emal contractor red book

8/22/2019 Emal Contractor Red Book

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EMAL Contractor EHS Requirements

EMAL CONTRACTORS

EHS REQUIREMENTS

Rev.00- October 2009 1


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IMPORTANT SAFETY NOTICE

The electro-magnetic fields generated in the production ofaluminium may cause malfunction of heart pacemakers orother electronic medical implants. Visitors to site fitted withthese types of devices are prohibited from entering theEMAL Industrial Area.

All visitors fitted with hear pacemakers or other electronicmedical implants must inform the EMAL SecurityDepartment on arrival at the main Security Gate.



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INDEX

1. Introduction

2. Disclaimer

3. Contractual Obligations

4. EMAL Core Values

5. EMAL EHS Policy

6. Contractor Site Access & Work Process/ Requirements

7. Safety Violations & Black Point System

8. Incident Communication, reporting and investigation

9. Personal Protective Equipments

10. Permit to Work

11. Lockout & Tagout

12. Working at Height (including portable ladders)

13. Confined Space

14. Mobile Equipment

15. Lifting Equipment

16. Hot Work

17. Signs, Signals & Barricades

18. Abrasive Wheels

19. Electrical Safety20. Excavation, Digging and Perforation

21. Housekeeping & removal of material

22. Cartridge operating fixing tools

23. Grit blasting

24. Working over water

25. Occupational Health

26. Environment

27. Fire Protection

28. Security Arrangements

29. Attachments



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1. INTRODUCTION

This booklet is issued to contractors carrying out work within EMAL. It outlines

Safety Health & Environmental requirements and procedures, which the Contractor

is required to follow when undertaking work.

The booklet is produced primarily for the use of Contractors Management and

supervisory staff who are required to ensure that the safety, Health and

Environmental requirements and procedures are brought to the notice of all

contractors employees and those requirements are and procedures are strictly

followed.

If there is any doubt or misunderstanding about the content of the booklet, the

contractor should consult EMAL Representative for clarification. Where the

contractors require special precautions or more detailed guidance on Safety

procedures, he should discuss this with the EMAL Representative prior to the

commencement of work.

2. DISCLAIMER2.1. This booklet provides summary of EMAL EHS requirements for contractors.

It has been prepared to facilitate EHS implementation by contractors when

working in EMAL, however it does not, in any way, relieve the contractors

from their contractual requirements to comply comprehensively with all

EMAL EHS procedures and standards. Relevant EMAL EHS Standards and

procedures shall be consulted for further details on specific issues.

2.2. The Contractor and the Contractors employees shall conform in all aspects

of their legal duties ad responsibilities as laid down by various U.A.E

Authorities. The following Safety, Health and Environmental requirements

and procedures do not relieve the contractor from his legal or contractual

obligations.



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3. CONTRACTUAL OBLIGATIONS

3.1. The contractor will ensure that all equipment, plant, machinery and

apparatus brought onto or used in EMAL are safe and without risk to health

and safety or the environment and is maintained to an acceptable standard.

All necessary test and examination certificates must be available for

verification at all times.

3.2. EMAL retains the right to stop any operation, activity or erection of plant/

equipment, etc., if it is considered to be detrimental to safety and health of

site personnel or (others). EMAL will not accept any responsibility for all

increased cost arising out of such action.

3.3. The contractor and contractors employees will obey all written or verbal

instructions given by EMALs representative and / or Area PTW Issuing

Authority in respect to Safety & Health of site personnel (or others).

3.4. EMAL retains, the right to remove the Security Clearance of any person not

complying with requirements, or any person in a Supervisory capacity who

permits such non- compliance.



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4. EMAL CORE VALUES

o SAFETY FIRST LAST & ALWAYS

o PROTECTION OF THE ENVIRONMENT

o EVERYTHING CAN BE IMPROVED

o INVESTING IN TODAY FOR TOMORROW

o WE RESPECT INDIVIDUALS AND THEIR DIFFERENCES

It is mandatory for every EMAL employee as well as contractors to comply and

follow the above five EMAL core values in all their activities and work. To help

EMAL realize its vision, we expect that all contractors will embed these core

values in their workforce and activities, resulting in a synergized effort for the

achievement of greater objectives.



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5. ENVIRONMENTAL, HEALTH AND SAFETY POLICY

We at EMAL are committed to continuous improvement and sustainable development.

We believe all accidents are preventable and we will work ceaselessly to ensure that our

business activities cause no harm to employees, contractors, visitors or community members,and have the minimum possible impact on the environment.

We are committed to achieving Environmental, health and Safety excellence through the

implementation of an effective Environmental, Health and safety management system, and more

specifically by:

- Creating a workplace culture where protection of peoples health, safety and the environment

is paramount and this is reflected in the behaviour of all concerned.

- Ensuring all EMALs management systems and procedures reflect current best practice,

specially in the areas of Health, Safety and the Environment.

- Ensuring all employees understand the Health, Safety and Environmental requirements and

impacts of their work, and their obligations in relation to this policy.

- Ensuring that all employees have the skills, knowledge and resources to allow them to work

safely, without impact on their health and the environment.

- Ensuring that all activities under EMALs control comply with this policy and all applicable

statutory requirements.

- Ensuring the environmental, health and safety aspects and impacts of our activities are fully

understood, and managed in accordance with best practices.

- Promoting Environmental, Health and Safety awareness amongst employees, contractors,

visitors, customers and the wider community.

EMAL Policy requires all its employees and contractors to behave consistently with the

requirements of this policy. Specifically:

- All employees area authorized to refuse to perform any act they judge to be unsafe

- No employee may be instructed to perform an unsafe act or work in breach of this policy

- All employees are required to stop any activity that they judge is unsafe or in breach of

EMAL policy.

- No employee shall incur any punishment or suffer any negative consequences as a result of

following this policy.

- No employee or contractor is permitted to act in breach of this policy and any such

occurrences may lead to disciplinary measures being taken against those accountable for

this breach.



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6. CONTRACTOR SITE ACCESS & WORK REQUIREMENTS

6.1. Before hiring

In order to guarantee that the potential tenderers have all information, know all

requirement and site conditions, the purchasing/ supply chain department will

attach to the project/ contract enquiry, the following documentation:

EMALs EHS policy

EMAL EHS Standards

Technical specifications

Other info sent by the contract administrator

H&S Prequalification Questionnaire (HS.SAF.09.F01)

6.1.1. Contractor prequalification

Prequalification is a mandatory requirement for all contractors who wish to

work for EMAL with the exception of the conditions stated for Service

Providers. Contracts can only be awarded by EMAL to pre-qualified

contractors. The H&S Pre-Qualification Questionnaire (HS.SAF.09.F01) is to

be sent with the enquiry documents to all proposed tenderers, if they are not

already pre-qualified.

To be placed on an approved contractor list, a contractor must obtain at least

40% rating in EHS prequalification.

The following categories will be assigned to the contractors based on their

pre-qualification ratings:

Exceed expectations for rating greater than 75%

Acceptable for rating equal to or greater than 40%

Not Acceptable for rating less than 40%



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6.1.2. EHS Standards

Purchasing/ Supply chain department shall send a CD containing all EMAL

EHS Standards to the potential tenderers along with the contract enquiry.

6.1.3. Plant Visit

For big projects or when requested by the project/ contract administrator, all

proposed tenderers shall visit the plant before sending the offer.

6.2. During hiring

Once the Contractor is selected, the purchasing department will request the

contractor to meet following EMAL requirements and submit appropriate

documentation related to the following to EMAL EHS department, at least 15

days prior to the start of the project.

6.2.1. EHS Plan/ Method Statement

EHS Plan to their scope of work comprising of identified hazards and their

control measures in accordance with EMAL standards. Risk Assessments

shall also be submitted along with this EHS Plan.

6.2.2. Contractor Site Representative and EHS RepresentativeThe Contractor shall nominate a Site representative and a EHS

Representative and notify EMAL in writing before start of the project. Prior to

that, CV of Contractor EHS representative shall be shared with EMAL EHS

for review and approval. If required, EMAL can ask for an interview of EHS

representative before approval.

6.2.3. Contractor employee list

The contractor shall submit a complete list of its employees who will work on

EMAL project. Attachment 1 (Form HS.SAF.09.F02) shall be used for this

purpose.

6.2.4. MSDS (Material Safety Datasheets)



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The contractor shall provide EMAL a list of all chemicals along with their

MSDSs, which are to be used during the works. Attachment 2 (Form

HS.SAF.09.F03) shall be used for this purpose. Material safety datasheets

(MSDS) shall also be available at the workplace.

The use of particular chemicals must be validated by EMAL Occupational

Health Service.

If additional products are to be brought to site, the contractor shall request for

EMAL approval prior to the mobilization of the product on EMAL premises.

6.2.5. Inventory of all equipments and machines

The contractor shall provide EMAL EHS with a complete list of all equipments

and machines to be used on the project along with relevant documentation.

Attachment 3 (Form HS.SAF.09.F04) shall be used for the purpose. The

documentation shall include a copy of the manufacturer instructions, and shall

be available in the workplace, equipment certification (if applicable) and legal

inspections of all equipments and machines to be used in the project/ contract

(welding machines, power generators, compressed air equipments, etc.).

Quarterly Inspections shall be done on all equipments and machines and an

inspection tag shall be posted in accordance with EMAL Electrical SafetyCode / Portable electrical tools standard.

No explosives shall be allowed on site other than cartridges used in cartridge

operated fixing tools.

EMAL can verify and inspect any equipment, inspection record.

6.2.6. Inventory of all standard free moving mobile equipments.

The contractor shall provide EMAL a complete list of all standard free moving

mobile equipments and their related documentation (Police Registration

document, valid third party certification, latest inspection record, operator

license and operators third party certification etc.) through Attachment 4

(Form HS.SAF.09.F05)



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6.2.7. Fall Prevention PPEs

The contractor shall provide complete list of all fall prevention PPEs to be

used on the project to EMAL. These include harnesses, lanyards, hooks etc.

Attachment 5 (Form HS.SAF.09.F06) shall be used for the purpose.

6.2.8. Lifting Tools (below the hook devices)

The contractor shall provide complete list of all lifting tools to be used on the

project to EMAL EHS. These include Lifting/ rigging tools and accessories like

slings, wire ropes, U-bolts and other such accessories. Attachment 6 (Form

HS.SAF.09.F07) shall be used for the purpose.

6.2.9. EHS Training & Certification

EMAL EHS will provide a Train the Trainer program for contractors. To attend

this Train the Trainer program, the contractor employee/ EHS representative

should have relevant EHS qualification and experience. Once the contractor

EHS representative successfully completes this program, a badge/ certificate

is issued, authorizing the EHS representative from contractor to train and

induct contractor employees for EMAL contract.

Each contractor shall provide relevant training as per the following table priorto the commencement of work as detailed in their EHS specification sheet.

Certificates of these trainings shall be made available to EMAL EHS.

Topic Theoretical

training

Practical

training

TEST Badge

Health & Safety Principles (UAE

Law)1h - - -

Forklifts YES YES YES YES

Cranes YES YES YES YES

Aerial Lifts YES YES YES YES

Loaders YES YES YES YES

Other Standard Mobile

EquipmentsYES YES YES YES



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Topic Theoretical

training

Practical

training

TEST Badge

LOTOV (Lockout & Tagout &

Verification)- AP level- See

LOTOV EMAL Standard

2h - YES -

Confined Space- Authorized

Entrants2h - YES -

Mobile Equipments (general

overview of the EMAL Mobile

Equipment & Pedestrian

requirements)

2h - YES -

Working at Height (If they are

going to use fall prevention

PPEs)

2h 2h YES -

Molten Metal overview (if they

are going to work inside Molten

Metal areas)

2h - YES -

Electrical Safety- Portable

Equipments. (If they are going to

work with portable electrical

equipments).

2h YES -

Heat stress control YES YES

Other training (required by the

Contract/ Project administrator or

HS department).

6.2.10.Medical Check-up Certificates

Each contractor has to submit to the EHS department, Medical check-up

certificates for all its workers in accordance with EMAL medical services

standards. Medical checks shall be done on an annual basis.

6.2.11.Access to the Site

If all documentation is correct and as per EMAL standards, only then the

contractor will receive a Contractor Site Access Permit (Attachment 7 Form

HS.SAF.09.F08) authorizing the contractor to enter EMAL premises.


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The access permit shall be signed by the relevant authorities from different

departments/ areas such as Contract Administrator, EHS department and

Security. EHS will keep a copy of the Access permit and all documentation in

the contractors file.

The following persons shall be required to carry EMAL authorization card in

their possession at all times during their work.

Operators of mobile cranes

Drivers/ operators of mobile plant (mechanically propelled vehicles)

Banksman for mobile cranes and heavy vehicles.

Persons authorized to use cartridge operated fixing tools Fire watchers

Persons authorized to change abrasive wheels

Persons entering into Potline Area

Alcoholic and non-Alcoholic prescription drugs shall not be permitted onto

EMALs premises. Persons suspected to be under the influence of alcohol or

drugs shall not be permitted onto EMALs premises.

6.3. During Work

6.3.1. Method Statements and Task Risk Assessments

A mandatory requirement to receive Permit-To-Work for any task is Method

Statement and Task Risk Assessment for that particular task.

6.3.2. Permit to work

Before starting the work the contractor shall request the Permit to Work. (See

EMAL Permit to Work Standard).



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6.3.3. Pre- Work Briefing

The first day of the work, all workers shall receive a pre-work briefing about

the risk of the area, emergency instructions, environment issues, reminders of

the special permits for special activities (if it is required).

6.3.4. Health & Safety Targets

The EHS department and the Contract/ project administrator will define EHS

targets for each contractor and subcontractor. The targets will be defined

according to the number of people, work durations and type of work.

The compliance level of the EHS targets will be used for the post work

evaluation. The contractor or subcontractor will be required to:

Self- Inspections

Risk Notifications

Job Observations

Toolbox Meetings

Participate in EMAL EHS Meetings and programs

Near Miss communication.

The Contractor shall also report its EHS Statistics every Sunday to the

Contract Administrator and EHS department. These statistics shall include

the following information from the start of the project:

Manhours worked

Number of Self-inspections

Number of Risk notifications raised

Job observations

Incidents including nearmisses

6.3.5. EHS Incidents



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All incidents shall be communicated to EMAL in accordance with EMAL

Incident Management system.

6.4. After the work - Post Work evaluation

After the completion of a project, the EHS department together with the project

owner/ contract administrator and contractor, will review the contractor

performance.

7. SAFETY VIOLATIONS AND BLACK POINT SYSTEM

7.1. General

7.1.1. Any Environment, Health or safety violation detected during the

contractor or subcontractor work execution shall be communicated to the

EHS department according to the EMAL Health & Safety Notification

standard. Once the EHS department receives the notification, it will

classify the violation and will assign the appropriate number of black

points and notify the contractor with a copy to the contract administrator.

7.1.2. The maximum number of black points allowed within a working year is

23, after which the contractor can be blacklisted from EMAL for 2 years,

meaning the contractor will not be allowed any further contract for this

duration.7.1.3. In case a contractor reaches 24 black points within a working year, a

panel will be formed comprising of EHS, Purchasing and relevant

department/s to decide the further course of action for the contractor.

7.1.4. The total number of black points accumulated by the contractor during

a contract shall be kept as a record in purchasing department and will

determine contractors future suitability for EMAL.

7.1.5. For every safety violation issued to the contractor, an action plan will

be required by the contractor to address the root cause of the violation

and rectify it, failing which the grade of safety violation will be raised.

NOTE: More details on safety violations and the process to raise them can be

found in EMAL Safety Notification Standard.



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7.2. Classification of Safety Violations

7.2.1. Low Risk

Minor flaws or faults in the following equipments, conditions

or tools, such as:

o Portable tools

o Welding equipments, power generators, compressed air

equipments, etc

o Portable electrical equipments

o Portable ladders

o Restrooms, warehouse, containers, etc

o Residual containers, not properly identified, etc.

Lack of:

o Housekeeping

o Incident reporting

o Secondary containers for residuals

Smoking in non designated areas

Over speeding for the first time.

First non-compliance of PPEs

Other safety violations classified as low risk by the EMAL

EHS department

7.2.2. High Risk

The non compliance of the safety rules, requirements

related to the following:

o Medical aptitudes

o Equipment or personal identification

o Inspection of a fall prevention PPE

o Equipment maintenance

o Lockout and tagout



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o Use of mobile equipments without the proper

certification

o Recurrence of a low risk by the same person

o Over speeding for a second time

Lack of maintenance, inspection or third party certification

related to the following:

o Lifting devices (slings, chains, tools, etc)

o Lifting equipments (Cranes, hoists, etc.)

Other safety violations classified as high risk by the EMAL

EHS department

7.2.3. Very High Risk

Failure to stop work immediately when asked by EMAL

because of high risk for people or equipments

Non compliance of a safety rule, procedure that generates a

high potential for a fatality or disabling injury.

Violating speed limit for a third time.

Soils, water or air contamination.

Work execution without EHS plan approval.

Other safety violations classified as very high risk by the

EMAL EHS department

NOTE: The above lists of unsafe events, conditions or acts for

determining different grades of safety violations, are not exhaustive and

any decision of EMAL EHS in this regard shall be deemed final.

7.3. Table of Black Points

The number of black points given for each grade of violation are detailed in

the following table:



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Type of Violation Number of Black Points

Low Risk Violations

First Notification 1

Second Notification 2

Third Notification 4

High Risk Violations



Third Notification 10

Very High Risk Violations



(NOTE: The decision of EMAL EHS in assigning number of black points to a

violation will be final.)

8. INCIDENT COMMUNICATION, RECORDKEEPING & INVESTIGATION

8.1. All incidents (with or without injury must be communicated, and properly

investigated). The non-reporting of an EHS incident is considered as a

serious fault and disciplinary actions could be taken.

8.2. In case of an incident, the worker or co worker must activate the emergency

response, 2111 or immediately notify to his supervisor. The Senior

Production Person, for the area, shall take immediate control, on arrival at

the scene.

8.3. An immediate investigation (preliminary investigation) shall be conducted by

the supervisor concerned. Attachment 8 (Form HS.SAF.03.F05) will be used

to record the preliminary investigation. The contractor EHS representativewill deliver a copy of the Preliminary Investigation to EMAL Contract

Administrator and EHS Department within 24hours of the incident.

8.4. A formal Incident investigation must be conducted and recorded in the EMAL

Incident Management System for all incidents with injuries.



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8.5. In EMAL The Incidents are Classified in:

Incident Without Injuries

o Near Miss

o Damage Incident

Incident with Injuries

o First Aid

o Medical Treatment

o Restricted Work

o Lost Time Injury

o Fatality

8.6. Incident Reporting Flowchart

NO

Did the employee experience an

injury or illness?

YES

NO

Is the injury or illness work-

related?

Yes

Is the injury or illness a new

case?NO

Update the previously recorded

injury or illness entry if necessary

YES

NO

Does the injury or illness meet

the general recorded criteria or

the application to specific cases?

YES

Do not record the injury

or illnessRecord the injury or illness



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9. PERSONAL PROTECTION EQUIPMENT (PPE)

9.1. General PPE requirements

9.1.1. All PPE must comply with European (EN) or the American National

Standards Institute (ANSI) safety standards.

9.1.2. Contractors shall provide EMAL a list of all the PPEs and their

specifications that will be used for the works for approval.

9.1.3. All PPE shall be of a safe design and construction for the work to be

performed.

9.1.4. There is a need to ensure that people with long hair, protect their hair

from contact with moving parts of tools and machinery. It is forbidden to

work outside of the office with long hair, unless it has been tied up out of

the way.

9.1.5. It is forbidden to work outside of the offices wearing jewellery in the

form of bracelets, necklaces and earrings. These must be removed prior

to going out onto the site.

9.2. Provision and suitability of PPE

9.2.1. The company shall issue safety equipment free of charge to

employees, dependant on the nature of their work.

9.2.2. Visitors to site shall be informed of PPE requirements before visiting

site.

9.2.3. The company will take into consideration the health of people wearing

PPE and its ergonomic effects. Employees should inform the company if

they start to have difficulty wearing any of their PPE due to health

reasons.

9.3. Compatibility

9.3.1. The PPE selected must fit the individual properly.

9.3.2. If more than one item of PPE is being worn, the different items of PPE

must be compatible with each other to ensure the risks are still being

adequately controlled.



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9.4. Assessment and identification of site and task PPE requirements

There are various ways in which site and task PPE requirements will be

identified and these are as follows:

9.4.1. Mandatory site PPE (outside of offices in designated areas)

All personnel entering designated PPE areas will be required to wear

the following items of PPE:

Hard hat

Safety glasses

Protective clothing/overalls. In Hot Work areas, flame retardant

garments certified with the EN 531:1995 level D2 is required.

Safety boots with methatarsal protection

9.4.2. PPE identified by mandatory signage

There are areas on site that will require you to wear additional PPE

when entering specified zones, for example hearing protection zones

or respiratory protection zones. These will be identified by mandatory

(blue and white) signage.

9.4.3. PPE identified by risk assessmentCertain tasks, for example working with substances, will require the

wearing of additional PPE. This additional PPE requirement will have

been identified by risk assessment and the information passed to

employees by supervisors or contract administrators.

10. PERMIT TO WORK (PTW)

Permit to work (PTW) will be required for all construction, modification,

maintenance, or inspection. Works that do not require PTW must be approved by

the department head and by the Safety Department. In such cases, the

Department is required to list the work and maintain proper record. All contractor

jobs will require a PTW.



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10.1. Issuing Authority (IA)

A competent person possessing the necessary experience, and technical

knowledge, appointed in writing by EMAL to issue, and cancel permits to work

within the terms of their authorization. An Issuing Authority will be always an

EMAL employee.

10.2.Receiving Authority (RA)

10.2.1. A contractor competent person possessing the necessary experience,

and technical knowledge, appointed in writing by EMAL to receive and

clear PTW.

10.2.2. For contractors, a letter shall be submitted by all contracting

companies stating competency of persons supervising all on-site

activities. Each supervisors letter shall be kept on file by EMAL EHS

Department who will ensure that the list of Receiving Authorities on the

EHS Homepage on EMAL intranet is updated.

10.2.3. The EHS department shall conduct a test for all contractor supervisors

applying to receive permits at EMAL. This shall be done prior to any

entry of the contractor supervisors name on the Safety Homepage onEMAL intranet.

10.2.4. In the event of a contractor coming to site for the purpose of

consulting, attending to a breakdown or doing an ad-hoc, once off task,

the contractor will only be allowed to work under EMAL supervision.

10.2.5. The Contractor Receiving Authority is responsible:

that the authorized employees comply with all requirements indicated

in the PTW.

Is responsible to lead and prepare the Pre-work check list.



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10.3.Permit to Work Process

10.3.1. The PTW has one sheet and all permits will be numbered. The PTW

sheet has three paper copies (white, yellow and pink).

10.3.2. The PTW will be completed by the issuing authority. Once the PTW is

completed the issuing authority and the receiving authority will sign the

PTW. The issuing authority will keep the original of the PTW (white copy)

and he will give the other two copies (yellow & pink) to the receiving

authority.

10.3.3. Before the commencement of any work under a PTW, the content and

work hazards and countermeasures (Pre- work check list Attachment 9

Form HS.SAF.01.F02) will be explained to the working party.

10.3.4. The receiving authority will give the pink copy of the PTW to a

competent person. This copy must be in the workplace.

10.3.5. Once the job is completed the CP will give back the pink copy to the

RA. The receiving authority will give back the two copies (yellow & pink)

to the issuing authority and he will sign the white copy of the PTW in theclearance box. The issuing authority will sign the PTW cancellation box

in the original paper (white)

10.3.6. A PTW will be valid until clearance and cancellation. A PTW once

issued, will be retained in the custody of the Receiving Authority, until

Clearance.

10.3.7. Receiving authority shall ensure the changes in the surroundings and

other environmental conditions at the work place. The responsibility of

checking the isolation status rests with isolating/issuing authority till the

PTW is cancelled. Where the Receiving Authority changes, then a

Transfer record must be completed. See Attachment 10.



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10.3.8. If during the work execution, changes are experienced in the work

conditions, the PTW will be cancelled until the normal condition will be

restored. If the PTW is cancelled, then a new PTW will be needed. The

PTW could be suspended and re-issued using the transfer procedure.

10.4.Pre- Work Check List

A Pre-Work Check List will be required for all jobs even when permit to work is

not required. See Attachment 9. The contractor receiving authority and the

contractor workers will complete the Pre-Work check list before starting the work.

The contractor receiving authority will sign the pre-work check list, with the sign

the receiving authority is confirming that the hazards and countermeasures were

explained and understood to the workers.

11. LOCKOUT, TAGOUT & VERIFY (LOTOV)

The EMAL Lockout, Tagout & Verification Program, describe the requirements to

guarantee a Zero Energy state for all Construction, Inspection or Maintenance

Jobs. It must be remembered that for certain tasks, it may not be possible to

guarantee zero energy. These jobs must be inventoried and the work procedure

approved by the HS department and Department Manager.

11.1. Isolating Authority (IsA)

A EMAL competent person designated by the owner of the area, with the

necessary experience, and technical knowledge for isolating equipment and for

implementing a tag out and lockout procedure.

11.2.Authorized Person (AP)

11.2.1. A EMAL or contractor competent person with sufficient technical

knowledge and practical experience who has been approved to carry out

a task on Plant or Apparatus that has been previously isolated by an

Isolating Authority (IsA)



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11.2.2. All EMAL and contractor employees with the exception of the

administrative personal must receive specific training about the energy

control program to assure the program is properly understood.

11.2.3. Refresher training will be required every two years or before if the

program changes or if it is considered because of increasing number of

incidents, violations or other reasons.

11.3. LOTOV Tags & Locks

The necessary elements for an equipment/ facility isolation are:

o Safety tags (Isolation tags, Personal and

Verification/Identification tags)

o Safety Locks (Isolation Locks and Personal Locks)

11.3.1.LOTOV Tags

Only tags are acceptable where no physical means of locking isolation

devices exists. The safety tag has three main purposes:

Isolation tag (red) Indicates that the energy isolation devices or

verification device are in the safe position. For example, supply

valve is closed, vent valve is open, etc

Equipment Identification and 0 energy verification tag

(yellow). Indicates the piece of equipment or equipment to be

worked on and confirms that the energy isolation devices were

verified and the equipment is at zero energy. If it has not been

possible to verify the equipment, then a verification tag should still

be attached for identification, but this should be noted on the tag.

In these cases the tag will be yellow with brand red diagonalstripes.

Personal Tags (blue) Indicates that there are people working on

the equipment out of service because of construction, inspection or



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maintenance. The personal tags are exclusively for personal use

and nobody could attach a personal tag of other employee.

The manipulation of a personal tag of another employee will be considered a

serious safety violation and disciplinary actions could be taken. The

contractor personal tags will be identified with the word CONTRACTOR in

print letters.

A safety tag is as restrictive as a safety lock.



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11.3.2.LOTOV locks

The purpose of the locks is to hold energy isolation device in the safe position

to prevent unexpected activation of an energy source, unexpected start-up or

unexpected release of stored energy. The locks are classified by colours and

with different means

Personal Lock (Blue)

IsolationLock (Red)

All locks shall be one key locks

11.4. Isolation Process

11.4.1. Isolations must be referenced in the Permit to work.

11.4.2. The Operations Team, use normal stop procedures to shut down the

Plant or Apparatus and release the Plant or Apparatus for Work.

11.4.3. An IsA will isolate (de-energize, tag out and lockout) the equipment. At

same time will verify the absence of energy and will attach the

equipment identification and 0 energy verification tag in the equipment or

piece of equipment to manipulate.

11.4.4. The IsA will introduce the keys of the isolation locks inside the key

safe and will close the Key safe with the control key. A Identification Tag

stating the Plant or Apparatus will be affixed to the Key Safe



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11.4.5. The IsA will sign the tag out and lockout procedure/Isolation Certificate

to confirm that the equipment isolation has been completed.

11.4.6. The Issuing Authority (IA) will attach one of the Key safe Keys to the

PTW, and will issue this key along with the PTW

11.4.7. The IA will also issue the completed LOTOV procedure/Isolation

Certificate to the Receiving Authority (RA).

11.4.8. The Receiving Authority will introduce the yellow copy of the PTW and

the key of the group box inside a card safe in the workplace or other

suitable location (workshop). They will close the card safe with their

Personal Lock and Tag. Each member of the working party shall also

secure the PTW/Key safe Key in the Card safe with a personal tag and

lock.

11.4.9. The personal tags could only be removed by the owner of the tags

when:

o The work is completed

o At the end of the shift



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o Other job is assigned or the person leaves the job before the

job is completed

11.4.10. Before starting to work, the receiving authority and each

member of the crew shall verify that the equipment/ facility is isolated

according to the LOTOV procedure.

NOTE: If a work in group isolation equipment continues for more than one shift,

the responsibility of the group isolation will be done by a Permit to Work

transference (see EMAL PTW Procedure HS.SAF.01).

11.4.11. The tags and locks removal will be according with this

sequence:

Each person will remove their personal tag and lock from the card

safe.

The RA will remove their personal tag and lock from the card safe and

will return the PTW to an Issuing Authority. The RA shall then sign the

white original copy of the PTW as work clearance.

The RA will give the yellow and pink copy of the PTW and the key of

the Key safe to the IA. The IA shall sign the PTW cancellation.

Once all of the Key safe Keys have been returned and all related

permits cancelled, the IA shall release the group tags and locks from

the Key safe and then remove the Isolation Locks from the energy

isolation devices and restart the equipment. The Plant or Apparatus

will then be returned to the Operations Team for safe return to service.

12. WORKING AT HEIGHTS

Fall control shall be required for personnel exposed to heights greater than 1.8m or

more and at lower heights if potentially hazardous situation exist.

All employees must take a three-step systematic approach to protect them from fall.



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The first step is to assess the workplace and the work itself. Fall hazard shall be

eliminated wherever possible by changing the sequence of the job, by working

from ground level or by the use of special tools, equipments.

The second step also requires assessing the workplace and work processes. If

fall hazard can not be completely eliminated during the first step, management

must take a proactive approach to the prevention of fall by improving the

workplace (collective protection). Early installation of stairs, guardrails, scaffolds,

and travel restriction systems can ensure a safe work environment.

The third step is to use fall arresting equipment. Use fall arresting equipment,

however, only after determining that potential fall cannot be eliminated by

changing work procedures or workplace or collective protection can not be used.

Equipment such harnesses, lanyards, shock absorbers, fall arresters, lifelines,anchorages and safety nets can reduce the risk of injury if a fall occurs.

12.1.Training

12.1.1. All contractor employees with the exception of the administrative staff

shall receive specific training about the working at height program to

ensure that the program is properly understood

12.1.2.Maintenance People or Those People Who Work At Heights: For

these people, refresher training will be required every two years or

before if the program changes or if it is considered because of increasing

number of incidents, violations or other reasons. The training shall be

documented and shall include the following topics/contents:

Use, visual inspection, and maintenance of fall arrest systems;

Practical training in the use of fall prevention equipments.

Must demonstrate competency in initial training

12.2.Scaffolds

12.2.1. Personal working on tubular or other scaffolds shall use a fall arrest

system unless the scaffold complies with the fall prevention system

requirements described in the Scaffolding EMAL Scaffolding standard.



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12.2.2. Scaffolds shall be erected and used in compliance with the EMAL

scaffolding standard and under the supervision of a competent person in

scaffold erection.

12.2.3. Before use the scaffold, the user must check the scafftag to verify that

the scaffold was inspected and the scafftag signed by a competent

scaffold inspector within seven days before the day of use.

12.2.4. A scaffold visual inspection shall be conducted by the user before

each use. If for any reason a user considers a scaffold to be unsafe he

shall immediately contact his supervisor. The supervisor shall

immediately remove the Scafftag and place barrier tape through the

lower rungs of the 1st access ladder. The supervisor shall then notify

the Scaffolding Supervisor.

12.3.Fall Arrest Equipment

12.3.1. The full body harness will meet ANSI (American National Standards

Institute) or EN (European Norms) standards. Safety belts are

prohibited.

12.3.2. A visual inspection shall be conducted by the user before each use of

fall arrest equipment.

12.3.3. Every quarter, a document inspection by a competent person shall beperformed on fall arrest equipment. Health and Safety Department will

nominate the competent persons for fall arrest equipment inspection.

12.3.4. Fall arrest equipment inspected and rejected for further use shall be

destroyed to prevent further use and inspection record shall be updated

to include the method of disposition.

12.3.5. The inspector shall complete the inspection record (Attachment 11

Form HS.SAF.04.F03) and forward a copy of the completed form to the

department EHS coordinator and another copy to the Health and Safety

department.



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12.4.General Practices

12.4.1. Workers must avoid climbing on equipment such as pumps,

exchangers, valve and wheels, transformers, electric motors, handrails,

structures, or any other facilities not specifically designed for climbing

12.4.2. Climbing on conduit, cable trays, or other similar equipment is not

permitted.

12.4.3. Climbing of vertical beams is not permitted.

12.4.4. Workers must not climb a ladder while another is above or below on

the same ladder.

12.4.5. Personnel performing jobs from an aerial lift, scissor lift or basket shall

use a fall arrest system attached to the basket.

12.4.6. Climbing onto the middle rail, top rail or working from the outside of the

basket is prohibited while the person is attached to the aerial lift, scissor

lift or basket anchorage point.

12.4.7. All work on flatbed trailers higher than 1.8m must be performed with

full fall protection such as - safety nets, fall arrest systems, or full

guardrail protection.

12.4.8. All work on flatbed trailers lower than 1.8m height shall be preferably

performed with full fall protection, if this is not possible anyone whoaccesses the flatbed trailer must be required to wear a hardhat with

chinstrap.

12.4.9. Climbing on top of a trailer load without fall protection is still prohibited.

12.5.Working at roof

Working at roofs require a Fall Protection Plan (HS.SAF.04.F02) and roof work

access permit.

12.6.Ladders

12.6.1. Portable manufactured ladders shall bear identification indicating that

they meet the appropriate ladder construction requirements of ANSI

(American National Standards Institute) or EN (European Norms)

standards.



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12.6.2. The use of metallic ladders is forbidden inside the Reduction

department, for electrical works or at proximity of live lines. For these

works a wooden or fiber glass ladders shall be used.

12.6.3. Portable single ladders shall not be used to jump heights greater than

3.5m.

12.6.4. Portable single ladders shall not be longer than 5m.

12.6.5. Ladders shall not be placed in front of doors opening toward the ladder

unless the door is blocked upon, locked, or guarded.

12.6.6. When ascending or descending, the climber must face the ladder and

must keep three points of contact. Tools should be carried on a waist

belt, in a shoulder bag or raised and lowered on a rope to ensure a

person climbing up/down a ladder maintains an adequate grip on the

ladder.

12.6.7. Ladders shall extend 1m above where a person can gain access at the

top of the ladder.

12.6.8. Ladders shall be placed at a gradient of not less than 1:4 (i.e. one

meter out horizontal for every four meters of height) and not greater that

1:6.

12.6.9. A portable ladder shall not be used by more than one person at the

same time.12.6.10. All portable ladders shall be equipped with shoes.

12.6.11. A portable ladder shall not be used as working surface. As

exception and when not possible to use a working platform, a scaffold or

an aerial lift, the next requirements must be considered:

12.6.12. When persons feet are positioned above 1.8m the employee

shall use a fall-prevention/arrest system.

12.6.13. Every three months a component person from the department

should inspect and maintain a list of all ladders in their charge and

record date of inspection and defects noted. See Attachment 12 (Form

HS.SAF.05.01 - Portable Ladder Inspection and Identification List).

Ladders adequate for using will be identified with a color code of the

quarter as follows:

1st

Q 2nd

Q 3rd Q 4th Q



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13. CONFINED SPACES

13.1.Definition

Means a space that:

- is large enough and so configured that an employee can bodily enter and

perform assigned work; and

- Has limited or restricted means for entry or exit (for example, tanks, vessels,

silos, storage bins, hoppers, vaults, and pits are spaces that may have limited

means of entry.); and

- Is not designed for continuous employee occupancy.

13.2.Confined Space Entry Permit

13.2.1. A Confined Spaced Entry Permit shall be required to entry in any

Confined Space.

13.2.2. Confined spaces shall be classified Class A or Class B confined

spaces. All the confined spaces entrances shall be identified with a sign

reading DANGER- PERMIT REQUIRED CONFINED SPACE, DO NOT

ENTER

13.2.3. The confined space entry permit is described in Attachment 13 (Form

HS.SAF.06.F01 - Confined space entry permit) and shall include:

All personnel in confined spaces and attendant will carry

portable lighting.

at least one attendant outside the permit space into which entry

is authorized for the duration of entry operations



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If hot works are done inside a confined space this one must be

reclassified as Class A confined Space. Hot work permit will

also be necessary and EMAL Hot Work standard shall be

followed.

Either double insulated or ground fault circuit interrupter

protected electrical tools and low current, low voltage (24 volt

maximum) lighting systems shall be used in damp or metallic

hazardous confined spaces.

Electrical and pneumatic tools shall be selected to eliminate

sparks and other hazards as required by the conditions of the

confined space.

Gas cylinders should not be used with in a confined space.

Should there be condition arises where gas cylinders have to

be used inside the confined spaces, special precautions are to

be taken and it shall be approved by H & S Department. At no

circumstances, CO2 fire extinguisher shall be taken into the

confined space.

Internal combustion engines should never be used inside

confined space.

13.3.Confined Space Training

13.3.1. Confined Space training for contractors shall be of two types:

o Level 0: All contractor employees must receive a general overview of

the EMAL Confined Space program.

o Level 1: All contractor authorized entrants and attendants shall

receive a specific training of the EMAL confined space program.

13.3.2. This training will be refreshed every two years. Each contractor must

have an updated list of all authorized entrants and attendants. The

certification shall contain each employee's name, the signatures or

initials of the trainers, and the dates of training.



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13.3.3. The training shall establish employee proficiency in the duties required

by this document and shall introduce examples of new or revised

procedures.

13.3.4. Additional to this training, all authorized employees and attendants

shall receive a specific pre-work meeting for the specific confined space,

before entering. This information will be provided by the confined space

issuing authority. This pre-work meeting is valid for six months in the

class B confined spaces and only for each work in the class A confined

spaces.

13.4.Duties of Authorized Entrants

The employer shall ensure that all authorized entrants:

13.4.1. Know the hazards that may be faced during entry, including

information on the mode, signs or symptoms, and consequences of the

exposure

13.4.2. Properly use equipment as required.

13.4.3. Communicate with the attendant as necessary to enable the attendant

to monitor entrant status and to enable the attendant to alert entrants of

the need to evacuate the space as required by this document;

13.4.4. Alert the attendant whenever:

The entrant recognizes any warning sign or symptom of

exposure to a dangerous situation, or

The entrant detects a prohibited condition; and

13.4.5. Exit from the permit space as quickly as possible whenever:

An order to evacuate is given by the attendant or the entry

supervisor,

The entrant recognizes any warning sign or symptom of

exposure to a dangerous situation,

The entrant detects a prohibited condition, or

An evacuation alarm is activated.



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13.5.Duties of Attendants.

The employer shall ensure that each attendant:

13.5.1. Knows the hazards that may be faced during entry, including

information on the mode, signs or symptoms, and consequences of the

exposure;

13.5.2. Is aware of possible behavioural effects of hazard exposure in

authorized entrants;

13.5.3. Continuously maintains an accurate count of authorized entrants in the

permit space. See Attachment 14 (Form No HS.SAF.06.F04 - Confined

space entry/exit record).

13.5.4. Remains outside the permit space during entry operations until

relieved by another attendant;

13.5.5. Communicates with authorized entrants as necessary to monitor

entrant status and to alert entrants of the need to evacuate the space

under described in this document;

13.5.6. Monitors activities inside and outside the space to determine if it is

safe for entrants to remain in the space and orders the authorizedentrants to evacuate the permit space immediately under any of the

following conditions;

o If the attendant detects a prohibited condition;

o If the attendant detects the behavioral effects of hazard exposure in

an authorized entrant;

o If the attendant detects a situation outside the space that could

endanger the authorized entrants; or

o If the attendant cannot effectively and safely perform all the duties

required for his position.

13.5.7. Summon rescue and other emergency services as soon as the

attendant determines that authorized entrants may need assistance to

escape from permit space hazards;



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13.5.8. Takes the following actions when unauthorized persons approach or

enter a permit space while entry is underway:

Warn the unauthorized persons that they must stay away from the

permit space;

Advise the unauthorized persons that they must exit immediately if

they have entered the permit space; and

Inform the authorized entrants and the entry supervisor if

unauthorized persons have entered the permit space;

13.5.9. Performs non-entry rescues as specified by rescue procedure

13.5.10. Performs no duties that might interfere with the attendant's

primary duty to monitor and protect the authorized entrants.

14. MOBILE EQUIPMENTS

The Industrial Free Moving Mobile Equipments are classified in:

14.1.Standard Free Moving Mobile equipments

Are operator controlled mobile equipment not constrained by Fixed rails and can

include gasoline, propane, diesel, or electrically powered used for labor activities

as, forklifts, aerial lifts, trucks, buggies, sweepers.

All standard Free Moving Mobile Equipment must be identified with:

- Mobile Equipment number (according to the EMAL identification code). This

identification must be painted or engraved in the Mobile Equipment and must

be visible from 20m distance. The recommended dimensions for the

identification are 21 x 30 cm.

NOTE: If the Mobile Equipment has official plate number, this identification

eliminates the previous requirement.

- SWL (Safe Working Load)



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.

14.2.Auxiliary Free Moving Mobile Equipments

These are Industrial Free Moving mobile equipments used to transport people

and equipment around site such as cars, 4x4, pick-ups and buses. The auxiliaryFree Moving Mobile Equipments do not have to comply with the 100% of the

requirements specified in this procedure (pre- use check list, audible backwards

signal) but must be identified with Department, Contractor Company or a visible

visitor vehicle pass.

The Auxiliary Free Moving Mobile Equipment is not allowed to be driven inside

the production buildings.

The use of two wheels mobile equipment is forbidden inside EMAL site. This

includes motorcycles and pedal cycles.

14.3.Free moving mobile equipment operators

14.3.1. The free moving mobile equipment operators shall pass the mobile

equipment medical evaluation. Moreover the driving license of every

driver should be checked prior to imparting of the training as per UAE

law (HS.SAF.13.A02).The driving license should be of the appropriate

category as the training category being imparted.

14.3.2. All Auxiliary Free moving mobile equipment operators shall be

required to provide a valid official UAE driving license for the class of

vehicle.

14.3.3. The Training for Standard free moving Mobile Equipment, shall

include:

- Theoretical trainingo EMAL Mobile Equipment Program

o General Safety rules and operating procedures

o Equipment controls and safe work instructions.

o Specific Mobile Equipment Instructions, including the manufacturer

indications.



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o Concepts about working with loads

- Practical training deployed by a competent person who has free

moving mobile equipment knowledge, training and experience.

Practical training shall include:

o Mobile Equipment driving, steering and maneuvering

o Vehicle pre operation checklist

o Load Manipulation, stacking and un stacking

o Vehicle stability

o They have to pass a written test and an accreditation will be given

to each authorized operator.

14.4.General Training

All contractor employees who do not drive Mobile Equipments and work in areas

where mobile equipment movement exists, will receive the same theoretical

training that is required for the Free Moving Mobile Equipment operators.

14.5.Mobile Equipment Certification

14.5.1. An EMAL Authorization Certificate to drive shall be issued to eachEMAL Mobile Equipment Operator which states Name, Employee

Number, department, class of vehicle, plant area, and validity.

14.5.2. The EMAL Authorization Certificate for Standard Free Moving Mobile

Equipment shall be issued by the Training department after confirming

that the employees have the medical aptitude and have passed the

theorical and practical training.

14.5.3. The EMAL Authorization Certificate for Auxiliary Free Moving Mobile

Equipment shall be issued by the Security department after confirming

that the employees have a valid UAE Driving License.

14.5.4. The Certificates shall then be forwarded to the H&S Department, and

a new ID badge will be issued indication that the employee is authorized

to drive on site, and category of vehicle.



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Photo

DriverCertification

Badge

Name

ID

Deptt

M.E

Driver CertificationBadge

Type of M.ETraining

(Next date)

Training

(Last date)

Photo

DriverCertification

Badge

Name

ID

Deptt

M.E

Driver CertificationBadge

Type of M.ETraining

(Next date)

Training

(Last date)

Note: Driver Certification Badge

14.6.Preventive Maintenance

14.6.1. Each contractor company will develop a preventive maintenance

program for all free moving mobile equipment according to the Original

Equipment Manufacturer (OEM) requirements and local legislation.

14.6.2. Mobile Equipment involved in incident shall not be repaired until

incident report is submitted to EMAL EHS department.

14.6.3. After every Preventive Maintenance, the contractor will fix a sticker in

the mobile equipment indicating the mobile equipment hours, km or date

for the next scheduled preventive maintenance.

14.7.Pre use inspections, Check List

14.7.1. A pre use inspection shall be performed on free moving mobile

equipment before each shift that the equipment is to be used to assure

that the following parts, equipment, and accessories are in safe

operating condition and free of apparent damage that could cause failure

while in use.

14.7.2. The pre use inspection will be divided in minor and major findings.

14.7.3. If a Major finding is detected the mobile equipment shall be

immediately locked out and tagged out according to the EMAL lockout &

tagout procedure. If Minor findings are identified, then it will be written in

the check list and communicated to the department mobile equipment



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responsible in order to include the equipment in the maintenance

program.

14.7.4. Major finding are considered all items that could affect the safety of the

Mobile equipment operator and/ or to the safety of the pedestrians, e.g.

seatbelt, flashing lights, brakes etc.

14.7.5. Pre use inspection records are to remain with the free moving mobile

equipment for the entire shift. Pre- use inspection records shall be

verified by each operator using the free moving mobile equipment. Pre

use inspection records shall be kept by the department mobile

equipment responsible for a minimum of three months.

14.8.Other Requirements

14.8.1. Do not block recognized gangways and access ways unless a clear,

safe diversion has been provided.

14.8.2. Only authorized routes must be used to and from work sites.

Contractors vehicles are not allowed to cross the Hot Metal Roads.

14.8.3. No road shall be closed off without written approval from EMAL. A

request for road closures shall be made at least 48 hours before the

closure is required. EMAL Representative shall send a copy of the

approved request to EMAL Security prior to closure of the road.14.8.4. All free moving mobile equipments and auxiliary equipments must be

equipped with seat belt. The number of passengers carried in company

vehicles will be determined by the fixed seating provided.

14.8.5. As general rule, if the mobile equipment is equipped with a closed

cabinet, the use of hardhat and safety glasses are not required.

14.8.6. The speed limits inside plant area are as follows:



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Outside

Buildings

Inside

Buildings

Auxiliary Free Moving Mobile Equipments:

Buses, trucks, cars30 10

Standard Free Moving Industrial Equipments

(forklifts, aerial lifts, )20 10

14.8.7. All vehicles should give prioritization to the Fire Brigade mobile

equipments or ambulances

14.8.8.Over speeding violations will be communicated according to EMAL

Safety Notification Standards. Moreover following steps would be taken

in case of a violation:

On first notification the operator/user would not be allowed to

operate/drive inside EMAL premises for 1 month in12 months.

On second notification the operator/user would not be allowed to

operate/drive inside EMAL premises for 3 months in 12 months

On third notification the operator/user would not be allowed to

operate/drive inside EMAL premises for 6 months in 12 months

and would have to pass through the mobile equipment training.

14.8.9.REVERSING WARNING: All free moving mobile equipment and any

associated towed equipment having obstructed rear vision shall be fitted

with an audible and or visible reverse warning system.

14.8.10. Splash guards: shall be required on all free moving mobile

equipment potentially exposed to molten substance splashes or in the

area of potential molten substance splashes such as free moving mobile

equipment used to charge, skim or carry molten splashes. Splash

guards shall be designed and installed to keep molten substances from

entering the cab or splashing the operator.



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14.8.11. CABS All vehicles with cabs shall be equipped with

windshields and powered wipers. Cracked and broken glass shall be

replaced.

14.8.12. WARNING LIGHTS All free moving mobile equipments shall

use flashing lights. If an Industrial Mobile Equipment does not have

flashing light, the use of a waning flag will be required

14.8.13. ROPS & FOPS All industrial mobile equipment shall be

provided with ROPS and FOPS. Any exception must be approved by the

Maintenance Senior Manager and HS Senior manager.

14.8.14. Parking

Auxiliary mobile equipment will always be parked in reversing

position. Before any startup the auxiliary equipment driver shall

have to sound the horn.

Parking violations would also be notified as per EMAL Safety

Notification standard and the same criterion as for over speeding

violation will be used.

14.9.Operational Guidelines

14.9.1. In darkness auxiliary mobile equipment operators should use hazard

lights while they stop at any instant and should be extra careful while

maneuvering.

14.9.2. The use of mobile phones whilst operating any mobile equipment shall

be prohibited. The use of a hands free device whilst operating Auxiliary

Free Moving Mobile Equipment shall be permitted.

14.9.3. No person shall be allowed to stand or pass under the elevated portion

of any standard free moving mobile equipment, whether loaded or

empty.

14.9.4. When standard free moving mobile equipment is left unattended, load

engaging means shall be fully lowered, controls shall be neutralized,



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power shall be shut off, and brakes set. Wheels shall be blocked if the

mobile equipment is parked on an incline.

14.9.5. Mobile equipment is unattended when the operator is 5m or more

away from the vehicle which remains in his view or whenever the

operator leaves the vehicle and it is not in his view.

14.9.6. When the operator of mobile equipment is dismounted and within 5m

of the mobile equipment still in his view, the load engaging means shall

be fully lowered, controls neutralized, and the brakes set to prevent

movement.

14.9.7. A safe distance shall be maintained from the edge of ramps or

platforms while on any elevated dock, or platform or freight car.

14.9.8. The safety distance shall be at least 1.8m from parallel edges or

ramps

14.9.9. The safety distance shall be at least 3.1m in front of edges or ramps.

14.9.10. Brakes shall be set and wheel blocks shall be in place to

prevent movement of trucks, trailers while loading or unloading.

14.9.11. Fire aisles, access to stairways, and fire equipment shall be

kept clear.

14.10. Travelling

14.10.1. All traffic regulations shall be observed. A safe distance shallbe maintained approximately three mobile equipment lengths from the

mobile equipment ahead.

14.10.2. The right of way shall be yielded to ambulances, fire trucks, or

other vehicles in emergency situations.

14.10.3. The driver shall be required to slow down and sound the horn

at cross aisles and other locations where vision is obstructed.

14.10.4. The driver shall be required to look in the direction of, and keep

a clear view of the path travel.

14.10.5. Grades shall be ascended or descended slowly

14.10.6. When ascending or descending grades in excess of 10

percent, loaded mobile equipment shall be driven with the load upgrade.

On all grades the load and load engaging means shall be tilted back if

applicable, and raised only as far as necessary to clear the road surface.



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14.10.7. Stunt diving and horseplay shall not be permitted

14.10.8. Speed, the hand steering wheel shall be turned at a moderate,

even rate.

14.11. Mobile Equipment and Pedestrian Segregation

Mobile Equipment and Pedestrian Segregation is a system to identify, develop

and implement mobile equipment only and pedestrian only ways to reduce the

chances of injury and address potential interferences. The segregation is color

coded for easy recognition in the Inside areas and the Outside areas.

The mobile equipment and pedestrian segregation in Inside areas and Outside

areas would be color coded as per the specifications given in the EMAL

Standard forMobile Equipment.

14.11.1. Inside Areas

1.0 m

Safe Pedestrian Walkway:without potentialinterferences with mobile equipment or

protected against the mobile equipment withphysical barriers

Solid Green RAL 6025 1.0 m

Safe Pedestrian Walkway:without potentialinterferences with mobile equipment or

protected against the mobile equipment withphysical barriers

Solid Green RAL 6025

1.0 mSolid Green RAL 6025

Safe Pedestrian Walkway and cautionmarking to segregate shared mobile

equipment area. Fo r crossing instructions

employees have to follow EMAL Mobile

Equipment Standard

Yellow lin e (RA L 102 3) with b lac k ( RAL 90 17)stripes at 45 degrees

0.2 m


Safe Pedestrian Walkway and cautionmarking to segregate shared mobile

equipment area. Fo r crossing instructions

employees have to follow EMAL Mobile

Equipment Standard

Yellow lin e (RA L 102 3) with b lac k ( RAL 90 17)stripes at 45 degrees

0.2 m

Red line (RAL 3020)


Safe Pedestrian Walkway and Red line to

segregate from mobile equipment area.

Physical barriers along with warning signs

would be placed as per the risk assessment

0.2 mRed (RAL 9017)Red line (RAL 3020)






0.2 m






0.2 mRed (RAL 9017)

Yel lo w (RA L 10 23) & R ed (R AL 90 17)

Safe Pedestrian Crosswalk between twopedestrian walkways through shared

m obile equipment area.

0.2 m 0.2 m

Yel lo w (RA L 10 23) & R ed (R AL 90 17)

Safe Pedestrian Crosswalk between twopedestrian walkways through shared

m obile equipment area.

0.2 m 0.2 m


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Y ello w (R AL 10 23) & R ed (R AL 901 7)

Safe Pedestr ian C rosswalk between twopedestrian walkways through shared

mobile equipment area.

0.2 m 0.2 m

Inward opening crossing

gates as per r iskassessmen t

Y ello w (R AL 10 23) & R ed (R AL 901 7)

Safe Pedestr ian C rosswalk between twopedestrian walkways through shared

mobile equipment area.

0.2 m 0.2 m

Inward opening crossing

gates as per r iskassessmen t

14.11.2. Outside Areas

1.0 m

Safe Pedestrian Walkway made of tough tiles

in outside area adjacent to the mobileequipment travel way

1.0 m

Safe Pedestrian Walkway made of tough tiles

in outside area adjacent to the mobileequipment travel way

Pedestrian Crosswalk outside with whitemarkings

Road

Pedestrian Crosswalk outside with whitemarkings

Road

Bicycleway

Road

Outside mob ile equipment area with a bicycle

way and adjacent pedestrian only walkway

1.0 m 1.0 m

Bicycleway

Road

Outside mob ile equipment area with a bicycle

way and adjacent pedestrian only walkway

1.0 m 1.0 m

Warning/Cautious area for hazardousactivities that involve pedestrians and mobile

equipment at the same place at any giventime

Warning/Cautious area for hazardousactivities that involve pedestrians and mobile

equipment at the same place at any giventime



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15. LIFTING EQUIPMENTS

15.1. Lifting equipment classification

The lifting equipments are divided in two main categories. In each category

different subcategories can be identified with different inspection requirements.

- Lifting gear

o Chain Sling, wire rope sling, Fiber rope slings and synthetic webbing

slings.

o Hooks, shackles , rings, eye bolts and swivels etc.

o Special purpose lifting equipment

o Lifting Beam/spreader Beams

o Beam Clamp and Plate clamps.

- Lifting Appliances

In EMAL the lifting appliances are classified according to the different

inspection requirements in the following categories.

o Fixed Lifting Equipments

o Electric overhead travelling cranes

o Special Purpose Lifting Equipmentso Molten Aluminium and Bath Crucibles

o Mobile Cranes & HIAB

o Forklifts

o Anode Elevators

o Furnace Door Lifting Equipment

o Powered Access Platforms

o Vehicle Lifts in Garage

o Passenger Lift

Contractors have to submit a list of all free moving mobile equipments including

lifting equipments as well as a separate list of lifting gears i.e. below the hook

devices 15 days prior to the contractors mobilization.



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NOTE: This is a mandatory requirement to obtain Contractor Site Access permit.

For more details, EMAL Contractor Management Standard shall be consulted.

15.2. Inspection Requirements:

15.2.1. Lifting Appliances:

All Contractor lifting appliances need to be inspected by EMAL Inspection

Services before being allowed entry into EMALs premises. It is

contractors responsibility to inform and schedule inspection of its lifting

appliances with the Inspection Service & EHS department of EMAL.

Following documents shall be submitted with the request for inspection,

by the contractor, at least 4 days prior to the expected mobilization date of

the lifting appliance:

- Valid 3rd

Party certificate

- Valid Police registration Document

- Valid Insurance Details.

- Valid Operators Driving License/ 3rd

party training & Certification.

- Manufacturers manual and certificates.

After the mobilization, the continuing inspection requirements for in-house

and 3rd

party inspections will be the same for contractors as detailed in

EMAL Lifting Equipment Standard.

15.2.2. Lifting Gears:

For lifting gears or below the hook devices, the contractor shall submit a

complete list (as detailed in EMAL Contractor Management Standard) with

necessary test certificates, manufacturers certificates and 3rd

party

inspection certificates before the lifting gears are mobilized on site. All

contractor lifting gears shall be identifiable with a unique serial ID.



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Once mobilized, the on-going inspection requirements of in-house and

third party inspections are as detailed in the next table.

Lifting

Equipment

Third Party

Inspection

Internal Inspection by

EMAL Inspection

Services

Visual

Inspection

by user

Lifting gear Every 6 months Every 6 months Before use

Fixed Lifting

Equipment

Every 12 months Every 6 months Before use

Special Purpose

Lifting

equipments

Every 6 months Every 6 months Before use

Mobile Cranes &

HIABs

Every year NDT every year on

crane hooks

Before use

Forklifts Every year Before use

Every 6 monthsPower access

platforms Load test every

year

Before use

15.3. Lifting gear safety Rules:

15.3.1. Slings, which are damaged or defective, shall be immediately returned

to the inspection services department, who after marking the sling will

destroy it.

15.3.2. Slings shall not be shortened with knots or bolts.

15.3.3. Slings legs shall not be kinked.

15.3.4. Slings shall be securely attached to their loads.

15.3.5. Employees shall keep clear of loads about to be lifted and of

suspended loads.

15.3.6. Slings shall be padded or protected from sharp edges of load.

15.3.7. Hands and fingers shall not be placed between the sling and load at

any time.

15.3.8. Sling should not be pulled from under a load when the load is resting

on the sling.



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15.3.9. Slings must be stored on suitable racks, shelves or hooks off the

ground and in clean, dry areas.

15.4. Safety Rules for Lifting Appliances (cranes, EOTC, hoists)

15.4.1. The rated load of the crane shall be plainly marked on each side of the

crane, and if the crane has more than one hoisting unit, each hoist shall

have its rated load marked on it or its load block, and this marking shall

be clearly legible from the ground or floor. The rated load marking color

shall be yellow background with black letters.

15.4.2. Only designated and certified personnel shall be permitted to operate

a crane. All crane operators shall possess valid third party certification.

15.4.3. Sheave grooves shall be smooth and free from surface defects that

could cause rope damage.

15.4.4. No less than two wraps of rope shall remain on the drum when the

hook is in its extreme low position.

15.4.5. Rope end shall be anchored by a clamp securely attached to the

drum, or by a socket arrangement approved by the crane or rope

manufacturer.

15.4.6. Rope clips attached with U-bolts on the dead or short end of the rope.

15.4.7. When a newly installed rope has been in operation for an hour, theoperation shall be stopped and all nuts on the clip bolts shall be re-

aligned.

15.4.8. Hooks shall meet the manufacturers recommendations and shall not

be overloaded. The hook shall conform to the cranes rated load

capacity.

15.4.9. A preventative maintenance program shall be established and

conducted as per the schedule.

15.4.10. All functional operating mechanism, air and hydraulic systems,

chains, rope slings, hooks, limit switches and other lifting equipment

shall be visually inspected on daily basis prior to each use. A check list

shall be completed. See Attachment V.

15.4.11. A thorough inspection of all ropes shall be made at least once

every six months by the inspection services department.



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15.4.12. The hoist rope shall be free from kinks or twists and shall not

be wrapped around the load.

15.4.13. The load shall be well secured and properly balanced in the

sling or lifting device before it is lifted and/ or after it is lifted just a few

inches.

15.4.14. The operator shall not leave his/ her position at the controls

while the load is suspended.

15.4.15. The operator will not be allowed to use mobile phone when the

crane is in operation.

15.4.16. At the beginning of each operators shift, the upper limit switch

of each hoist shall be tried out under no load.

15.4.17. For mobile cranes, a load chart must be posted in a

conspicuous position, easily visible to the operator.

15.4.18. All hooks must be equipped with a safety latch to prevent

accidental disconnection of the load.

15.4.19. For mobile cranes, when a load is being lifted, the area equal to

the boom radius of the crane will be barricaded and un-authorized

personnel will not be allowed inside that radius.

16. HOT WORKAny work which generates spark, flame and/or heat. Hot work includes, but is not

limited to, welding, cutting, burning, grinding, and any related heat-producing jobs

that could ignite combustible materials or flammable atmospheres.

A Hot Work Permit shall be issued for all cutting, burning, welding and grinding work

preformed outside of designated safe work areas which has the potential to promote

ignition.

16.1. Designated Hot Work Area:

Specific area designed or approved for hot work, such as maintenance shop or a

detached outside location that is of non-combustible or fire-resistive construction,

essentially free of combustible and flammable contents and suitably segregated

from adjacent areas.



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16.2. Non - designated Hot Work Area:

Areas where there is a presence/potential for presence of explosive atmospheres

(mixtures of flammable gases, vapours, liquids, or dusts with air), or situations

where explosive atmospheres that may develop inside uncleaned or improperly

prepared tanks or equipment which have previously contained such materials, or

areas where accumulation of combustible dusts may develop or any equipment

which are part of the plant or areas near the storage of large quantities of

exposed, readily ignitable materials such as baled paper, or cotton.

Area which is adjacent to fuel gas or fuel oil systems or fuel oil systems.

16.3. Other areas:

Areas which are neither classified as designated hot work area nor as non

designated hot work area. When a hot work has to be carried out in these areas,

check list to be completed. If fire hazards are found whilst completing check list,

then hot work permit shall be obtained.

16.4. Hot work receiving Authority:

An EMAL or contractor competent person possessing necessary experience andknowledge and appointed in writing by EMAL to receive hot work permits.

16.5. Hot Work Training

16.5.1. Level 0: General Overview

All EMAL and contractor employees should receive a general overview of

the EMAL Hot work procedure

16.5.2. Level 1: Hot work operators

All EMAL and contractor authorized hot work operators and fire watchers

shall receive a specific training of the EMAL hot work procedure.

This training will be refresher every two years. Each department must

have an updated list of all authorized hot work operators and fire

watchers. The certification shall contain each employee's name, the



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signatures or initials of the trainers, and the dates of training. See

attachment II.

16.6. Hot Work Permit

16.6.1. Hot Work Permits will be required in non-designated areas. Hot

Work permit has an original and one copy (yellow) for the receiving

authority, see attachment 15 (Hot Work Permit Form No.

HS.SAF.14.F01). The permit (Yellow copy) must be posted at the

location of the work being performed.

16.6.2. If hot work has to be carried out in a location which is neither a

designated hot Work area nor a non-designated hot work area,

then the hot work operator/Maintenance personnel responsible for

the activity shall complete a hot work check List. See attachment 16

(Form No. HS.SAF.14.F04 Hot Work Checklist).

16.6.3. While completing the check list, if any fire hazards are identified

in the vicinity of proposed hot work area, then hot work permit shall

emal contractor red book

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