Maaden Safety - Contractor Ehs Requirements

Contractor EHS
Requirements
Table of Contents
1. Purpose 4
2. Scope 4
3. Definitions 4
4. References 5
4.1. Ma’aden Aluminium EH&S Policy 5
4.2. Government Acts and Regulations 5
4.3. Ma’aden Aluminium Environmental, Health & Safety Policies and
Procedures 5
5. Work Description 5
5.1. General Site Rules 5
5.2. Contractor and Sub-Contractor Responsibilities 6
5.3. Personal Protection Equipment 7
5.4. Confined Space Entry Program 8
5.5. Electrical 10
5.6. Overhead Power lines 12
5.7. Generators and Welding Machines 14
5.8. Barricade Procedure 15
5.9. Fall Prevention/Working at Heights Procedure 16
5.10.Elevating Work Platform (EWP) or Boom lift Procedure 17
5.11.Safe Loading and Unloading of Trucks 17
5.12.Grating or Chequerplate removal and Installation 17
5.13.Portable ladders. 18
5.14.Scaffolds and Scaffolding 19
5.15.Workboxes and Lift Boxes 20
5.16.Excavation Trenching and Shoring Procedure (and Permit To Dig) 20
5.17.Formwork and Shoring 21
5.18.Mobile Equipment 21
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5.19.Site Restrictions 23
5.20.Heavy Mobile Equipment site access 25
5.21.Lockout Tag Out Verification 26
5.22.Chemical Exposure 27
5.23.Machinery/Plant Equipment 28
5.24.Lifting Equipment 33
5.25.Significant Lifts 35
5.26.Hot Work 36
5.27.Fire Protection 39
5.28.Site Facilities 39
5.29.Health 41
5.30.Molten Metal 43
5.31.Hazardous Materials 43
5.32.Site Access 46
5.33.Environment 47
5.34.Attachment 1 52

1. Purpose
1.1. All contractors and their employees are expected to understand, promote and
assist in the implementation of Ma’aden Aluminium Environmental, Health and
Safety (EHS) Values, Policies and Principles, and to comply with all applicable
EHS rules and regulations.
1.2. This document describes the minimum requirements of Contractors,
Subcontractors and Contract Service providers to ensure that the appropriate
EHS Values, Policies and Principles are implemented and maintained during
all phases of work or contracted service.
2. Scope
2.1. This plan applies to all contractors and sub-contractors, service provider and
their employees working within Ma’aden Aluminium Facility.
2.2. Its prime purpose is to provide information relating to the Environmental
Health and Safety standards and the EH&S behaviors required from the
Contractor, Subcontractors or Contract Service provider (herein known as the
Contractor) while performing work at Ma‘aden Aluminium sites. This
document also outlines the administrative requirements for
contracts/contracted services.
3. Definitions
3.1. Acceptable: signifies that the Contractor’s methods and/or materials must be
acceptable to Ma’aden Aluminium.
3.2. Approved: Signifies that Ma’aden Aluminium must approve the exact details
of the Contractor’s methods and/or materials.
3.3. Competent person: Means a person who is appointed or designated by the
employer to perform specific duties, which the person is qualified to perform
by knowledge, training and experience.
3.4. Contractor: Describes entities or employees or contractors of entities that
perform activities or services governed by a contractual arrangement for
Ma’aden Aluminium.
3.5. Contracted Services: Are on-site activities such as security, janitorial,
cafeteria, uniform delivery, lawn care, garbage disposal, pest control, vending,
engineering, design, training, consulting, or other professional services not
directly controlled or supervised by Ma’aden Aluminium employees.
3.6. Hazard Assessment: the identification of all existing or potential risks,
hazards and environmental pollution control issues associated with the
location and/or the work, which may need to be abated or controlled through
the implementation of the Permit to Work Program to ensure the safe
completion of the scope of work.
3.7. Incident - Any event resulting in an injury, illness, major injury-free event or
environmental release.

3.8. May: Signifies an action, which is optional.
3.9. Ma’aden Aluminium: Is Ma’aden Aluminium and its subsidiaries and covers
all Ma’aden Aluminium employees or its agents involved in administering the
Contractor’s work.
3.10. Shall: Signifies a mandatory action required (by Ma’aden Aluminium or the
Contractor.)
3.11. Site: Is defined to include the operating area currently being utilized by the
Principal for its mining, refining, administration, storage shipping or other
business activities within the various locations.
3.12. SPA: Single Point Accountable person.
3.13. Sub-Contractor: Describes entities or employees of entities that perform
activities or services governed by a contractual arrangement between a
Contractor and the entity and who is not directly controlled or supervised by
Ma’aden Aluminium employees. Subcontractors must comply with the same
requirements as Contractors.
4. References
4.1. Ma’aden Aluminium EH&S Policy
It is Ma’aden Aluminium’s policy to operate worldwide in a safe, responsible
manner, which respects the environment and the health of employees,
customers and the communities in which it operates. Ma’aden Aluminium shall
not compromise environmental, health or safety values for profit or production.
4.2. Government Acts and Regulations
The Contractor shall comply with all applicable requirements, which includes
Royal Commission, PME, SASO and HCIS regulations.
4.3. Ma’aden Aluminium Environmental, Health & Safety Policies and
Procedures
To assist the contractor, the following set of safety policies and procedures
applicable to individual sites are available as a reference. The Contractor shall
comply with these practices in the performance of site work.
As a minimum, this document provides the summary of the key areas of the
particular standards which everyone working on a Ma‘aden Aluminium site
must comply with. Where a contractor requires more details on Ma‘aden
Aluminium Programs, they shall request this from the procurement
representative. The Contractor is responsible for ensuring that all relevant
programs and procedures are complied with during the execution of
contracted work.
5. Work Description
5.1. General Site Rules
Contractors, Subcontractors and their employees shall observe the following
site rules.
a) Each responsible person at a Ma’aden Aluminium site must ensure that
competent persons as defined by the relevant legislation carry out work
at the facility.
b) Cameras are not permitted to be taken onto site unless authorized by
c) Authorization requires a signed permit being obtained from Ma’aden
Aluminium, and being carried by the permit holder.
d) Intoxicating liquor (including alcohol) or drugs (other than prescribed by a
medical doctor) shall not be allowed on site. Persons under the apparent
influence of drugs or intoxicating liquor shall not be permitted entry to the
site.
e) Firearms/offensive weapons shall not be permitted.
f) Gambling, horseplay and fighting is not permitted.
g) Abuse, theft or destruction of another person’s property, is an offence
and is liable to be treated by the law enforcement authorities as such.
h) Subject to the Contract, all damage to plant, utilities and structures of
Ma’aden Aluminium or others, caused by the Contractor shall be made
good at the Contractor’s expense. Should the Contractor fail to carry out
repairs in a reasonable time Ma’aden Aluminium may carry out the
repairs and the costs shall be charged to this Contractor.
i) Contractor’s employees shall not take items, other than essentials such
as toolboxes, onto the Plant site. All such items may be subject to
inspection by Ma’aden Aluminium Security personnel, both upon
entering and leaving the plant site.
j) It is essential that persons wishing to visit the Contractor do so at the
Contractor’s site office. If it becomes necessary for a visitor to enter the
plant site the Contractor shall apply to Ma’aden Aluminium for a Visitors
Pass.
5.2. Contractor and Sub-Contractor Responsibilities
a) The Contractor shall be responsible for the safety of its own employees
as well as the safety of all its Subcontractor’s employees. To this end,
the contractor is responsible for ensuring that there is adequate
supervision at all times and that their processes cover as a minimum the
requirements as outlined in the Contractor Supervision Criteria
Document.
b) The contractor and sub-contractor line management including supervisor
and foreman shall directly be involved in the contractor‘s responsibilities
for the safety and health of all personnel at the work site and for making
safety and health compliance a part of all work assignments.
c) If the main contractor plans to utilize a subcontractor for part of any
works, the main contractor shall submit a request to Ma’aden Aluminium
for approval prior to any subcontractor commencing work on any of
Ma’aden Aluminium sites. The submission shall include a “Safety Pre-
Qualification” on the sub-contractor, and subject to the result, approval
shall be granted for the subcontractor to perform work on a Ma’aden
Aluminium site.
d) Contractor shall identify a SPA for EHS communication purpose. The
EHS SPA shall be fluent in spoken and written English.
e) Assigned EHS SPA or EHS staff shall prepare and submit the
weekly/monthly EHS statistics as per attachment 1 format.
f) Contractor shall provide full time, on site, qualified safety staffs in
accordance with table below:
1 safety supervisor for every 50 contract
Normal activities
employees, in excess of 50 on-site employees
1 safety supervisor for every 30 contract
Night shift work
employees, in excess of 30 on-site employees
Turnaround, maintenance and high- 1 safety supervisor for every 15 contract
risk activities. employees, in excess of 15 on-site employees
In Addition
More than 50 contractor work force Safety Manager and 1 trainer
Safety Manager, trainer, engineer and
More than 100 contractor work force
supervisors per ratio above.
g) Assigning EHS staffs shall be fluent in spoken and written English and
shall have a relevant experience in EHS field.
h) The EHS staffs positions shall fill prior to commencement of on-site work
and staffs shall remain filled until completion of work scope.
i) Prior to mobilizing contractor safety staffs, the Ma‘aden Aluminium EHS
shall screen the staffs, if required, the Ma‘aden Aluminium may also take
a written examination.
j) The Ma‘aden Aluminium EHS reserve the right to require the contractor
replace the any EHS staffs whose work is deemed unacceptable by the
Ma‘aden Aluminium.
k) The Ma‘aden Aluminium EHS reserve the right to require the contractor
to provide additional safety, health and environmental specialist where
special technical expertise is required.
l) Under normal circumstances, including construction activities, all of
Ma’aden Aluminium operations fall under the jurisdiction of HCIS for Fire,
Emergency Response, Safety and Security. The Ras Al Khair Facility
will also fall under the jurisdiction of the Royal Commission and the Al
Ba‘itha Mine site will fall under the Jurisdiction of the PME.
5.3. Personal Protection Equipment
a) The Contractor shall ensure that, as a minimum, the following personal
protective equipment (where mandated) is provided, maintained and
worn by all employees working on site.
Safety helmet.

Eye protection: Safety glasses or monogoggles based on site
requirements and risk assessment for the type of work.
Long sleeve shirt and long trousers or overalls.
Safety footwear (minimum six inch height, steel toe type boots)
areas may have special requirements such as electrically rated
boots for smelter or static dissipating boots for coil coating line.
Other specific equipment, e.g. gloves, ear protection, leather
aprons, sun protection, etc shall be provided as required to safely
undertake the work being done.
b) Each site has designated low risk areas (generally in and around
administration buildings), which are exempted from the compulsory
wearing of helmets and eye safety protection, unless construction work
is being performed in or around these buildings. A risk assessment shall
be carried out by the contractor to determine appropriate PPE for the
works.
c) The contractor shall provide contractor and their sub-contractor
personnel who work in Ma’aden Aluminium plant area where use of
flame retardant or special clothing is required with the proper type, size
and quantity in accordance with Ma’aden Aluminium requirements.
5.4. Confined Space Entry Program
a) The Ma‘aden Aluminium Confined Space Entry Program details the
requirements and procedures that must be fully complied with to ensure
the health and safety of any persons required to enter or work in a
confined space. The program applies to all Ma’aden Aluminium
personnel, contractors, subcontractors, contracted services, visitors and
vendors.
b) The Confined Space Entry Procedure requires that each and every
confined space shall be assessed for hazard potential at the time of
entry. After each hazard assessment, by the qualified personnel the
Confined Space is classified into either a permit required confined space
or a non-permit required confined space.
c) Responsibilities
Before entry into a confined space, it is a requirement as a minimum
that:
Each designated confined space entry point shall be evaluated to
ensure entrants can safely enter and exit the confined space.
When working in or near confined spaces all employees shall know
the location specific procedures for confined spaces, including
rescue methods, confined space classification, and specific
confined space entry procedure.

Each individual shall be trained and assessed as competent in
Confined Space Entry via the Ma’aden Aluminium confined space
entry training program.
Each work group shall ensure that control measures are in place for
any specific work being performed in the confined space.
Contractor shall ensure that a location based rescue plan is
available and a trained rescue teams and rescue equipment is
available.
An atmospheric gas testing shall be conducted in accordance with
Ma’aden Aluminium Confined Space Entry Program.
Maintained an effective means of communication with entrant,
attendant and rescue services.
Either double insulated or Ground Fault Circuit Interrupter protected
electrical tools, low current low voltage shall be used in confined
space.
If the confined space entry activity is suspended, the entry point
shall be barricaded and a no entry sign shall be posted.
Fall hazards shall be eliminated or controlled in accordance with
the Ma’aden Aluminium Fall Control Program in Confined Space.
Before personnel are permitted to enter a confined space, all
equipment’s and sources of kinetic and potential store energy shall
be physically de-energized, immobilized, disabled, relived,
disconnect restrained in accordance with Ma’aden Aluminium
Lockout Tagout Verification Program.
d) Hazardous Atmosphere is any atmosphere that may expose personnel
to the risk of death, incapacitation, injury, acute illness or may prevent
the unaided escape from a hazardous confined space. The following are
hazardous atmospheres.
Atmospheric oxygen concentration below 19.5% or above 23.5%.
Flammable gas, vapor or mist in excess of 5% of its lower explosive
limit.
Airborne combustible dust at a concentration that meets or exceeds
its lower explosive limit.
Atmospheric concentration of any substance where entrant
exposure exceeds the dose or occupational exposure limit
established by local regulations.
Any other atmospheric condition that is immediately dangerous to
life or health.
e) The following procedures shall be applied in conjunction with Confined
Space Entry procedures

Falls Prevention Program.
Hot Work Program.
Barricade and Overhead Work Program.
Lockout Tag Out & Verification Program.
Electricity Inside Vessels and Tanks Program.
5.5. Electrical
Portable / Plug in Appliances and Leads
a) All users of electrical tools, appliances and extension leads are
responsible for visually inspecting their electrical equipment for signs of
damage and unusual wear prior to using the equipment. This is in
addition to the quarterly appliance checks carried out by qualified
electrical workers.
b) All electrical equipment used on a construction site such as leads,
appliances and tools including office and crib appliances shall undergo
inspection and testing prior to initial connection and use on site.
c) Portable electrical equipment, portable tools, extension leads,
generators, welders, etc used on construction work, other than offices
and crib rooms, shall be tested and inspected quarterly and appropriately
tagged.
d) Portable electrical equipment and appliances used in offices and crib
rooms shall be tested and inspected every twelve (12) months and
appropriately tagged.
e) All electrical testing shall be carried out by a licensed electrical
worker/contractor approved by Ma’aden Aluminium. The tests shall
include:
Earth continuity where applicable
Insulation megger test of active and neutral leads
Testing of Residual Current Devices (Earth Leakage units)
check visually for obvious external damage or component defects
in accessories, connectors, plugs or sockets
Check that inner cores of flexible supply cords are not exposed and
that external sheaths are not cut, abraded or damaged in any way.
Also, check that unprotected conductors or insulation tape are not
in evidence.
Fixed equipment and installations such as huts, workshops, urns,
etc shall be inspected and tested by the electrical
worker/contractor.

Residual Current Devices / Safety Switches
a) Function tests on Residual Current Devices by use of the ‘test button’
should be performed by anyone about to plug a lead or electrical tool into
the protected outlet.
b) In addition a performance test of verifying the trip current and trip time
shall be carried out and recorded for each device by a licensed electrical
worker every quarter.
High Voltage Access Permit
a) All persons engaged on design, construction, operation and
maintenance of electrical high voltage equipment shall be comply with
the Ma‘aden Aluminium High Voltage Electrical Standard.
b) High Voltage Access Permits shall be used when access is required to
power distribution systems that normally carry voltages in excess of
1000 volts AC or 1500 volts DC.
c) The purpose of the permit is to specifically state the precautions and
actions of isolation, the verification of zero energy of equipment and the
placing of grounding on equipment. All persons required to work on the
specified equipment must inspect and satisfy themselves that the above
steps were taken and sign the permit to confirm this has happened,
before placing their white personal danger tag and starting the work. At
the completion of the work, or when leaving the job site, the workers
must first sign-off the permit and remove their personal lock and danger
tag.
d) People issuing the permit must be specifically trained in High Voltage
Switching and Isolating Procedures, and jointly assessed and approved
in writing, by the Site Electrical Superintendent or Senior Electrical
Engineer.
e) The reasons for the above stringent requirements are primarily because
of the high potential for fatality when exposed to live high voltage power
distribution systems, and the need to ensure that the people performing
the isolation have the specific technical knowledge to guarantee a
system is isolated, discharged and made totally safe for personnel
access. It also ensures that all the appropriate safeguards are met to
prevent re-energization while people are signed on a permit.
Temporary Power and Lighting
a) All temporary lighting shall be fixed to the structure by the use of safety
chains. Lamps shall be protected by the use of a fine wire mesh guard.
Lighting installation shall be located such that clear access is given for
persons and accidental physical contact is avoided.
b) Hand held/portable lighting shall not exceed a potential of thirty-two (32)
volts AC or 12 Volt DC.

c) All power circuits above 32 volts for lighting shall be protected by a
Residual Current Device located external to the tank or work area.
d) The lighting circuit shall not be energized until the installation is
complete, tested and the current inspection tag affixed.
e) Should the work area be, or become, a Class A (explosive atmosphere)
area, then all equipment and fittings shall conform to Class A
classification, e.g. Chalmit 487 fitting and no cable joints in the area.
f) As far as practicable, power leads shall not enter a vessel through the
personnel entry point. If this is not possible, then additional mechanical
protection shall be provided.
g) No person shall remove or interfere with any permanent light or power
installation without permission from Ma’aden Aluminium. Use of Ma’aden
Aluminium single-phase power outlets or 3-phase welding outlets is not
permitted unless written permission is given by Ma’aden Aluminium.
h) Any permanent lighting installation or fitting removed or temporarily
disconnected for construction tie-in or relocation, shall be replaced with a
temporary installation (by a licensed electrical worker), to satisfy 24-hour
operation requirements.
Flexible Cords/Extension Leads
a) Flexible cords, cord extension sets, flexible cables and accessories used
to connect appliances and equipment to a power supply shall have a
minimum cross sectional area of 1.5 mm2. This shall not include the cord
that is permanently attached to the appliance or light fitting.
b) Maximum length of a flexible cord shall be 32 meters. The cord shall not
be joined in lengths in which the total length exceeds 32 meters.
c) Extension cords shall not extend from a work level to more than one
level above or below it, except where the cords are used for work in lift
shafts or stairwells.
d) Cords should be elevated at 2.4m on stands, or attached to structure by
the use of cable hangers. Welding rods, wire and rope are not approved
for tying cords to structure.
e) Extension leads shall not be left plugged in, turned on and with no
appliance plugged into the socket end. An open-ended live extension
lead, exposed to the environment is a possible fatality waiting to happen.
f) Extension cords shall not be used as a substitute for permanent wiring in
portable office facilities. If re-locatable power cords using in temporary
office facility shall be of the polarized or grounded type with over current
protection and should be “UL, FM or SASO” listed.
5.6. Overhead Power lines
a) Any work required to be performed on or adjacent to overhead power
lines shall be controlled by a High Voltage Access Permit.

b) The term ‘adjacent to overhead power lines’ shall be interpreted as
equipment or personnel entering within the distance of a 3-metre
horizontal and vertical exclusion zone. Particular note shall be taken
with crane booms or hooks, which may drift into the area of exclusion.
c) All non-electrical work (welding, cutting, lifting, digging, fitting etc)
required to be performed within 10 meters of an overhead power line or
other exposed high voltage conductor, shall be controlled by a High
Voltage Vicinity Permit.
d) 10 Meter Rule
A “power line corridor” that extends 10 meters, horizontally, either
side of the nearest power line conductor (wire). With power lines
being about 2 meters from wire to wire, most power line corridors
shall be at least 22 meters wide. The regulation requires that you
must have written authority to carry out any work within the power
line corridor. Ma’aden Aluminium uses the HV Vicinity Permit to
record the conditions by which that authority is granted. Material
shall not be stored within the power line corridor.
e) 3 Meter Rule
Under no circumstances shall any person, material or equipment
(mobile or fixed) approach closer than 3 meters to an overhead
power line of a working voltage up to 50,000 volts. This rule applies
to approach from any direction below, side or top. There is no
circumstance under which work or lifting may take place above live
overhead power lines.
If, during the course of work, it is physically possible for material or
equipment to inadvertently extend into the 3-metre exclusion zone,
grounding provisions shall be required, and these shall be noted on
the High Voltage Vicinity Permit.
Plant Manager approval is required for specialized high voltage
electrical work, which may breach the 3-metre exclusion zone.
Using Mobile equipment
a) Mobile equipment and vehicles may transit under power lines at all times
without permits, so long as there is 3 meters clearance can be
maintained in the transit zone at all times.
Working in proximity to live cables in cable trays procedure
a) A detailed procedure has been developed for working near or lifting
loads over cable ladders (trays) containing live electric cables. The
procedure aims at preventing contact or disturbance of high voltage
cables, but the principles apply equally to all cabling.
b) When working within 3 meters of insulated cables, the job JSA shall
assess the risk of accidentally contacting the cables. If it is determined
that contact may be possible, then defensive techniques such as placing

planking over the cable ladder should be used. When working or lifting
loads within 1 meter of cables, barriers and barricades shall be used to
protect the cables unless it can be demonstrated that the work method
guarantees no contact shall be made.
5.7. Generators and Welding Machines
Generators
This section covers portable, transportable or mobile generators including
welding machines with auxiliary power outlets or terminals.
a) Self-contained transportable generating sets driven by internal
combustion engines which are intended to provide an independent 50 Hz
A/C. supply at above 32V A/C., single phase or three phases, shall meet
the following requirements:
All live parts, including ‘neutral’ parts shall be guarded and
insulated, including terminals at the back of the outlet.
Single-phase windings shall have the neutral terminal connected to
the earth terminal of the device. Three phase units shall have the
star point of neutral connected similarly.
All socket outlets providing non-welding power shall be
weatherproof hi-impact polycarbonate or similar construction, with
an isolating switch, which operates in all, live conductors.
All the single-phase outlets above shall be protected by a residual
current operated circuit breaker set to trip at a maximum earth
leakage of 30 mA.
b) Generators shall be inspected and tested by an electrician and tagged.
c) Generators shall be protected from weather at all times.
d) Generators shall have an accessible stop buttons/emergency shut off
switch.
Welding Machines
a) Where welding machines are installed adjacent to one another or where
required to work in close proximity to one another, the Contractor shall
ensure that the open circuit potential difference between the electrode
holders of adjacent machines does not exceed 115 volts DC or 80 volts
AC.
b) Automatic voltage reduction devices (VRDs) shall be fitted to all welding
units (engine driven and mains powered). The automatic voltage
reducers shall NOT replace the need for the work lead isolation switch
that is mandated for Confined Space Entry welding.
c) The automatic voltage reduction units shall meet the following :
The VRD device shall be suitable for the welding machine on which
it is installed.

The VRD device shall be proven in the heavy industry workplace
with high utilization of welding machines
The VRD device shall operate at resistance levels that provide a
suitable safety margin to the welding operator.
The VRD device shall not compromise welding capacity of the
machine it is installed on.
The VRD device should be locally supported, both technically and
for maintenance
The VRD device shall be TAMPERPROOF and FAILSAFE in
operation.
The VRD device should have a means of go/no-go testing by field
trades people.
The VRD device shall have a clear visible status indication.
d) Welding machines shall be stopped or switched off before the
connection or disconnection of leads to the machine terminals. All
exposed terminals shall be insulated or covered.
e) Welding leads shall undergo two levels of inspection. The trades/crafts
person shall inspect his leads regularly, and on a monthly basis record
the inspection in a register. On three monthly bases an electrical trade’s
person, and record the outcome in the register shall inspect the leads.
f) Welding leads shall be elevated where pedestrian access is required.
Leads should be elevated at 2.4m on stands, or attached to structure by
the use of cable hangers. Welding rods, wire and rope are not approved
for tying leads to structure.
5.8. Barricade Procedure
a) The Barricade Procedure is designed to restrict access to location roads,
work areas and access ways, to control any situation where hazardous
conditions are evident or potentially foreseeable, which may present
danger to persons, or damage to equipment or property.
b) Consideration should be given to the type of barricade material used, i.e.
A hard physical barricade constructed from material such as scaffold
tubing shall be used around excavations and holes in floors.
c) Red/white barricade means do not enter. Yellow/black barricade means
enter with caution.
d) Barricades are required and shall be erected in such situations as:
overhead work
enclosed space entry
scaffold erection and protection
chemical and product spills
traffic and pedestrian control
blasting and charging situations
excavations
road works
descaling
High pressure water use
5.9. Fall Prevention/Working at Heights Procedure
a) The ‘Fall Prevention and Control Policy’ shall be applied in establishing
work procedures for each and every task where a potential exists to fall.
b) In every situation where a fall arrest device is required to be used, the
preferred method is a retractable lanyard with an approved ‘safety
harness. Lanyard with shock absorber may be used if a retractable
lanyard not available.
a) In each and every fall potential situation, a safe method of work shall be
identified and documented. The normal hierarchy of controls applies
placing PPE equipment (Harness and Lanyard) at the lowest level of
protection. All other means of performing the task should be reviewed
before consenting to PPE being the only control to prevent a person from
falling.
b) Additionally, the following rules shall be followed:
Safety nets shall not be used as a means of personal fall
protection.
Install barricades and safety signs below elevated work.
Ensure access ladders are secured and inclined at 1 in 4 (or where
not practicable develop a JSA which shall be approved by Ma‘aden
Aluminium specifically to ensure safe access).
Vertical access ladders shall have landings at least every 6 meters.
Access ladders that allow for a potential fall of greater than 4
meters, or access ladders that are external to the scaffold shall be
provided with a shoulder rail.
Use modular assembly methods at ground level to reduce working
at height exposure.
Use workboxes or EWP’s to eliminate climbing of columns by
riggers/steel fixers.
Ensure that fall arrest equipment is inspected by a competent
person and is serviced or discarded in accordance with
manufacturer’s specifications.

5.10. Elevating Work Platform (EWP) or Boom lift Procedure
a) EWP’s shall only be operated by competent, certificated persons.
b) EWP’s shall always have a competent person as a watch person on the
ground. The role of the watch person is in the case of emergency to
lower the basket.
c) When working from EWP’s, a “tool tidy” shall be used to keep tools
components and equipment off the floor of the basket.
d) EWP’s working adjacent or on a roadway shall operate within a
barricaded area to prevent direct interface with normal traffic, where this
restricts traffic flow a flag person shall ensure that traffic flow is
maintained.
e) Egress/Access to EWP’s while the basket is elevated shall only be done
after Ma’aden Aluminium has granted permission. A specific JSA shall
be developed and submitted to Ma’aden Aluminium together with a
permit for approval.
f) All personnel in the bucket of the EWP shall wear the correct PPE and
be attached to an approved anchor point.
5.11. Safe Loading and Unloading of Trucks
a) No standing or climbing on to a flat bed truck without fall prevention or
fall protection in place.
b) To unload a truck safely it has to be loaded in a safe way. It is required
that where possible, loads shall be unitized to enable safe lifting from the
truck. Flat racks, cradles, crates and pallets are all examples of unitized
loads. Where equipment is larger than can be accommodated by these
means focus on preventing people from accessing onto the load for
unloading. This can be done by leaving slings attached to the load when
loaded onto the truck and secured for the duration of the journey.
5.12. Grating or Chequerplate removal and Installation
c) An approved permit is required prior to the removal and/or installation of
grid mesh or chequerplate. When grid mesh or chequerplate is being
installed, falls risks shall often exist and must be considered in the safe
method of work.
d) Floor openings require a permit authorized by Ma’aden Aluminium.
e) Temporary flooring shall be inspected for integrity by a competent
person prior to the commencement of work, on each working day.
f) Process and Operating areas: The contractor shall complete a “job
safety analysis” prior to installation of temporary flooring to ensure that
process and operating personnel are not put at risk of injury by the
temporary flooring configuration.
g) Every open-sided floor (temporary or under construction) where there is
a risk of injury to employees from falling shall be protected by a guardrail
constructed of metal tubing, hardwood timber 75 x 50mm or equivalent
around its perimeter.
h) Standards covering platform hole covers, guards and handrails on steps,
stairs, elevated walkways, elevated platforms are designed to eliminate
the risk of a fall to the workforce.
i) No person shall remove any part of any permanent handrail, mid rail,
platform, kick plate or stairway from any site fixed installation without
specific prior approval from Ma’aden Aluminium.
j) Rope or chain shall not be used as a temporary handrail. Steel cable
may be used where specific approval has been granted by Ma’aden
Aluminium.
k) A standard temporary railing shall consist of a top rail, at a height of not
less than 0.8 meter and not more than 1 meter above the surface being
protected, with vertical support posts spaced at intervals not exceeding 3
meters. Intermediate railing shall be required. Minimum size material
used for temporary railing shall be equivalent to 100 x 50mm hardwood
timber.
l) Hardwood timber shall be “first class straight grain”.
m) Platforms and stairways shall be kept clear of equipment, gear, rubbish,
etc. that may cause a person to fall, trip or stumble.
n) Whenever electric welding leads and/or oxy-acetylene hoses or air
hoses traverse platforms or stairways, they shall be located and secured
on the mid rail of the platform or stairway by cable hanger.
o) Stairway landings shall not be used to store material or equipment. No
person shall run up or down a stairway.
5.13. Portable ladders.
a) Aluminium ladders whether of whole or part construction shall not be
brought on to, or used at any Ma’aden Aluminium site without prior
approval.
b) Ladders shall only be located in Plant and Mine Site areas for such time
as is reasonable to affect work.
c) Each overhead work situation wherein a ladder is used shall be
assessed for Overhead Work Precautions.
d) All portable ladders shall be inspected for damage and integrity prior to
use on any specific job.
e) A competent person shall secure portable ladders when in use, with rope
or ladder clamps to prevent slipping or overbalancing.
f) Ladders shall always have a firm footing to prevent the ladder feet from
moving unexpectedly. Wooden blocks, off cuts, bricks, etc shall not be
used to level the feet of any ladder.

g) Portable ladders shall be placed on a substantial base at a 4:1 pitch,
have a clear access top and bottom and extend a minimum of one (1)
meter above the egress landing.
h) All ladders shall be equipped with approved safety feet.
i) Portable metal ladders and wire-reinforced ladders shall not be used for
any electrical work, for any work using portable power tools or where
contact with electrical conductors is foreseeable.
5.14. Scaffolds and Scaffolding
a) All scaffolds and scaffolding shall only be erected, modified or
dismantled in conjunction with the Ma’aden Aluminium Fall Control
Program.
b) All working platform planks shall be closely laid and securely lashed at
both ends with either 8- mm fiber rope or 4 mm wire rope.
c) Scaffolds shall not be erected in such a situation that it shall impede the
access of emergency vehicles unless a permit has been obtained from
Ma’aden Aluminium
d) Scaffolds shall not be erected on roadways and access ways unless a
permit has been obtained from Ma’aden Aluminium and considering
application of collision protection from vehicles and mobile equipment.
e) Scaffolds shall not be erected without consideration and application of
the relevant Barricade Procedure, and Overhead Work Procedure.
f) Every scaffold and scaffolding components shall be capable of
supporting, without failure, its own weight (dead load) and at least four
times the maximum intended load (live load) applied or transmitted to it.
Self-weight of platform units (including planks) shall be considered as
dead load.
g) Purchaser shall obtain a test and inspection report for tubing from
supplier or manufacturer, which shall be in English.
h) Couplers shall meet the requirements of BS or EN standards.
i) Tube and coupler scaffolds over 125 feet in height shall be designed by
a qualified competent engineer, and shall be constructed and loaded in
accordance with such design.
j) Scaffold components from different manufacturers shall not be
intermixed unless the components are compatible and the scaffold
structural integrity shall maintained.
k) Scaffolds, where exposed to extremes of weather, adverse location
conditions, shall not be left in positions for a period in excess of one (1)
month without a thorough inspection of the components.
l) Whenever a scaffold is damaged or dislodged by incident it shall be
dismantled to a point where any damaged components can be removed
and replaced.
m) Any scaffold component, which is damaged as a result of an incident,
shall be destroyed (after investigation of cause of damage).
Suspended scaffolds
a) Particular attention shall be given to the implementation of the ‘Danger -
Workers Above' signage and barricades and the requirement to carry out
inspection and testing by a competent person prior to use.
b) Any person who works from a light duty suspended stage shall not sit or
stand on the mid or top rail of a stage.
c) Scaffold planks or other such material shall not be placed on fender
boards or guardrails in an endeavor to gain extra working or access
height from the stage.
d) Persons using or working from a light duty suspended stage shall remain
within the confines of the stage.
Scafftag Procedure
a) Scafftag is an internationally used scaffold safety system and through its
simplicity, encourages and controls the safety of scaffolding, and of
those who erect/dismantle and use it.
b) The ‘Scafftag System’ shall be used as a visual warning system to
display the status (i.e. safe versus unsafe) of scaffolding.
5.15. Workboxes and Lift Boxes
a) Lift Boxes are best described as “non-fixed load-lifting attachments” and
are intended to lift equipment and/or material loads (not personnel).
b) Workboxes are intended for personnel use and shall not be used as
general-purpose material or equipment hoists.
c) During raising and lowering of workboxes with persons therein, no part of
the person(s) shall extend beyond the confines of the workbox.
d) No person shall ride on, or in, a lift box.
e) Whenever equipment or material is raised or lowered in a lift box, such
material or equipment shall not protrude from the confines of the lift box.
f) Lift boxes shall be purpose built and conform to engineering standards.
Each lift box shall have available an approved design and drawing.
g) Lift boxes shall be fitted with a lid that is capable of containing any loose
items that may inadvertently fall, should the lift box tip on its side whilst
being landed.
5.16. Excavation Trenching and Shoring Procedure (and Permit To Dig)
a) The Excavation Trenching and Shoring Procedure is designed to control
excavation and digging activities that have the potential to damage
essential service facilities, e.g.:
underground power cables
sewers and drains
process piping and facilities
natural gas & other fuel lines
foundations and footings
earthing networks
potable water lines
b) No excavation shall be commenced before obtaining a fully authorized
“Permit to Dig”.
c) Adequate and suitable protective systems shall be planned for any types
of excavation and trenching.
d) Adequate safe means of egress shall be maintained in all excavation
and trenching.
e) Mechanical excavators shall not be used until all underground utilities
and installations have been exposed by hand digging in energized
areas/brown fields.
f) Employees shall not work in excavations where there is pooled water, or
in excavations in which water is accumulating, unless adequate
precautions have been taken to protect employees.
5.17. Formwork and Shoring
a) Persons shall not be permitted to work above or adjacent to (where there
is a likelihood of them falling or stumbling) vertically protruding
reinforcing steel, unless such steel has been adequately guarded to
eliminate the potential of impalement.
b) Structural engineering design calculations shall be prepared by a
degreed structural engineer for all elevated formwork. These calculations
shall ensure that vertical and lateral loads to be imposed upon the
formwork, including during placement of concrete, shall be safely
supported.
c) Approved “Issue For Construction” drawings or plans for formwork and
shoring shall be available at the job site.
5.18. Mobile Equipment
Mobile Equipment LO/TO/V
a) All service and maintenance work to be performed on Contractor's
mobile equipment shall be performed using Ma’aden Aluminum’s
Lockout Tag out Verification System.
Road Escort Procedure
a) The Road Escort Procedure provides control of the interface between
light vehicles and other traffic whenever heavy equipment and large

mobile cranes travel on public roads, in process areas, and on plant
access roads. The movement of oversize loads is also governed by this
procedure.
b) Directions and instructions from those persons in control of escort
activities shall be strictly obeyed.
Mobile Equipment and Power lines
a) Refer to the 10-metre rule and the 3-metre rule under High Voltage.
Roads, Footpaths and Access Ways
a) At all times the contractor shall be aware of vehicle / pedestrian interface
issues and put systems in place or rearrange the work method to
eliminate the potential for injury, particularly where it is necessary for
vehicles to reverse.
b) The Contractor shall obtain specific approval from Ma’aden Aluminium
prior to setting up any form of access restriction (barricade) that shall
restrict access or close a road.
c) Vehicle and pedestrian access may be essential for 24 hour a day
production and maintenance requirements.
d) Ma’aden Aluminium’s mining operations have a mandatory 50 meter
exclusion zone between light vehicle/pedestrians and operating heavy
mobile equipment.
e) Exclusion zones shall be applied where there is potential interface
between earthmoving equipment, light vehicles and or pedestrians.
f) Restriction of access shall include such situations as:
Scaffolds
Temporary access platforms
Any road works or excavation
Cable pulling
Locating mobile welding equipment
Mobile air compressors and other such equipment
Barricading for overhead work precaution
Locating mobile cranes and Elevated Work Platforms and other
special vehicles
Locating delivery vehicles such as concrete trucks, steel and
equipment delivery vehicles
Temporary buildings including toilets
Spray painting locations
High pressure water usage areas.

Roll-Over Protection and Falling Object Protection Standards
a) Mobile equipment that is used at Ma’aden Aluminium’s sites shall have a
risk assessment undertaken to determine the need or otherwise for the
use of ROPS and/or FOPS. Risk assessment documentation shall be
held by the contractor and a copy provided to Ma’aden Aluminium.
b) The Contractor is responsible for ensuring that all equipment used on
site is maintained and used in a mechanically safe and sound condition.
c) Heavy Mobile Equipment/Light Vehicle/Pedestrian Interface Policy
d) On all of Ma’aden Aluminium’s bauxite mining and large earthworks
projects (such as mudlake and road construction), a >50M exclusion
zone between heavy mobile equipment and light vehicles/pedestrians is
required. Refer to the location Operating Procedures for specific
requirements. Should the 50m-exclusion zone prove impracticable, then
a specific approved exclusion zone procedure including hazard risk
assessment and a JSA shall be developed and deployed after approval
by Ma’aden Aluminium.
5.19. Site Restrictions
a) The number of light vehicles permitted on operating sites shall be
controlled by Ma’aden Aluminium and restrictions may vary between
locations.
b) Prior to commencing work on site, the Contractor shall submit for
Ma’aden Aluminium’s approval, a list of vehicles requiring site access. A
copy of current registration documents for all light vehicles used on site
shall be maintained with Contractor’s Site Office.
c) Ma’aden Aluminium reserves the right to inspect the contents of any
vehicle entering or leaving a site.
Speed Limits
a) All Contractor employees driving vehicles on an operating site shall drive
within the speed limits applicable in the location of the contracted work.
Speed limits vary between locations and shall be addressed during the
Induction course.
b) Cranes carrying loads shall travel at a walking speed, not more than 5
km/hr or as per manufacturer’s limits.
c) All drivers shall acknowledge and comply with speed limits, reduced
speed zones, and prohibited light vehicle access areas, stop signs and
other traffic warning signs.
Vehicles for Transport of Employees
a) Contractor transport of employees on operating sites shall be as
approved by Ma’aden Aluminium. Examples of approved transport are:
Bus

Inside vehicle cab
All vehicles approved for the transport of employees on site shall be
fitted with seat belts, which shall be worn by the occupants (bus
passenger seats excluded unless fitted as original equipment).
Vehicle Inspections
b) Prior to mobilization to site, the Contractor shall submit a Light Vehicle
Site Access Report, duly completed and signed by a competent person
as written certification that each vehicle intended for use on the site is
registered, licensed and in a mechanically safe and sound condition.
c) The Contractor’s vehicle shall be maintained in the required condition
whilst on site. Periodic inspection of equipment on site shall be at
intervals not greater than three months using the above documentation
to ensure continued acceptability.
d) Ma’aden Aluminium reserves the right to audit any procedures adopted
by the Contractor to certify equipment. Ma’aden Aluminium shall audit
inspections from time to time, and the Contractor shall make available,
on request, the vehicles and related documents for that purpose.
However, this shall not absolve the Contractor of responsibilities for
ensuring acceptable vehicle maintenance, nor shall the failure of
Ma’aden Aluminium to detect defects in the Contractor’s vehicle be taken
as acceptance of the vehicle.
Vehicle Passes
a) Vehicle access to Ma’aden Aluminium’s operating sites shall be
authorized by one of the following passes:
b) Long Term Vehicle Pass
A long-term vehicle pass shall be issued to vehicles requiring on-
going site access.
Note: Some sites have “barcode electronic surveillance” instead of
Long-term passes, the contractor shall check with the particular site
to ensure compliance.
These passes shall be displayed in a suitable location on the
vehicle to facilitate the sighting of the passes at site access control
points.
Long-term passes shall be renewed on an annual basis and shall
be color coded for control purposes.
The Contractor shall be required to re-apply for site access
approval at the end of each 12 month period
c) Short Term Vehicle Pass
Vehicles requiring site access on a short term, or daily basis, shall
need to obtain a temporary pass, which shall be surrendered when

leaving the site. The passes shall be made available to approved
vehicles at site access control points.
Drivers Licenses - All Sites
a) The Contractor shall ensure that all employees permitted to drive a
vehicle on site hold a current KSA driver’s license for that class of
vehicle.
Site Transportation - Non Standard Loads
a) Various load clearance restrictions for height, width and length exist on
each location. Prior to any material/equipment being brought to site, the
Contractor shall seek the relevant information from Ma’aden Aluminium
on specific site transport restrictions to develop an appropriate safe site
access route.
Licenses, Permits and Certificates
a) Only plant and equipment having the correct log book, manufacturers
Operation and Maintenance Manual and current certification shall be
permitted to operate on site.
Plant and Equipment Operators
a) The Contractor’s plant and equipment operators shall possess all
necessary licenses, registrations and certificates in accordance with
statutory requirements, which qualify them as competent operators of
that plant or equipment. Copies of it shall be provided to Ma’aden
Aluminium prior to the safety induction and when other classifications are
granted.
b) The Contractor is responsible for ensuring that all plant and equipment
operators are competent persons in relation to the use of such plant and
equipment.
5.20. Heavy Mobile Equipment site access
Heavy mobile equipment includes, but is not limited to, vehicles such as
- trucks, low loaders, tractors, scrapers, dozers loaders excavators,
backhoes.
Mobile Equipment and Vehicle Safety Standards
a) Contractor's Mobile Equipment, as a minimum, shall meet the
requirements of the mobile equipment safety specification for each type
of equipment.
b) All Light mobile equipment shall be inspected. The inspection report
shall be used to obtain a site access pass and for logging inspection of
light vehicles.
c) All heavy mobile equipment used for on-site contract work shall be
inspected in accordance with the Mobile Equipment Inspection Report.
This shall ensure there is written certification that each piece of

equipment for use on the site is registered, licensed and in a
mechanically safe and sound condition.
d) The following is a list of vehicles categorized as “light” and “heavy”.
Heavy Mobile Equipment Light Mobile Equipment
Front End Loaders Skid steer loaders
Haul Trucks Conventional forklifts
Trucks and semi-trailers Sedans/vans/utilities
Low loaders and floats Trailers
Bulldozers Farm tractors
Scrapers Farm equipment
Graders Powered mobile platforms
Tracked Pipe Layers Electric carts
Excavators Buses
Backhoes, Tractor Drills, Rock Road Sweepers
Breakers, Mobile Cranes, Road Rollers
Road laying machinery All Terrain Forklifts
Elevated work platforms
e) The Contractor’s equipment shall be maintained in the required condition

whilst on site. Periodic inspection of equipment on site shall be at
intervals no greater than six months using the above-mentioned
documentation to ensure continued acceptability. Operator inspections
are required at pre-start and a more detailed inspection on a weekly
basis shall also be recorded.
f) Ma’aden Aluminium reserves the right to audit any procedures adopted
by the Contractor to certify equipment. Ma’aden Aluminium shall audit
inspections from time to time, and the Contractor shall make available,
on request, the vehicles and related document for that purpose.
However, this shall not absolve the Contractor of responsibilities for
ensuring acceptable vehicle maintenance, nor shall the failure of
Ma’aden Aluminium to detect defects in the Contractor’s vehicle be taken
as acceptance of the vehicle.
g) When using mobile equipment on Ma’aden Aluminium’s sites, due
consideration shall be given to the ENVIRONMENTAL impact.
5.21. Lockout Tag Out Verification
Isolation and Danger Tag Procedure
a) The Fixed Plant Tagout/Lockout/Verification Procedure is designed to:

Protect people and equipment from the unauthorized operation of
primary isolation devices.
Ensure that only specific equipment so isolated and tagged is
worked upon.
b) An Identification Tag or Green Flag is used to positively identify
equipment where there is potential to incorrectly identify the equipment
that is to be worked on or removed for all work completed on an
isolation. Contractors shall not commence work on any system or
equipment without identification tags.
c) There are five fundamental rules.
No person shall isolate any primary isolation device unless they are
competent and authorized to do so.
No person shall place a red equipment isolation tag and lock unless
they are competent and authorized to do so by Ma’aden Aluminium.
Competent and authorized persons may place White Personal
Danger Tag and lock on a single isolation point or at a common
isolation point.
Where white personal danger tags and locks are required,
individuals shall place tag and lock at the start of a job and shall
remove the lock and tag at the finish of the job or at the end of the
work period/shift.
Removal of a danger lock and tag, without prior Ma’aden
Aluminium approval, is regarded as a serious breach of safety
regulations and may result in dismissal from site.
d) In the interests of safety anyone can tag out their own non-process
equipment that is considered to be in a dangerous state (i.e. broken
ladder, damaged portable tool cords) using the yellow equipment out of
service tag. If process equipment is found to be in a dangerous state,
then contact the relevant control room and advise your supervisor.
5.22. Chemical Exposure
Acids, Flocculants, Solvents, Defoamants, Lubricants, Distillate, Lime, Starch,
Dusts (alumina, bauxite, residue), Caustic Based Dusts (sodium oxalate, sodium
aluminate), contains caustic), Laboratory chemicals, Sulfur Dioxide, Fluoride,
industrial lubricants, oils and molten metal.
a) In the event of a chemical coming into contact with part of your body.
REMOVE any contaminated clothing
WASH the affected area for a MINIMUM of 20 MINUTES under a
safety shower/eyewash station
All chemical contacts must be reported immediately to the Medical
Centre. Walk around spills and drips

Ensure that the equipment you are working on has all caustic
removed prior to leaving an Ma’aden Aluminium site.
b) Refer to Hazardous Materials Management Program.
5.23. Machinery/Plant Equipment
Removal of Out of Service/Redundant Equipment
a) In removing redundant or out of service equipment or piping, the risks
are different from those of installing new equipment or piping. Initially a
method statement shall be developed and potential risks and hazards
identified. Once this has been completed and only then can the “specific”
JSA’s for the removal be developed.
Demolition Planning
a) Demolition of structure, equipment and piping is an inherently hazardous
process. Formal processes shall be adopted to ensure that the task is
undertaken in a safe manner. As a minimum the following shall be in
place before work begins:
Hazard identification register, including Hygiene and Environmental
review Risk assessment
Step by step method statement Specific to task JSA’s
Conveying Equipment
a) Conveying equipment and large industrial machines such as crushers,
stackers, reclaimers, mills, apron feeders, boilers, slurry pumps and ship
loaders are vital to Ma’aden Aluminium’s operations and the safeguard
of these installations to ensure continued operation is essential.
b) Stackers, reclaimers, conveyors, pumps and ship loaders are typical of
plant that can start up automatically or by remote control. No person
shall access or climb onto or over any part of this equipment at any time
without due consideration of the following:
Work on machines and equipment shall not be commenced until
the relevant system has been appropriately isolated and tagged in
accordance with Fixed Plant Isolation Procedures.
Safety guards, handrails or safety interlock devices shall not be
removed or overridden unless specifically approved by Ma’aden
Aluminium for testing purposes.
An on-line conveyor system shall not be stopped by any person
unless specifically authorized to do so, outside an emergency
situation.
Material shall not be thrown or shoveled onto a moving conveyor,
unless a suitably designed installation has been provided
specifically for that purpose.

Hot work (cutting, welding or heating) shall not take place over a
rubber conveyor belt without a Hot Work Permit.
Access ways beside all conveyor belts shall be kept clear of all
material. Conveyors shall not be used to convey tools, equipment
or personnel.
Portable conveyors shall have skirt boards to keep heavy material
from falling over the sides and light or loose material from blowing
off.
All conveyors including bucket elevators shall be fitted with a
locking or anti-rollback device to hold the conveying unit at various
fixed locations.
Shear and Metal Presses
a) Ma’aden Aluminium’s workshop guillotines and metal presses are not
available for use by the Contractor, unless otherwise advised by
b) Shear and metal presses used on site shall be provided with guards and
controls equal to accepted standards for machine shop equipment.
c) Belts, gears, shafts, pulleys, sprockets, spindles, drums, fly wheels,
chains or other reciprocating, rotating or moving parts exposed to
contact by any person, shall be permanently guarded.
Pedestal Drills, Grinders and Buffers
a) No person shall remove any safety guard device from a grinding or
drilling machine unless the equipment is tagged out of service.
b) Buffing, grinding and drilling operations produce airborne projectiles.
Operators of such machines shall protect themselves and others in the
work vicinity by the use of personal protective equipment, the minimum
being hearing protection, safety glasses and face shield.
c) No person shall operate a bench or pedestal drill, grinder or buffer in a
temporary work situation until the equipment has been leveled and
securely anchored.
d) No grinder or buffer shall be fitted with any other cutting wheel, e.g. saw
blade, polishing disc or pad, etc than those recommended by the
manufacturer.
e) 9” electric grinders must never be fitted with cutting disks. (Maximum
size electric grinder for cutting is 7”).
Fans and Blowers - Portable
a) All electric powered fans and blowers shall be protected by an Earth
Leakage Circuit Breaker. (E.L.C.B.)

b) No person shall continue to use a portable fan or blower that is not
equipped with a protective mesh or grill device designed to prevent
accidental personal contact with the fan blade therein.
c) When used as a forced ventilator for a vessel or confined space, the
intake or exhaust to the fan/blower shall not be obstructed by any
material so placed that the capacity of the fan is reduced.
d) Devices which may produce noxious fumes (e.g. mobile welder, fuel
storage tank or an air compressor) shall be kept clear of the fan intake
area.
e) Dust producing activities (e.g. grinding) shall be kept clear of the fan
intake area.
Pumps - Portable
a) Portable pumps, including their delivery hoses, shall not be positioned in
such a way to restrict access to operating equipment.
b) Pump delivery hoses shall have safety clips at each set of hose joiners.
c) Barricading of portable pumping installations shall be performed to the
relevant site standard where normal roadway, access way or path is
restricted by such installation.
Fuel Gas Lines and Facilities
a) Any construction, testing, inspection, operating and maintenance work
associated with fuel gas pipelines shall be in accordance with Ma’aden
Aluminium’s Industrial Gas and Oil Appliance Management Manual.
b) Pipelines carrying fuel oil and gas are either buried or supported on
above ground pipe racks.
c) Any modification to an existing gas or oil facility shall not commence until
the contractor has an approved “Permit for Industrial Gas and Oil
Appliances” issued by Ma’aden Aluminium’s nominated responsible
person and the Area Engineer. See Ma’aden Aluminium’s Industrial Gas
and Oil Appliance Management Manual for details.
d) High risk of fire and explosion exists on pipelines and facilities serviced
by natural gas and oil. Cutting and welding activities within 11 meters of
any natural gas or oil line appurtenance, or facility, requires a Hot Work
Permit.
e) Flammable material of any type e.g. oxy/acetylene, LPG, paint, solvents,
fuel powered machines such as cranes, pumps, compressors, welders,
etc shall not be stored adjacent critical plant such as substations and
pipe racks containing cable ladders and/or gas lines.
Hoses - Air, Water, Hydraulic and Gas
a) All hose connections shall be installed in such a manner to eliminate any
risk of a hose parting from the coupling or connections as follows:

Safety clips and retainers shall be securely installed and
maintained on pneumatic impact tools to prevent them from being
accidentally expelled.
Where two or more air hoses are joined, they shall not be used
unless couplings/connections are fitted with approved safety
pins/clips and hose clamps
b) Aluminium hose couplings, clamps and other fittings shall not be used
where there is any risk whatsoever of these coming into contact with
caustic soda or its derivatives (i.e. hose water, liquor and slurry).
c) Hoses used for high-pressure water equipment shall be of an approved
type as outlined in the document Guidelines for the Use of High Pressure
Water Equipment.
Porta Power Equipment
a) On site use of high-pressure hydraulic equipment in the form of ‘Porta
Power’ type units (electrically, air, petrol or manually powered) shall be
operated in strict accordance with the manufacturer’s instructions.
b) All manufacturer maintenance instructions must be adhered to.
c) Only manufacturer recommended hydraulic oil is to be used in ‘Porta
Power’ hydraulic equipment.
d) Pressure shall only be applied to loads once the cylinder has been
centered and has a solid, firm foundation.
e) Adequate supplementary bracing for loads may be necessary. Hydraulic
pressure must not be applied through kinked hoses.
f) Packers shall not be placed between the porta power equipment and the
load; if packers are required they shall be designed for the purpose and
be placed between the porta power equipment and the supporting floor.
Concrete and Brick Cutting Equipment
a) Any concrete cutting device brought on site must comply in accordance
with manufacturer’s instructions. Operators shall be trained and
competent in the use, care and maintenance of cutting machinery before
operating such machinery on site.
b) When operating a concrete/brick-cutting device on site the Contractor
shall take effective measures to suppress and/or control dust generated
by the cutting operation. This suppression and/or control may be in the
form of:
ventilation system
wet cutting procedure
respiratory protection

High Pressure Water Equipment
a) High-pressure water jetting operations shall only be carried out by
competent personnel experienced in the handling of the equipment being
used.
b) Contractors using high pressure jetting equipment shall conform to the
Guidelines for the Use of High Pressure Water Equipment.
c) Definition
d) The term “High Pressure Water Jetting” covers all water jetting systems
including the use of additives or abrasives with an output capability
greater than 800 bar liters per minute. Jetting systems with an output
capability greater than 800 bar liters per minute and less than 5600 bar
liters per minute are identified as Class A systems. Jetting systems with
a capability in excess of 5600 bar liters per minute are identified as Class
B systems.
e) High pressure blasting areas shall be barricaded (red & white) and
danger signs with wording “Danger Do Not Enter - High Pressure Water
in Use” shall be erected.
f) Personal protection equipment suitable to the work being done shall be
worn and shall include:
Eye protection - Combination of visor and chemical goggles
Foot protection - Safety boots with steel toecap
Head protection - Safety helmet
Body protection - Gloves and waterproof clothing having regard to
the nature of work being done.
Hearing Protection - Ear plugs and ear muffs
g) Prior to performing any High Pressure Water jetting work, the contractor
shall carry out a risk assessment as detailed in the Guidelines for the
use of High Pressure Water Equipment.
Portable Tools
A portable tool is defined as any hand tool or power tool (electric, pneumatic,
hydraulic, explosive or fuel driven) that can be manually transported by one
person.
a) Portable tools may be subject to inspection by Ma’aden Aluminium
during on-site work. Excessively worn tools and tools requiring
maintenance shall be removed from the job site.
b) Electric power operated tools shall be of an approved double insulated
design and be fitted with a Ground Fault Circuit Interrupter.
c) All portable tools shall be in good state of repair and intrinsically safe for
the user and other people in the same area. They shall be used only for

the job they were designed, and in accordance with the manufacturer’s
instructions.
Identification of Tools and Equipment
a) It is the Contractor’s responsibility to ensure that all of their tools and
equipment, which are taken onto Ma’aden Aluminium sites, are clearly
identified as belonging to that Contractor. The onus of proof shall be the
Contractor’s responsibility. Any tools and/or equipment that do not have
such an identifying mark may be retained at the Ma’aden Aluminium
location until such time that the Contractor can prove ownership.
5.24. Lifting Equipment

Lifting equipment records shall be kept in a register along with test certificates
for each piece of equipment.
Fixed, Davit, Pillar and Monorail Cranes
a) No person shall be permitted to operate fixed, davit or pillar cranes
unless trained and recorded by the contractor as competent to do so.
b) All power-operated cranes so installed shall be fitted with an emergency
hoist stop limit switch. The safe working load (S.W.L.) of each crane and
its lifting elements shall be clearly posted. When maintenance/repair
work is necessary, the main power supply shall be locked and tagged
(by an authorized person) in the OFF position in accordance with the
Lockout Tag out Verification Program.
c) All guards and safety devices shall be in position before the cranes are
brought into service. Crane operators shall not leave their position at the
controls while the load is suspended.
d) Before leaving the crane unattended, the operator shall land any
attached load and place the pendant control in the OFF position.
e) In the event of failure of the crane functions whilst a load is suspended,
the crane operator shall barricade off the load landing area to ensure no
other person enters that area and notify his/her Supervisor. The
barricade shall remain in place until repairs are complete.
f) Where monorails are used and the pendant operator is required to walk
with the pendant, the aisles or access ways shall be kept clear to avoid
tripping hazards.
g) All lifting methods shall facilitate true vertical lifts only. Stationary or
mobile cranes shall not be used as a ‘Cum-a-long” to drift loads away
from or to a vertical lift position.
h) Where a suspended load on a monorail crane can swing as a result of
travel, the load swing shall be controlled by a tether rope.

i) Crane operators must be instructed that the crane is to be immediately
isolated, and tagged out should there be any failure of a crane, crane
component or lifting equipment.
j) Any failure of the lifting equipment shall be reported to Ma’aden
Aluminium immediately.
Mobile Cranes
a) All Mobile Cranes operated by contractors shall carry the current Log
Book and crane manufacturer’s Operation and Maintenance Manual/s at
all times.
b) All mobile crane operators shall be properly licensed and certified.
c) Daily pre-operational inspection shall be performed by crane operator.
d) Crane operation and limitations shall be in accordance with crane
manufacturer recommendations and or Ma’aden Aluminium
requirements.
e) Cranes with a free fall facility (e.g. Manitowoc) shall have the facility
locked out while on an Ma’aden Aluminium site.
f) Crane operators must be instructed that the crane is to be immediately
isolated, and tagged out should there be any failure of a crane, crane
component or lifting equipment.
g) Any failure of the crane or lifting equipment shall be reported to Ma’aden
Aluminium immediately.
h) Note: The carrying of the Operation and Maintenance Manual/s may be
waived with the prior written authority of Ma’aden Aluminium.
Rigging Equipment and Winches
Lifting gear includes, chain, rope, fastening, coupling, fitting, hoist block, stay,
pulley, hanger, sling, brace, or movable contrivance of a similar kind, used or
intended for use on or in connection with construction work.
a) Crane operators, riggers and doggers must be instructed that lifting
equipment is to be immediately isolated, and tagged out should there be
any failure of a crane, crane component or lifting equipment.
b) All lifting gear shall be visibly marked in accordance with the relevant
Australian Standards. Such markings shall be legible throughout the
working life of the equipment (i.e. principally showing load capacity).
c) All slings shall be inspected regularly by a competent person for the
purposes of determining their suitability for safe use. The inspection shall
be recorded in a rigging register. Some items to be considered in the
inspection are
wear or deterioration,
elongation or deformation,

cuts, nicks, breaks or chafing,
legibility of markings including safe working loads,
chemical attack,
unauthorized repairs,
deteriorating stitching or
any other defect that may render the equipment unsafe for its
designated application.
d) Job or shop hooks and links, or makeshift fasteners, formed from bolts,
rods, etc. or other such attachments, shall not be used.
e) All ferrules on slings shall be steel. Slings with aluminium & alloy
ferrules shall not be permitted on Ma’aden Aluminium’s sites without
written approval.
Hydraulic and Mechanical Jacks, and Equipment Support Stands
a) All hydraulic and mechanical jacks shall comply with latest version of
ASME B30.1 with respect to stability, durability, loss of height under
load, ease of operation and load capacities.
b) Equipment support stands used on site shall follow guidelines set out by
ASME B30.1 specifically relating to strength, stability, access, height
adjustment and labeling requirements.
c) All equipment support stands shall have on them SWL for the particular
stand.
d) Drawings indicating structural and mechanical design specifications shall
be available for inspection on request.
e) All hydraulic and mechanical jacks shall be installed in accordance with
manufacturer’s instructions.
f) No person shall remain on or in any equipment being lifted or supported
by a mechanical or hydraulic jack.
g) All lifting support equipment shall be inspected prior to use to ensure
safe operating conditions. Packers shall not be placed between the lifting
support equipment and the load; if packers are required they shall be
designed for the purpose and be placed between the lifting support
equipment and the supporting floor.
5.25. Significant Lifts
Lifts that require a significant lift study are defined as
a) Lifts that exceed 20 tons or
b) 85% of crane capacity or
c) where it is proposed to use more than one crane or

d) more than one hook on the crane is used to lift one load or
e) where a load greater than 2 tons is to be lifted over or within 6m of a
critical service or
f) where there is potential to damage underground services or
g) Lifting over the operational facilities.
5.26. Hot Work
a) Where possible or feasible, avoid performing Hot Work but rather
substitute another work method. Examples of some options may include
moving the work to a Designated Area or using a pipe cutter or other
non-sparking, open flame or heat producing equipment.
b) Designated Areas shall be specified in Ma’aden’s Hot Work Program as
soon as they are identified. Designated areas must be approved by Fire
Protection, the Department Superintendent and the EHS Department.
c) Wherever Hot Work must be performed outside of Designated Areas, a
Hot Work Permit must be issued. Non-designated areas may be
classified as Designated Areas if they are assessed for hazards, the
precautions identified and the area entered onto the list of Designated
Areas. Designated Areas must protect personnel from hazards
generated by hot work with welding curtains, walls, etc.
d) The permit shall be displayed for the duration of the work (normally one
shift) in a visible location at the job site. At the conclusion of work, the
Location Designee shall review the permit, note any irregularities and
cancel the permit with his signature.
e) Hot work inside of Designated Areas shall be performed in accordance
with Ma’aden’s Hot Work Program and shall not be performed until a B4
EHS Risk Assessment or a SWI has been prepared for the work.
f) All completed hot work permits shall be forwarded to the Department
H&S Supervisor. The H&S Supervisor shall review the completed hot
work permits periodically to ensure compliance with the hot work
program.
Hot Work Permit Procedure
The Hot Work Permit Procedure (sometimes known as a Cutting and Welding
Permit Procedure), is designed to minimize the potential for fire and/or
explosion, whenever “Hot Work” is undertaken.
The term “Hot Work” is meant to mean and shall include:
All or any work involving the use of electric welding equipment,
oxygen/acetylene - LP gas cutting or heating equipment, and any
other work, which involves the use of, or introduces an open flame
or any such other ignition source, to specific areas, locations, or
equipment sites.

A Cutting and Welding Permit shall be obtained for all high-risk fire
and explosion hazard areas, particular those
a) Contractors involved with “Hot Work” shall acquaint themselves with the
“Cutting and Welding Permit Procedure” at each location.
b) It shall be the Contractor’s responsibility in consultation with the site
Safety Dept. to determine and cover the need for a competent fire watch
person.
Welding and Gas Cutting
a) All welding and gas cutting work shall be carried out in accordance with
the Ma’aden Aluminium Hot Work program.
b) All persons carrying out welding shall be suitably qualified to do so.
Welder's qualifications shall be held on file at the work site and shall be
audited by Ma’aden Aluminium.
c) Contractors shall instruct employees in the safe use of welding and gas
cutting equipment.
d) Fuel gas hose and oxygen hose shall be of an approved type, being
easily distinguishable and shall not be interchangeable. Hoses shall be
inspected at the beginning of each workday and shall be repaired or
replaced if defective.
e) Harmful gases can be given off when carrying out certain types of cutting
and welding work and the Contractor shall provide a proper atmosphere
or appropriate respiratory protection when welding, cutting or heating.
f) Zinc, lead, cadmium, mercury or beryllium bearing based or coated
materials, stainless steel with inert gas equipment can cause an unsafe
accumulation of contaminants, particularly in confined spaces.
g) An approved operable fire extinguisher with current inspection tag must
be available for standby use at the job site.
h) Incombustible or flameproof shields in high activity areas to protect
persons from direct rays shall shield cutting or welding operations. This
can be achieved by the erection of temporary welding bays and /or
welding blankets being hung around the welding area.
i) No person shall use matches, rope, wicks or other shouldering materials
for the lighting of gas torches. An approved type flint gun shall be used
for this purpose.
j) No welding or burning shall be undertaken where hot metal can fall into
an uncovered cable ladder or onto electrical cables. Before cutting or
burning work is started, all cables shall be covered in an approved
manner, using sheet metal or fire protection blankets. Contractors shall
request inspection by Ma’aden Aluminium before starting work.
k) Gas cutting of drums is not permitted on Ma’aden Aluminium’s work
sites.

l) Under no circumstances shall any person use high-pressure bottled gas
to dust down clothing or one’s skin.
m) The use of flammable solvents, oil or grease is strictly forbidden for the
cleaning or lubrication of gas or oxygen hoses, fittings or other apparatus
because of the risk of explosion in the oxygen atmosphere.
n) Whenever oxy/acetylene cutting is necessary in an enclosed space, the
cylinders shall not be positioned in that space. The vessel or space shall
be well ventilated by forced fan, if necessary.
o) Oxy/acetylene flame must be established outside of the enclosed space.
p) Oxy/acetylene cutting/heating torches shall not be ignited inside tanks
and vessels or any other place where gases can accumulate.
q) Flashback arresters shall be fitted to both the gas hand piece and the
gauges.
Gas Bottle Handling and Storage
a) The safe use, handling and storage of gas bottles on Ma’aden
Aluminium’s Flammable Liquid and Gas Program.
b) All lifting devices shall be designed for the specific purpose and have
SWL clearly marked. Gas cylinder storage areas shall be separated by
at least 8 meters from combustible liquids,
c) Flammable materials or heat sources. If a storage area is space
restricted, a non-combustible fire barrier, with a half-hour fire retardant
rating shall isolate the oxygen storage area.
d) Fuel, gases, e.g. acetylene, carbon monoxide, LPG, etc. shall be stored
separately from oxidizing gases, e.g. air, oxygen and nitrous oxide.
Oxygen storage areas shall be properly ventilated.
e) Gas cylinders are color coded and identified and no cylinder shall be
repainted or its content identification marker changed.
f) Cylinder valves shall be closed when work is finished and when cylinders
are empty. Valve caps shall be in place when cylinders are transported
or moved.
g) Compressed gas cylinders shall be secured in an upright position when
in use, in storage and during transport.
h) Gas cylinders shall not be transported or raised or lowered to another
work level unless an approved holder or carrier designed for the
transport of gas cylinders is used.
i) Cylinders shall be kept at a safe distance and shielded from welding or
cutting operations. Cylinders shall not be exposed to electrical circuits or
heat.
j) Oxygen and fuel gas regulators shall be in proper working order whilst in
use and spark arresters fitted.

k) Use only the correct opening key. Opening keys should not be modified
nor extended. Leave key connected to the cylinder when in use.
l) Acetylene and other fuel gases shall not be stored in enclosed spaces
even overnight, e.g. panel vans, vessels or containers.
5.27. Fire Protection
Fire protection and prevention is an on-going program that shall be integrated
with all phases of work.
a) When work is carried out in critical fire hazard areas designated by
Ma’aden Aluminium, the Contractor shall carry out a job safety analysis
in and shall conform to the Hot Work Permit Procedure
b) Supply and maintenance of fire extinguishers shall conform to the HCIS
standards.
c) The Contractor shall furnish, install, and maintain portable fire
extinguishers in workshops, site offices and equipment (lube trucks,
cranes, refueling trucks, etc) as required by statutory regulations.
d) Open fires are prohibited.
5.28. Site Facilities
Site Office and Crib Facilities
a) Any type of temporary site facilities sited in Ma’aden Aluminium shall be
in accordance with HCIS SAF 03.
b) Where the scope of the job requires so, the Contractor shall provide a
site office and crib facilities to effectively manage the contracted work,
unless otherwise advised by Ma’aden Aluminium.
c) The Contractor shall be notified at the pre-tender site visit with full details
of site facilities and services that shall be provided by Ma’aden
Aluminium. The Contractor shall provide all other site facilities and
services required to complete the contracted work.
d) Contractor’s site facilities shall be established only in locations approved
by Ma’aden Aluminium and in accordance with the following guidelines.
e) On completion of the contracted work, all Contractor site facilities,
including tie lines into power and water services, shall be removed and
the plant area restored, by the Contractor, to the satisfaction of Ma’aden
Aluminium.
Amenities Buildings
a) The Contractor shall ensure that the following minimum standards are
provided and maintained:
A weatherproof shelter with fly-screened windows capable of being
opened.

Each unit shall be of a size with not less than one square meter of
flooring area for each person.
Each unit shall be lined, adequately lit and ventilated (including an
extractor fan) and shall have washable floors and fly strips to the
doorway.
b) Each unit shall be equipped with:
A non-absorbent washable table or tables with seating
accommodation providing a bench of not less than 400mm wide
and 450mm long for each person.
Hooks at least 450mm apart for the purpose of hanging clothes.
Covered garbage bins.
A notice board or place where notices may be displayed.
c) Cool, clean drinking water shall be provided at all times.
d) Brooms, mops, buckets and approved cleaning compounds (MSDS to be
provided) shall be provided and used to maintain each shed in a clean
condition at all times.
e) No unit shall be used for the storage of building materials and tools
except where no more than ten persons are employed; the amenities
building may be used for the purpose of tool storage and site office.
Workshops and Storage Areas
a) The Contractor may establish site workshops and/or storage areas if
approved by Ma’aden Aluminium. The Contractor’s request for approval
to establish workshop and/or storage areas shall include details of
building type and size of the proposed facilities.
Toilets
a) The Contractor may be required to provide temporary construction toilet
facilities in some work locations. Requirements shall be notified at the
pre-tender site visit.
b) Toilet facilities shall be maintained in a clean, sanitary condition at all
times. These facilities shall be subject to inspection by Ma’aden
Aluminium.
First Aid
c) The Contractor shall provide first aid stations at their work sites. First Aid
stations shall be subject to periodic inspection by Ma’aden Aluminium’s
medical staff.
d) Ma’aden Aluminium’s first aid facilities shall be made available for
emergency care only.

5.29. Health
Health Surveillance
Ma‘aden Aluminium requires that an employee of a Contractor who is
engaged to work at a Ma‘aden Aluminium facility for a period exceeding three
months at any one time shall undertake a health assessment comprising:
A record of the persons work history
A respiratory questionnaire
A lung function test.
An audiometric test
a) “Initial” and “periodic” health assessments shall be carried out in
accordance with the above. A health assessment is carried out on each
employee at intervals not exceeding 5 years.
Noise
Noise is any unwanted or damaging sound. Noise induced hearing loss is the
main consequence of exposure to excessive noise, and is closely related to
the average amount of noise received by a person over a working day.
a) A persons’ exposure to noise in the workplace shall be managed in
accordance with Ma‘aden Aluminium‘s hearing conservation program
b) Noise exposure shall be reduced as far as practical by controlling noise
at the source. Hearing protection shall be worn in areas where noise-
warning signs are posted. Hearing protection shall be worn when using
portable tools such as:
Jack hammers
Rivet busters
Grinding tools
Air operated chisels
Impact wrenches
Circular saws
Power drills
Retubing tools
Air arc gougers
Any tool where the noise generated exceeds 82dB(A)
c) In some situations double hearing protection may be required. Consult
the site Occupational Hygienist for assistance.

d) Where a person is required to wear hearing protection, they shall be
trained annually in the principles of hearing conservation and in the
correct use and maintenance of hearing protection.
Dust, Fumes, Mists, Gases and Vapors
a) Persons required to wear respiratory protection shall be trained in its use
and fit tested for the specific respirator annually.
b) Point of source extraction equipment shall be used when welding in
workshops, confined spaces and during welding of stainless steel and
galvanized materials. In addition respiratory protection for the protection
against welding fumes shall be used in confined spaces.
c) Do not weld on painted or chemically treated surfaces.
d) No angle grinding shall be carried out on materials which contain
asbestos, synthetic mineral fibers (glass fiber, ceramic fibers, etc.) and
polyurethane or on any piping or vessel lagging, plastic, rubber or any
other synthetic material.
e) Respiratory protection shall be worn in those areas designated by
Ma’aden Aluminium and when airborne dust is clearly visible. Some
areas where this may be necessary are in alumina transportation,
calcination vessels, crushers and during descaling, grit blasting, jack
hammering and angle grinding & cutting.
f) When chasing/cutting concrete or bitumen using brick cutters, water
shall be used to suppress dust and respiratory protection shall be worn.
g) Compressed air shall not be directed upon a person or used to blow
down equipment. Flammable materials shall only be taken into a
confined space in accordance with the Confined Space Entry
Procedures.
h) When belt-splicing chemicals are being used, organic vapor cartridge
respirators and nitrile gloves shall be used. In confined spaces,
ventilation shall also be used.
Fitness for work
a) Each contractor company shall have a process to ensure employees are
fit for work. The process shall have regard for physical fitness, mental
fitness (not affected by a family death or tragedy for example), drugs or
alcohol. Supervisors shall have the skills to ensure that the employees
for whom they have a duty of care are fit for work.
b) If in the opinion of the supervisor, a person is adversely affected by
drugs, alcohol, or is not fit for work (i.e. due to fatigue or psychological
issues) the supervisor must prevent the person from working, and
remove them from site.

Heat Stress
a) Where exposure to heat stress may result in ill health effects such as
heat stroke, the Contractor shall control exposures by implementing a
prevention program consisting of acclimatization, water replacement,
provision of shade, ventilated work-areas and personal protective
equipment as appropriate.
b) Prior to performing work during hot weather, the contractor shall conduct
a thorough heat stress evaluation to identify tasks and conditions that
present a potential heat stress hazard. This evaluation shall include
observations, discussions with workers and supervisors, review of any
previously reported heat-related illnesses.
c) The contractor shall develop and implement a written heat stress
management program based on the results of the heat stress evaluation,
as well as Ma’aden Aluminium heat stress requirements.
5.30. Molten Metal
a) Where contractors are required to work in molten metal areas, approved
fire retardant clothing is to be worn. Where exposure to molten metal
may occur, molten metal face shields shall be worn at all times. Fire
retardant tops shall not be tucked in to the trousers, as in the event of
contact with molten metal there is a risk that it may enter the pants.
b) Anything containing moisture or water must be well segregated from
molten metal, as liquid causes rapid expansion of the metal and can
cause explosions.
5.31. Hazardous Materials
A “HAZARDOUS MATERIAL” is defined as any workplace substance (liquids,
gases, powders, fibers, chemicals) which can be inhaled, ingested, or come in
contact with the skin or eyes and has the potential to cause injury by way of its
chemical, physical or toxicological properties or has the potential to harm the
environment.
a) The storage of chemicals including fuel, oil and other hydrocarbons and
gases shall be in accordance with Royal Commission Environmental
Regulations 2010 (RCER-2010). Certain stores of chemicals and gases
must be manifested and audited as part of Ma’aden Aluminium’s site
permits and RCER-2010 requirements. These stores require the
approval of the EHS Department and must meet Ma’aden Aluminium
and Royal Commission Standards.
b) All chemicals brought onsite are required to undergo a Hazardous
Materials assessment, carried out by the EHS department according to
the Hazardous Materials procurement procedure. Approval needs to be
obtained before the chemical can be used onsite.
c) Chemical and hydrocarbon containers shall be stored and transported
securely to minimize the risk of spillage and have secondary

containment such as a designated bund, bunded pallet or cabinet with
the ability to contain leaks and spills.
d) The Contractor shall minimize the number of drums brought on to site.
Contractors shall take all measures possible to minimize the risk of
contaminants entering unsealed ground especially with regard to run-off
within contractor yards or during onsite activities.
e) All spills of chemicals or hydrocarbons must be cleaned up and reported
as per Section 7.5 Spill Control and Clean-Up.
f) The Contractor shall maintain a hazardous materials register containing
copies of MSDS’s for all hazardous materials used on site. A copy of
this register and updates for new hazardous materials shall be submitted
to the location Hygiene Department prior to using these hazardous
materials.
g) Hazardous materials shall be managed in accordance with the Royal
Commission Environmental Regulations (2010).
h) The Contractor shall ensure that all hazardous materials used on site are
handled in accordance with the Manufacturer’s Safety Data Sheet
(MSDS).
i) The MSDS shall be made available to all end users of hazardous
materials and they shall be instructed on their safe use.
j) The critical elements of the MSDS shall be referenced in the JSA, or
alternatively the MSDS shall be attached to the JSA for the job being
done.
k) The Contractor shall have a copy of his Hazardous Materials Register
available on site at all times when he is on site.
l) Waste hazardous materials such as PCB’s, asbestos or fibrous materials
shall be disposed of in a manner approved by Ma’aden Aluminium.
m) Ozone depleting substances e.g. trichloroethane of BCF fire
extinguishers and asbestos are not permitted to be used on any site.
Caustic
Caustic is found in most pipes and tanks within alumina refineries and residue
storage areas. Caustic can create significant chemical burns when contacting
the skin. When contact with caustic occurs it can penetrate deep into the
layers of skin.
a) If you come in to contact with any chemical, including caustic take the
following actions:
WASH the affected area for a MINIMUM of 20 MINUTES under a
safety shower/eyewash station
Call the emergency response number for the site and obtain
treatment from a medical professional

b) All chemical contacts must be reported immediately to the Medical
Centre.
Solvents, Asbestos, Silica, Isocyanides, SMF and PCB’s
a) Waste hazardous materials shall be disposed of in a manner approved
by Ma’aden Aluminium.
b) No asbestos or asbestos containing substance shall be brought onto site
without written approval from Ma’aden Aluminium.
c) Existing asbestos containing materials shall only be handled in
accordance with site Asbestos Policies and Procedures.
d) Silica shall not be used for abrasive blasting. Where possible abrasive
blasting shall be wet garnet blasting must have approval from the site
Hygienist, Environmental and the Department Manager prior to
commencing work.
e) Paints and polyurethane containing isocyanides shall not be used,
unless written approval is obtained from Ma’aden Aluminium.
f) Synthetic mineral fibers (glass fiber, Rockwool and ceramic fibers) shall
be handled in accordance with site policies and procedures.
g) No ceramic fiber or ceramic fiber containing substance shall be brought
onto site without approval from Ma’aden Aluminium.
h) No PCB or PCB containing substances shall be brought onto site without
written approval from Ma’aden Aluminium.
Explosives and Blasting
a) No explosives shall be brought onto site without prior approval of
b) Explosives shall be registered with Ma’aden Aluminium when brought
onto and taken from the site. Detonators shall be stored separately from
explosives.
c) Report immediately to Ma’aden Aluminium any theft, loss or
disappearance of explosives or detonators.
d) When electric blasting caps are used, warning signs against the use of
mobile radio transmitters shall be displayed on all roads and areas within
300 meters of the blasting area.
e) Explosives shall be stored in approved, registered facilities.
f) Smoking and open flames shall not be allowed within 20 meters of
storage facilities. Only authorized and licensed persons shall be
permitted to handle and use explosives.
Radiation Procedures
a) The use of radioactive substances in the Kingdom of Saudi Arabia is
governed by “KACST“.

b) Before removal, radiation devices are required to be isolated. No
maintenance/construction work shall be done on or adjacent to
radioactive instruments without permission from Ma’aden Aluminium’s
Radiation Safety Officer or delegate. If in doubt, check.
c) Portable radiation sources, e.g. welding, x-ray testing equipment,
observe the appropriate procedures and clearance requirements.
d) Under no circumstances shall untrained or inappropriately qualified
personnel or unauthorized persons attempt to remove, or in any way
interfere with, the radioactive sources or carry out any maintenance,
adjustment or modifications to radiation gauges or remove any pipe work
which has a radiation gauge mounted or attached.
e) Contractor’s employees shall report all defects in equipment that come to
their notice which they believe are likely to cause a radiation exposure or
contribute to one arising.
f) Contractors’ employees shall acquaint themselves with and obey all
radiation notices displayed in places they occupy and all instructions
issued to them to protect their safety and the safety of others.
g) Any person possibly contaminated shall be referred to the Medical
Centre. If any radiation incident occurs Ma’aden Aluminium’s Radiation
Safety Officer shall be informed immediately.
h) Contractor's employees shall use, in a manner required by the statutory
authority, devices or equipment furnished to them to assess their
personal radiation exposure when required.
i) Employees shall be provided with and use the necessary personal
monitoring and protection measures while using/handling ionizing
radiation equipment.
j) All portable radiation sources shall be surveyed before and after use or
movement using proper and calibrated radiation survey equipment
5.32. Site Access
Safe Access Induction
a) The Ma’aden Aluminium Safe Access Induction to be followed at all
times. The procedure details all relevant information for contractor
access to Ma’aden Aluminium sites. During larger construction projects
there may be additional criteria to be met prior to access being granted.
b) The table below indicates the minimum requirements for induction but
not be limited to:

Company policy Incident reporting
Emergency Response and PPE

notification
Security policy Basic safety rules
Smoking Policy Site Traffic regulation
Understanding safety signs and Work permits

warnings
Heat stress Industrial hygiene
5.33. Environment
Contractor’s Responsibilities
a) It is the responsibility of the contractor to manage themselves in
accordance with Ma’aden Aluminium’s EHS Policy and applicable rules
and regulations, which include but are not limited to those outlined in
Section 4.
b) Should the contractor require assistance each facility and site has an
Environmental or EHS Department that is available to provide advice on
environmental issues.
Contractor’s Yard Management
a) It is the responsibility of the Contractor to manage their yards in
accordance with Ma’aden Aluminium standards and Royal Commission
regulations. The yards are located on or adjacent to the facilities and
mine sites and hence must be managed according to the same laws and
regulations.
Above Ground Storage Tanks & Bunding
a) All above ground storage tanks shall be contained in accordance with
the requirements of RCER-2010. Secondary containment facilities shall
be regularly inspected to ensure good maintenance and integrity. All
tanks owned by contractors must meet requirements of RCER-2010 and
good engineering practice.
b) Underground storage tanks are not permitted on Ma’aden Aluminium
sites.
c) Any water discharged from secondary containment to the environment
shall be first confirmed by testing to be uncontaminated, or be rerouted
to an appropriate disposal system approved by Ma’aden Aluminium.

Chemical Contamination
a) Chemical contamination (such as caustic or hydrocarbons) of soils,
groundwater and surface water shall be avoided. In the event that a
spillage occurs an immediate response is required to contain, remove
and clean up the area according to the procedures detailed in Section
7.5 Spill Control and Clean-up. Depending on the severity of the spill,
Ma’aden Aluminium staff must be notified according to the Loss of
Containment Reporting and Investigation Guideline. For a spill >20L
offsite or onto unsealed ground the site Environmental or EHS Manager
must be notified immediately and an investigation shall be conducted.
Any spill >20L inside a bund/containment facility or on sealed ground or
any volume offsite or on unsealed ground must have an environmental
incident raised as soon as possible (see Section Environmental Incident
Reporting).
Spill Control and Clean-Up
a) Each site has an Emergency Response Plan which contains Inventory of
hazardous materials (MSDS), Spill response and prevention procedures
and Notification requirements.
b) It is the responsibility of the Contractor to be familiar with the specific site
plan and what to do in the event of a spill.
c) Spills >20L in a contained area (sealed surface) or any volume offsite or
on unsealed ground shall be recorded on the Environmental Incident
Reporting system (see Section 5.25.11 Environmental Incident
Reporting).
In addition to requirements of the emergency response procedure,
Contractors shall adhere to these general requirements:
All reasonable precautions shall be taken to prevent the spillage of
caustic fluids, hydrocarbons or chemicals.
In the event of a spillage implement immediate temporary control to
stop the spillage from spreading (e.g. earthen bund wall).
Arrange the removal and disposal of contaminated soil according to
Ma’aden Aluminium’s direction.
Waste Disposal
a) The Contractor is responsible for the disposal of its own waste unless
otherwise agreed to with Ma’aden Aluminium. All waste must be
disposed of in accordance with the requirements of RCER-2010.
b) Ma’aden Aluminium operates a waste segregation system, where waste
types are segregated in accordance with the type and disposed of
appropriately. Bins and dumpsters are labeled and color coded to assist
with segregation of waste. At contractor yards Ma’aden Aluminium shall
be providing large serviced bins to facilitate waste segregation. Bins are
regularly assessed for cross contamination.

c) Waste from other premises, the public, or your home is not permitted for
disposal in Ma’aden Aluminium bins or any waste facility or accumulation
area at each Ma’aden Aluminium Operation.
d) Process wastes such as residue material, scale, alumina or sand cannot
be placed in general waste or recycling bins. Process waste dumpster
bins are located around site to safely dispose of process wastes.
e) Contractors handling or transporting hazardous or large volumes of
wastes should consult with the Ma’aden Aluminium environmental or
EHS department to ensure that they meet Ma’aden Aluminium’s
standards and the relevant legislation. All contractors disposing or
receiving waste from Ma’aden Aluminium must be audited prior to
commencing work to ensure they meet these requirements and shall be
subject to regular audits thereafter.
f) All wastes travelling offsite shall be transported by Ma’aden Aluminium
approved contractors and disposed of at Ma’aden Aluminium approved
facilities. The details of each load must be recorded on a Ma’aden
Aluminium standard Waste Manifest form report and must be reported to
the site Environmental or EHS Department.
g) For more information on correct waste disposal contact the site
contractor waste coordinator or the site Environmental or EHS Dept.
Vegetation Clearing
a) No clearing of vegetation shall occur on any Ma’aden Aluminium land
without approval from the Environmental Department. A Ma’aden
Aluminium Vegetation Clearing Permit is required for clearing of any
vegetation unless it is an ornamental plant planted in an ornamental
garden. Native vegetation includes live trees, dead trees, bushes and
grasses. If you are unsure, contact the Environment or EHS Department.
Dust Management
a) The facilities operate under environmental permits that have specific
dust management requirements and emission limits.
b) Dust suppression controls and monitoring shall be used when a
Contractor is conducting work that has the potential to generate dust.
Where work has the potential to generate significant dust, e.g. large
construction projects, dust suppression plans and controls must be in
place and approved by the Environmental or EHS Department prior to
the commencement of the work.
c) Significant dust emissions shall be raised as an Environmental Incident
Report in IHS.
d) At the mine, dust suppression is also a safety issue, particularly on haul
roads. Contractors must liaise with their Ma’aden Aluminium
Responsible Person to manage dust within the Mine.

Emissions Management
a) The Contractor shall not install, remove or modify any noise or air
emission control equipment unless they have received prior approval
from Ma’aden Aluminium. The Contractor shall familiarize itself with the
emission control equipment installed in the area the Contractor is to visit.
b) The site Environmental or EHS department or their representative is
available to instruct the Contractor.
Water Management
a) Water supply shall be standalone aboveground water tank provided by
the contractor. However if this is not possible, connection to the Plant
water supply system must be approved by the Ma‘aden Aluminium EHS
Department. If connection is granted Plant water use must be minimized
and a minimization plan submitted to the Ma‘aden Aluminium EHS
Department for prior approval.
b) Wastewater streams from the site must be managed by the contractor
and a wastewater management plan submitted to the Ma‘aden
Aluminium EHS Department for approval prior to constructing the facility.
Note that all wastewater is treated by the Naturally Engineered
Wastewater Treatment (NEWT) system and the treated effluent is
reused on the site. Therefore Ma‘aden Aluminium does not discharge
wastewater from the site. The contractor wastewater may be accepted
for treatment by the NEWT but only upon application to the Ma‘aden
Aluminium EHS Department.
c) No wastewater is permitted to be discharged in an uncontrolled manner
from the contractor site.
Environmental Incident Reporting
d) The Contractor is responsible for ensuring that all environmental
incidents involving their employees are recorded and reported, in
accordance with the Ma’aden Aluminium EHS Non-Conformance and
Corrective Action procedure.
e) All incidents involving the Contractor’s employees shall be reported in
Ma’aden Aluminium’s Incident Management system known as IHS.
Contact the site Environmental or EHS Department for assistance with
entering an incident. You shall be required to provide details as to what
occurred as well as participate in any investigations that are required. If
access to this system is not available an incident can be recorded on an
incident template form, available from the Environmental or EHS
Department.
f) Examples of incidents that require reporting include;
Spills greater than 20 liters onsite inside or outside a bund
Any spill that occurs offsite or on unsealed ground
Visible dust emissions
Any clearing not authorized by the site Environmental Department
Breach of RCER-2010 Regulations
g) A full list of examples is available in the Ma’aden Aluminium Incident
Management System IHS. If in doubt about whether an environmental
incident has occurred, contact the site Environmental or EHS
Department for guidance on cleanup and reporting.

5.34. Attachment 1
Ma'aden Aluminium Weekly EHS Statistics Report Form
Company Name: Week End:

Plant/Unit: Date:
Prepared By: E-Mail ID:
Scope of Work:
SI Description This Week Accumulative
1 Safe Man-hours worked
2 Total Man-hours worked
3 Man Power
4 Fatality (FAT)
5 Lost Time Injury/Illness (LTI)
6 Restricted Duty Injury/Illness (RDI)
7 Medical Treatment Injury/Illness (MTI)
8 First Aid Injury Case (FAI)
9 Property Damage
10 Fire / Explosion
11 Near Miss
12 Environment
13 Total Recordable Cases
14 Number of days lost because of LWI
Number of Restricted / Job Transfer
15
days
16 Total Days Lost
17 Recordable Incident Rate (IR)
18 DART
19 Lost Time Injury Rate (LTIR)
20 Severity Rate of Lost Work Injury/Illness
21 Severity Rate of Total Days Lost
SI Skilled Staff Details Figure

1
2
3
4
5
Last review date Approved date Changes

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Contractor EHS

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

e) The Contractor’s equipment shall be maintained in the required condition

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

5.24. Lifting Equipment

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Emergency Response and PPE

Security policy Basic safety rules

Smoking Policy Site Traffic regulation

Understanding safety signs and Work permits

Heat stress Industrial hygiene

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

Ma'aden Aluminium Weekly EHS Statistics Report Form

Company Name: Week End:

SI Skilled Staff Details Figure

Last review date Approved date Changes

Ma’aden Aluminium Contractor EHS Requirements Printed: 7/28/2013 5:10:09 PM

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