 For one day pass of All the heavy vehicles except technological vehicle, the following
criteria must be followed.
 All the one day pass vehicle must enter in to one day pass after proper approval from HOD.
Drivers training must be ensured.
5. PPE AND SAFETY EQUIPMENT

 All the persons are required to follow mandatory PPE requirements.

 All employees & operators involved in the loading and unloading activity must wear
appropriate gloves, unless they are operating equipment e.g. crane, truck or forklift.
 Stairs or platforms are to be used to access truck or trailer decks when rigging/unrigging
loads.
 Appropriate equipment such as traffic cones, flags and/or bollards, are to be used to mark the
exclusion zone around the work area and safe zones. For example, red/orange traffic cones for
work/exclusion zones.

6. SAFE HANDS APPROACH

To comply with safe hands approach, the hierarchy of risk controls is to be applied when planning
tasks e.g. consider if a Hyva or Excavator or a crane, hydra, or tag lines can be used prior to using
hands (with gloves). In addition, consideration must be given to the potential stored energy of the
object being used..

If a task is unable to be completed hands off, this should be discussed during the prestart at the
beginning of the work. In the event an unplanned task requires the use of hands, the individual must;

 Conduct a step back 2x2 meter.

 Seek approval from the Supervisor prior to handling the load
 If it is deemed safe to do so, proceed with handling the load; and
 If it is deemed unsafe, stop the job until the task can be made safe.

When touching the load the safe hands approach must be used which includes;

 Keeping hands flat and fingers spread

 Not gripping the load to minimize the opportunity for fingers to be caught or crushed
 Keeping hands between chest and eye level; and
 Keeping hands, feet & body parts clear of pinch/crush points.

7. STOP WORK AND HAZARD AND INCIDENT REPORTING

All employees and workers have the right to stop the job if they believe there is an unsafe situation,
condition or that an unsafe act is being performed.

Except when there is an immediate risk of injury or harm, the stop work should be coordinated
through the supervisor or manager. A Stop Work Order will only be lifted by the person in charge of
the work following an appropriate review and implementation of any remedial action necessary to
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undertake and complete the work safely.

If you identify a hazard:

 if possible remove or eliminate the hazard;

 make the work area safe e.g. barricades, tag out;
 alert your colleagues;
 report it to you supervisor;
 that is not able to be resolved and you are still exposed to an unsafe situation then stop the
work
 report the hazard

8. PRIOR TO COMMENCING THE WORK

Daily Inspection - pre driving checks

Before driving heavy vehicle all drivers must conduct a daily inspection. In very limited
circumstances, there may be an urgent need to use the vehicle without carrying out a daily inspection
(e .g . urgent assistance, a person's life in danger, etc.). In such circumstances, once the initial threat
has been dealt with, the daily inspection must be carried out before any further use of the vehicle .
The purpose of the daily inspection is to ensure that the vehicle is in a safe condition to drive and that
any unreported damage is recorded . It is an individual's responsibility as the driver of the vehicle to
carry out the checks.

Traffic Management

A traffic management plan for the task is to be discussed between the involved parties, for example at
a toolbox talk, prior to loading and unloading. All the persons involved in the programme must attend
the TBT. The traffic management plan will be discussed and appropriate controls to be implemented,
including traffic cones designating specific work areas and safe zones. Ensure the work area well
segregated for man and machineries movement.

Flagman

The need of a flagman may be identified as part of the traffic management plan, for a specific task,
 When trucks are reversing:
 when there is overcrowding or simultaneous operations such as multiple work zones,
vehicle movements or personnel;
 when the drivers vision is obstructed; or

The flagman could be a competent & trained person. Reversing alarms must be installed and in good
working order on all trucks. In addition, it is recommended that truck trailers have reversing beepers.
Also ensure all the trucks or vehicles must have reversing camera and in working condition.

9. GENERAL LOADING AND UNLOADING & SHIFTING PROCEDURE SAFETY

CHECKS
 Never stand under the load;
 Be aware of pinch points and crush hazards during the loading and unloading process. Keep
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hands away from truck trailer during loading and unloading and avoid touching the load with
your hands while it is moving or suspended. Utilizing hands free tools and tag lines for
assisting load control is appropriate and where required to touch the load, use the safe hands
approach;
 Truck drivers are not to walk into the work area during material handling operations unless
authorized by job supervisor.
 drivers must stay in the safe zone, for example next to the cab, until the load has been loaded
or unloaded and/or the truck driver has been authorized to leave the safe zone by the job
supervisor.
 Truck drivers to remain with their vehicles unless there is an operational requirement to do
otherwise;
 If trucks are required to reverse, ensure flagman with whistle.
 Trucks may be loaded and unloaded either by cranes and/or hydra.
 Loading/unloading activity to be performed by competent persons only.
 Unauthorized person must not stand on truck trailers during placement or removal of loads by
cranes or hydra. Access to truck trailers should be avoided where possible and only occur
with the authorization of the supervisor/person in charge.
 If the sling is unable to be accessed from the ground, stairs or a platform to be provided, then
the load is to be freed.
 Avoid working under line of fire.
 Ensure no person sitting inside of the trailer driver room during loading of dismantled
material in the trailer.
 Provide wheel jammer while loading and unloading of the materials in t the trailers.
 Don’t overload the trailer. Load materials that are lower than the rated capacity of the trailer.
 Use of leather hand gloves by the workers must be ensured.
 All the material shall be shifted with tailor of sufficient length to avoid from falling objects.
 All material to be tie-up properly with end stopper / roll over protection.
 Material transportation activity to be performed in day light only.
 Proper ladder to be provided to approach on the tailor bed platform.
 Suitable length of trailer shall be arranged according to length of dismantled structure.
 Speed limit shall be maintained (not exceeding 30 KM/H)
 Overtaking, reverse / rash driving shall be strictly prohibited.
 Flagman shall be assigned with trailer wherever required.
 Traffic signs and regulation shall be strictly followed while transporting materials.
 Installed red flag if any part of piping materials equipment is protruding outside trailer.
 Ensure that Structural material is properly secured/tied on the trailer.
 Access route shall be surveyed before transporting of material.
 Road survey shall be carried out to ensure the existing road condition.
 Ensure the length of the flat bed trailer is adequate for transportation of materials
 All the material shall be shifted with tailor of sufficient length to avoid from falling objects.
 Extra precautions shall be taken where overhead utility line or electrical line is there.
 All material to be tie-up properly with end stopper / roll over protection.
 Material transportation activity to be performed in day light only.
 Use leather gloves for hand protection.
 Keep away body parts (hand, feet, head, etc) from the line of fire (LOF).

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 Proper ladder to be provided to approach on the trailer bed platform.

 Trained and competent riggers shall be engage in loading and unloading activities.
 All the operators should undergo mandatory training as per BALCO standard before
deployment at site.
 Remove all the obstructions or Paste reflectors in the obstructions coming on the way of the
vehicle movement.
 Ensure man-machinery segregation in the vehicle movement way.
 Only identified route to be used. Unloading point must be displayed with entry/exit signage
boards for identification of route.
 PTW system to be followed at dumping site by competent person.
 Supervisor and signal man must be always present at dumping yard while unloading of soil.
 Only identified route to be used.
 Trip register to be maintained at unloading point to track the soil is dumped at the designated
unloading point only.

10. SAFE PRACTICE FOR TRUCK DRIVERS

Personal protective equipment -Hardhat and high-visibility clothing to be worn when not inside the
cab. Safety boots in good condition, properly laced, must be worn at all times. Worn-out soles and
heels could lead to slips and falls.
Eye protection will be worn where there is danger of falling or flying debris from equipment or loads,
especially in windy conditions.
Hand protection will be worn when handling cable or any other material where there is danger of cuts
or puncture injury.
Hearing protection will be worn when exposed to noise levels exceeding 85dBA.

Mounting and dismounting – three-point contact will be used to mount and dismount equipment.
Inspection and repairs – trucks will be inspected prior to use to ensure good mechanical condition.
When working under or around trucks, for inspections or repairs, the truck must be locked and tagged
out, and immobilized and secured against inadvertent movement.
Housekeeping – cabs, steps, windows, windshields, and mirrors must be kept clean at all times. All
debris should be removed from truck and trailer.
Parking – the truck must be parked on level ground, clear of hazards, to allow ease of access. Ensure
key must be takeoff from the starting point before leaving the seat. Wheel chocks must be installed.
Travelling – proper gear selection must be used to maintain control. Drive according to terrain
conditions. Drivers are responsible for load security.
Danger zone – danger zone is defined as the area around operating machines or working personnel, in
which there is potential for being struck by moving equipment or objects. The danger zone may vary
according to the machine or work being performed. Operators must make sure that all persons,
vehicles and equipment are clear of the danger zone before the vehicle or its components are moved.
Lockout – lockout procedures must be followed during mechanical service, repairs or inspection for
the protection of employees and equipment.
Refer to company and manufacturer’s procedures on lockout.
Communications while assisting in mechanical repairs – When operators are assisting mechanics
to repair machines, clear communications must be established prior to starting the tasks. The operator
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and the mechanic must each know who will be responsible for:
a) Starting or moving a machine

b) Ensuring that anyone involved is in a clear and safe position

c) Directing the movement of the machine

d) Ensuring that it is safe to resume working and that all guards are in place.

The operator must have a clear understanding of what is to be done and follow the specific lockout
instructions and instructions given by the mechanic responsible for performing the job.
Fueling – shut off the engine while fueling. No smoking. Be aware of slip and trip hazards.
Beware of spills and splash-back. Return hose to its proper storage position when fueling completed.
Follow refueling SOP
Hazardous materials – read WHMIS label. If there is no label, contact the supervisor. Refer to
MSDS if further information is needed.
Use protective equipment and follow safe handling instructions as outlined on WHMIS label.
If an incident occurs, follow first aid instructions.
Use proper storage procedures.
Trailer hook-up – When hooking up to a trailer, check fifth wheel to see if jaws are open, hook up
air hoses, and set brakes on trailer, hook up and be sure the fifth wheel jaws are locked and the safety
pin is secured and keyed. Check trailer dollies and be certain they are in up position.
Truck must have flags, long/wide load signs and load permits where necessary. Unit must not be
moved until air pressure is built up in tank and brakes are tested. Brakes on empty vehicles still have
all the power necessary for a full load, so brake with extra care – is easy to over brake.
Working on top of load – wear appropriate fall protection equipment if working at a height of 1.8
metres and above

Fatigue Management There are numerous hazards that directly impact our level of fatigue and the
resulting increased risk of accident or injury.
These include, but are not limited to:
• Poor or insufficient sleep
• Poor diet
• Mental exhaustion
• Physical exhaustion
• Driving tired
• Feeling unwell

The following control measures shall be consider to overcome from fatigue while working.

 The Heavy vehicles activities in Project Area are being operated in General shift as well as
round the clock divided in 3 shifts with separate set of drivers depending on the activity
schedule.
 No such Job performed by vehicle drivers in which they feel fatigue, because there is no
continuous operating of vehicles. The Heavy vehicle activities are being halted during No-
Entry Timing and Lunch/Snacks and Tea Timing, described as follows,

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SI. No. Lunch/Snacks and Tea Timing No-Entry Timing

1 07:00 to 08:00 05:45 to 06:15
2 10:30 to 11:00 08:15 to 08:45
13:00 to 14:00
3 13:45 to 14:15
(only for General shift drivers)
4 15:30 to 16:00 17:15 to 17:45
5 17:30 to 17:45 21:45 to 22:15
6 00:30 to 01:00 -
7 03:30 to 04:00 -

 The Heavy vehicles are operated in batches for transportation of Loading / Unloading of
material.
 While loading / unloading of bags/materials using Hydra, Trailer / Dumper driver remains idle.
 While Transportation of coal / material using a Loaded / Unloaded Trailer / Dumper, Hydra driver
remains idle.
 No Over time is allowed for a vehicle driver after “C” shift.
 Consider fitness to drive to and from work and make alternative arrangements where required.
 Postpone critical work where high-levels of concentration and/or judgment is required.
 Maintain a fatigue management register for each driver to track the record of vehicle driving
separately.

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