Doc No:
AP_ME_4.4.04007
Revision:
3
Series:
Management Plan
Location:
Mining East
Cristal Mining East
Mine Safety Management Plan
Next Review:
Nov-2015
Owner:
J. Sulicich
Revision Date:
Nov-2014
Approver:
C. Reynolds
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Cristal Mining East Mine Safety Management Plan
Rev
3
1.
INTRODUCTION ................................................................................................ 5
2.
DEFINITIONS .................................................................................................... 5
3.
PLANNING GOALS AND TARGETS ........................................................................... 8
4.
5.
6.
7.
8.
9.
3.1
Documents .............................................................................................. 9
3.2
Policies .................................................................................................. 9
3.3
Standards ............................................................................................... 9
3.4
Management Plans .................................................................................. 10
3.5
Procedures ............................................................................................ 10
3.6
Standard Operating/Maintenance/Isolation Procedures ....................................... 10
3.7
Forms and Manuals.................................................................................. 10
3.8
Operational HSE Targets and Objectives ........................................................ 10
LEADERSHIP AND ACCOUNTABILITY ..................................................................... 11
4.1
HSE Management System ......................................................................... 11
4.2
Management Responsibility ........................................................................ 12
4.3
Supervisor Responsibility ........................................................................... 12
4.4
Personal Protection Equipment .................................................................... 12
4.5
Contractor Pre-Selection and Assessment ...................................................... 13
LEGAL REQUIREMENTS AND DOCUMENT CONTROL .................................................. 13
5.1
State Specific Australian Statutory Requirements .............................................. 13
5.2
Document Control .................................................................................... 13
RISK AND CHANGE MANAGEMENT ........................................................................ 14
6.1
Process for Hazard and Risk Management ...................................................... 14
6.2
Hierarchy of Controls ................................................................................ 15
6.3
Hazard Reporting .................................................................................... 15
6.4
Job Hazard Analysis (JHA) ......................................................................... 15
6.5
Take 5.................................................................................................. 15
6.6
Safety Interaction Program ......................................................................... 16
6.7
Management of Change (MOC) ................................................................... 16
INDUCTION, COMPETENCE AND BEHAVIOUR .......................................................... 16
7.1
Induction ............................................................................................... 16
7.2
Training and Competency Assessment .......................................................... 17
COMMUNICATION AND CONSULTATION ................................................................. 17
8.1
Daily Pre-Start Meetings ............................................................................ 17
8.2
Toolbox Meetings .................................................................................... 17
8.3
Safety Alerts, Bulletins and Incident Notifications .............................................. 18
8.4
Disciplinary Process ................................................................................. 18
EMERGENCY PREPAREDNESS AND RESPONSE .......................................................... 18
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9.1
Emergency Services ................................................................................. 18
9.2
First Aid and Injury Management .................................................................. 18
9.3
Incident Reporting.................................................................................... 19
9.4
Injury Definitions...................................................................................... 19
INSPECTIONS, AUDITING, MONITORING AND REVIEW ................................................ 20
10.1 Inspection and Testing .............................................................................. 20
10.2 HSE Management System and Compliance Auditing .......................................... 20
10.3 HSE Audits ............................................................................................ 20
10.4 HSE Review .......................................................................................... 20
11.
FITNESS FOR WORK ......................................................................................... 21
11.1 Drugs and Alcohol ................................................................................... 21
11.2 Fatigue and Working Hours ........................................................................ 21
11.3 Employee Assistance Program (EAP) ............................................................ 21
11.4 Hygiene .............................................................................................. 22
11.4 Noise and Vibration .................................................................................. 22
11.5 Dust, Fumes, Mists, Gases and Vapours ........................................................ 22
11.6 Chemicals and Hazardous Materials ............................................................. 22
11.7 Radiation .............................................................................................. 22
11.8 Smoking .............................................................................................. 22
11.9 Sun Protection and Awareness .................................................................... 23
12.
SAFETY STANDARDS ........................................................................................ 23
12.1 Subcontracting and Purchasing ................................................................... 23
12.2 Handling, Storage, Packaging and Delivery ..................................................... 23
12.3 Manual Handling ..................................................................................... 23
12.4 Confined Space Entry ............................................................................... 24
12.5 Isolations and Tagging .............................................................................. 24
12.6 Housekeeping ........................................................................................ 24
12.7 Excavations ........................................................................................... 24
12.8 Barricading ............................................................................................ 24
12.9 Grid Mesh, Flooring and Handrail Removal ..................................................... 24
12.10 Working at Heights ................................................................................... 24
12.11 Scaffolds and Scaffolding ........................................................................... 25
12.12 Man cages / Workbox ............................................................................... 25
12.13 Ladders, Fixed and Portable ....................................................................... 25
12.14 Fire Protection ........................................................................................ 26
13.
SAFETY STANDARDS – VEHICLES AND MOBILE PLANT ............................................... 26
13.1 Vehicle Maintenance and Mechanical Inspections ............................................. 27
13.2 Speed Limits .......................................................................................... 27
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.............................................................................................. 27
13.4 Significant Crane Lifts ............................................................................... 27
13.5 Mobile Elevated Work Platforms (EWP) .......................................................... 28
13.6 Forklifts
14.
.............................................................................................. 28
SAFETY STANDARDS – FIXED PLANT AND EQUIPMENT............................................... 28
14.1 Equipment Safeguarding ........................................................................... 28
14.2 Lifting Equipment and Winches .................................................................... 29
14.3 Welding and Gas Cutting ........................................................................... 29
14.4 High Pressure Water Equipment .................................................................. 30
14.5 Compressed Air Equipment ........................................................................ 30
14.6 Hoses – Air, Water, Hydraulic and Gas .......................................................... 31
14.7 Portable Tools ........................................................................................ 31
15.
SAFETY STANDARDS – ELECTRICAL ...................................................................... 31
15.1 Electrical Equipment – Inspection, Testing and Tagging Procedure......................... 31
15.2 Flexible Cords/Extension Leads ................................................................... 32
15.3 Generators and Welding Machines ............................................................... 32
16.
ENVIRONMENT ............................................................................................... 33
16.1 General Environment Conditions .................................................................. 33
16.2 Discharge of Liquids ................................................................................. 34
17.
COMMUNITY .................................................................................................. 34
17.1 Concerns of the Local Community ................................................................ 34
17.2 Caring for the Environment ......................................................................... 35
18.
APPENDIX A – ORGANISATIONAL STRUCTURE. ........................................................ 36
19.
APPENDIX B – REFERENCED AND APPLICABLE LEGISLATION, AUSTRALIAN STANDARDS
AND CODES OF PRACTICE ................................................................................. 37
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Cristal Mining East Mine Safety Management Plan
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INTRODUCTION
Cristal Mining Australia Limited (Cristal) is fully committed to the ‘journey to zero’ harm and
believes that all incidents are preventable. Cristal has a clearly defined ongoing responsibility and
commitment to Workplace Health, Safety and the Environment (HSE).
This Management Plan lists the minimum requirements to comply with HSE targets and objectives
to achieve a workplace that is free of risks to health or safety as far as reasonably practicable.
The HSE performance of Cristal will be reviewed and audited on a regular basis against the
requirements of this plan. Results of these audits shall be used to assess workplace health, safety
and environmental performance / compliance in accordance with all statutory and company
requirements.
This Management Plan has been developed so that it may be used by all workers. The Plan
contains a series of systems designed to assist with maintaining the highest levels of HSE
performance.
2.
DEFINITIONS
Term
Definition
ALARP
As low as reasonably practicable – used in defining the desired level
of risk and hazard control measures
At-risk behaviour
Conduct (whether witnessed or not) that unnecessarily increases the
likelihood of injury.
At-risk situation
A physical situation in the workplace that may lead to an incident or
injury if not corrected
Competent Person
A person assessed as competent for the tasks they shall perform and
who has acquired, through training, qualification, experience or a
combination of those things, the knowledge and skills required to
perform the required task competently and safely
Consequence
Outcome or impact of an event
Contractor
An individual, company or other legal entity that carries out work or
performs services pursuant to a contract for service, this includes
sub-contractors/third parties
Emergency
An abnormal occurrence that can pose a serious threat to the safety
or health of workers, customers, local communities or which can
cause significant damage to assets or the environment.
Event
An occurrence of a particular set of circumstances
Fall Prevention
Fall prevention is creating a safe working area that eliminates the
possibility of a fall or objects falling by using fixed working platforms,
temporary working platforms, scaffolding, and physical barriers,
elevating work platforms, lanyards or mobile work platforms.
Fatigue
It is a state of impaired physical performance and lowered alertness
arising as a result or combination of hard physical and mental work,
health and psychosocial factors or inadequate restorative sleep. It
can be either work or non-work related or a combination of both.
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Term
Definition
Harm
Significant and / or long-lasting adverse impact on people, the
environment or the community.
Hazard
A source of potential harm, injury or detriment.
Hierarchy of Controls
A series of controls, which should be applied in the following order;

Elimination

Substitution

Isolation

Engineering/Redesign

Administrative
 Personal Protective Equipment
A number of these options may be considered and applied
individually or in combination.
Incident
Any occurrence that has resulted in, or has the potential to result in
(i.e. a near miss), adverse consequences to people, the environment,
property, reputation or a combination of these. Significant deviations
from standard operating procedures are also classed as an “incident”.
Ongoing conditions that have the potential to result in adverse
consequences are considered to be incidents.
JHA
A Job Hazard Analysis. A process to document the systematic
identification, assessment and elimination or control of hazards (to
“as low as reasonably practicable”) prior to the commencement of a
task by a work group which is outside the scope of a Procedure or
where a procedure is not in place.
Near Miss
A near miss is any occurrence or a situation which potentially could
have caused adverse consequences to people, the environment,
property, reputation or a combination of these but which did not.
PCBU
Person conducting business or undertaking as referred to in the NSW
WHS Act 2011. May be Cristal Mining or Contractors where
contractor is a company, partnership or sole trader
Procedure
A specified, documented way to carry out an activity or a process.
PPE
Personal Protective Equipment. Worn by personnel to protect them
from hazards which cannot be eliminated by other reasonable and
practicable controls
Risk
The Danger that injury, damage or loss will occur, it has two
dimensions: the likelihood of something happening and the
consequences if it were to happen
Risk Assessment
A formal systematic examination of a process, design, plant or other
situation/condition to identify and assess the potential hazards of
operation and the proposed methods of their control.
Shall
Referenced requirement must be complied with and is not negotiable
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Term
Definition
SIP
Standard Isolation Procedure
Smart Solve
A document management system that stores relevant documents
pertaining to the Safety Management System
SMP
Standard Maintenance Procedure
SOP
Standard Operating Procedure
Working at Heights
Ascending, descending or working in any position where a person
can fall from one level to another.
HSE
Health, Safety and Environment
Worker
Any person, including staff, labour hire, contractors, work experience
or others, who undertake work for Cristal
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PLANNING GOALS AND TARGETS
Cristal has a “Journey to Zero” vision. That being that Cristal believes that all injuries and incidents
are preventable and will continually work towards achieving this. Health, Safety and Environmental
(HSE) management is integral to the ongoing success and sustainability of Cristal Mining
Operations. This HSE Management Plan is designed and developed to ensure that goals and
targets are established to drive continuous improvement of performance in line with company and
legislative requirements, mining industry best practice and the “Journey to Zero” philosophy.
The relationship between Corporate, site Company and Legislative requirements is shown below.
Figure 1.0 – HSE Management System Structure - Hierarchy of Documents
‘What’ needs to be
done?
‘How’ it is done
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Cristal Mining East Mine Safety Management Plan
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Documents
This section covers the documents related to the management system.
3.2
Policies
Policies are high level documents that define the intent, broad approach and beliefs in relation to
health, safety and the environment.
3.3
Standards
The Standards are a set of relatively brief statements which set out the requirements in relation to
a range of issues which have the potential to affect the safety and health of people, or the
environment. The Standards are effectively an expansion of the Policies and are high level
statements that define ‘what’ has to be achieved in relation to HSE, without including any
prescriptive requirements as to exactly ‘how’ these requirements are to be met.
The Standards are as follows:
•
Accountability and Commitment
•
Planning and Resources
•
Legal Compliance
•
Hazard and Risk Management
•
Training and Competency
•
Incident Investigation and Reporting
•
Performance Measurement
•
Documentation and Records
•
Reviews, Audits and Inspections
•
Communication and Consultation
•
Capital Projects and Design
•
Construction, Demolition and Decommissioning
•
Management of Change
•
Contractors, Suppliers and Visitors
•
Emergency Preparedness and Response
•
Product Stewardship
•
Operational Procedures
•
Control of the Working Environment
•
Plant and Equipment Integrity
•
Hazardous Materials Management
•
Fitness for Work
•
Environmental Effects
•
Waste Management
•
Resource Management
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Cristal Mining East Mine Safety Management Plan
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Management Plans
Management Plans document commitment, intentions and principles in relation to overall
management of a particular aspect of the operation (i.e. emergency response plan) and to provide
the framework for action and the setting of its objectives.
3.5
Procedures
Procedures are a series of documents that define what will be done, when, and by whom and what
records will be kept. They are an expansion of the Standards and apply to all Mining East sites.
The requirements of the Procedures are mandatory.
3.6
Standard Operating/Maintenance/Isolation Procedures
Standard Operating Procedures (SOP’s)
Standard Maintenance Procedures (SMP’s)
Standard Isolating Procedures (SIP’s)
These are site specific procedures that are required by operations to meet the requirements of the
Mining East Procedures. They are step by step instructions that define what will be done, when
and by whom.
3.7
Forms and Manuals
The associated documentation required to support the various elements of the management
system.
3.8
Operational HSE Targets and Objectives
As part of the ‘Journey to Zero’, the HSE Management Plan commits to the objective of achieving a
target of Zero Harm to people, the environment and the community.
Cristal has established Key Performance Indicator (KPI) targets specifically for the purpose of
monitoring SHE performance. Performance is reviewed against targets monthly with the KPI metric
also reviewed annually. Cristal will regularly communicate, consult, and provide feedback and
direction on HSE performance and issues in support of the Journey to Zero. These KPI’s are
cascaded down to individual employee safety performance goals that are formally reviewed
biannually through performance appraisals.
HSE KPI’s that are recorded and reviewed monthly include (but are not limited to) the following:
Lead Indicators

Safety Interactions Performed

Workplace inspections and audits conducted;

Hazards Reported

Take 5’s completed

Near Misses Reported

Action Completion %
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Lag Indicators

Recordable Injury Frequency Rate

All Injuries Frequency Rate

All Incidents Frequency Rate

Environmental Incidents Frequency Rate

Reportable Incidents
4.
LEADERSHIP AND ACCOUNTABILITY
All Cristal personnel must be committed to and support the Journey to Zero. Senior Leaders will
provide visible proactive leadership to assist in achieving the highest attainable standards of HSE
performance. The following SHE Operations Statement was issued by the Director of Cristal
Mining.
4.1
HSE Management System
Cristal has a HSE Management System with documented standards and procedures detailing the
company’s commitment, responsibilities and methods to achieve leading HSE performance. The
structure of the HSE Management System is shown in Figure 1.0. In the implementation of this
HSE Management plan, Cristal will:

Specifically address and develop Standards and Procedures that meet Cristal Corporate
and Legislative Requirements.

Make available all relevant Statutory Acts and Regulations, Australian Standards, Codes of
Practice and the HSE Management Plan

Ensure a communication and consultative mechanism is developed and promoted in the
implementation the HSE Management Plan.
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Management Responsibility
Cristal will:

Have in place a visible SHE Policy and objectives which have been distributed and
communicated to all workers;

Provide information regarding SHE requirements to all workers including subcontractors
and visitors

Monitor, review and communicate the HSE Management System;

Provide adequate, suitably qualified and experienced supervision to act in Supervisor
positions

Audit and monitor the SHE performance

Identify safety critical roles and ensure these roles are suitably fulfilled.

Consult, communicate and coordinate HSE requirements with all key stakeholders

Maintain an up to date Organisational Structure
4.3
Supervisor Responsibility
Supervisor roles and responsibilities include (but are not limited to) the following:

Complying with the HSE Management Plan and HSE Management System requirements;

Ensuring risk control measures are implemented in areas and activities for which they are
responsible
Communicating safety information to relevant persons, including between supervisors at
the change of shifts.

4.4

Are responsible for ensuring that workplace inspections are carried out in accordance with
MB Procedure – Workplace Inspections

Ensuring personnel under their supervision have the appropriate skills, training,
competency and knowledge (including access to relevant procedures) to perform their
required tasks

Ensuring all employees associated with their department can attend a toolbox talk each
month and the minutes of the meeting distributed appropriately and outcomes
communicated to the appropriate people.

Being aware of the MB’s Emergency Response and Crisis Management Procedure and
act accordingly.

Giving appropriate feedback to those employees seeking clarification on Health, Safety
and Environmental issues.

Investigating and reviewing all accident/incidents within their work area and ensures all
information from accidents/incidents is communicated to all personnel within the
department and other relevant parties.
Personal Protection Equipment
Cristal will ensure that personal protective equipment (PPE) is provided to all personnel and that
personnel are trained in the correct use and maintenance of all PPE they are required to use whilst
undertaking their assigned duties.
Risk Management principles will be used to determine appropriate PPE for all site activities,
whenever PPE requirements are not covered by existing Procedures.
Minimum site requirements;
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
High Visibility Long sleeved shirts and/or High Visibility Vests (with reflective stripes at
night or in dark periods)

Long trousers

Safety footwear

Safety helmets

Safety glasses and

Gloves
Additional information regarding PPE is detailed in the Personal Protective Equipment Procedure
available from SmartSolve.
4.5
Contractor Pre-Selection and Assessment
Cristal has established and implemented a process for the selection and engagement of
subcontractors. This process ensures that information is gathered and an assessment of the
contractors SHE Management activities, quality programs and insurances prior to engagement.
Subcontractors shall be audited for HSE compliance during the work as part of planned audits.
Any Contractor who is unable to satisfactorily meet the minimum Cristal HSE requirements shall be
required to follow the Cristal HSE Management whilst working on site.
Any Contractor who is unable to provide sufficient evidence of a commitment to HSE policies,
principles, procedures and/or statutory compliance shall be excluded from the tendering, selection
or work process.
Additional Information regarding Contractor Management can be found in the Contractor
Management Plan available from SmartSolve.
5.
LEGAL REQUIREMENTS AND DOCUMENT CONTROL
Cristal has an obligation and duty of care to comply with legislation. Cristal will document through
the HSE Management System how it will aim to meet legislative requirements.
5.1
State Specific Australian Statutory Requirements
The main legislative requirements governing the Cristal Mining East Operations are:

Work Health and Safety Act 2011

Work Health and Safety Regulation 2011

Mine Health and Safety Act 2004

Mine Health and Safety Regulation 2007
Refer to Appendix E – Legal Requirements for further information
5.2
Document Control
Cristal has an established Document Control procedure and electronic Document Management
System (SmartSolve) for the purposes of controlling documents that form the HSE Management
System.
Specific information on the document control process can be found in the Document Control
procedure available via SmartSolve on the company’s intranet.
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RISK AND CHANGE MANAGEMENT
Cristal will integrate risk management into its everyday activities. Cristal shall establish a risk
registers to identify all foreseeable HSE risks associated with its operation, as far as is reasonably
practicable.
Cristal shall:
a)
Ensure the HSE risk register is reviewed regularly
b)
Ensure HSE risk assessment controls are implemented prior to an activity commencing;
c)
Maintain and supply documented training records; and
d)
Develop, implement and communicate HSE standards, procedures and work methods as
required for work activities including, but not limited to:
6.1

Hazard identification and risk assessment;

Document control and records management;

Workplace inspections;

Working at heights;

Confined space entry;

Personnel training and induction;

Excavations and open edges;

Emergency preparedness and response;

Scaffolding;

Hot works;

Isolation and tagging;

Electrical equipment safety;

Hand and power tools;

Dangerous goods and hazardous substance management;

Traffic control and safe movement of vehicles;

Fitness for work and fatigue;

Alcohol and other drugs;

Noise control;

Water, air and soil contamination;

Waste management;

Use of ladders;

Cranes and rigging;

Personal protective equipment;
Process for Hazard and Risk Management
The following hazard and risk management processes will be followed:

defining the job/task;

identifying the hazards;

assessing the risks;
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
implementing control measures (controlling the risk); and

Monitoring and reviewing the process and the effectiveness of controls in place.
3
For further information on Risk Management refer to the procedure available via SmartSolve
6.2
Hierarchy of Controls
Cristal will develop and implement controls with consideration and priority given to the “Hierarchy
of Controls”.
Control measures to eliminate or minimise the risk, as low as reasonably practicable, will be
considered and implemented in the following order of priority:
Elimination: The complete elimination of the hazard
Substitution: Replacing the material or process with a less hazardous one
Isolation: Isolating the hazard by guarding or enclosing it
Engineering/Redesign: Application of suitable guarding or protection
Administrative: Providing control such as training, procedures, signage etc.
Personal Protective Equipment: Use appropriate and properly fitted PPE where other
Controls are not practical or in combination with other controls as a final ‘barrier’.
6.3
Hazard Reporting
Identified hazards are to be reported and rectified as a matter of priority in accordance with the
level of risk. Identified hazards will be discussed at daily pre-start meetings and a summary of
hazards provided monthly. Hazard reports and resulting corrective actions are be tracked through
Accstat, the incident/Event tracking database.
For further information on Hazard Reporting refer to the procedure available via SmartSolve.
6.4
Job Hazard Analysis (JHA)
A Job Hazard Analysis is required to be developed by work teams prior to commencing any task
that is not already covered by a procedure or where a task varies from the standard operating /
standard maintenance procedure or as determined by a “Take 5”. The JHA shall be used to list the
specific job steps, identify potential hazards or risks associated with job step (including the
immediate work environment) and appropriate control measures that mitigate the identified risks
(using the “Hierarchy of Controls” methodology) ensuring they are as low as reasonably practicable
(ALARP).
JHAs are developed by the personnel conducting the task, required to be signed by persons
completing the task and reviewed prior to commencing and periodically during the task. The
completed JHA must be reviewed and approved by a Responsible Supervisor prior to commencing
the task.
If a JHA is continually being completed for a task, A Standard Operating or Standard Maintenance
Procedure shall be developed.
For further information on Job Hazard Analysis’ refer to the procedure available via SmartSolve.
6.5
Take 5
Cristal has established a ‘Take 5’ risk assessment tool that is used by personnel to assist them in
identifying and documenting risks associated with their job/task and work environment.
The “Take 5” is to be used as the first action of assessing risk in a task prior to commencement. If
the hazards identified in the “Take 5” cannot be reduced to a LOW residual risk rating, then a JHA
must be completed.
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A take 5 must be used in conjunction with an SOP at least once prior to commencing the work to
identify is anything has changed since the SOP was written. If there are changes, these shall be
added to the SOP and signed by all people undertaking the task
6.6
Safety Interaction Program
Cristal has established a robust program for performing safety interactions. Specialised training
has been performed aimed at Supervisory and Management level on how to perform safety
interactions, what to look for and how to deal with or manage any ‘at risk behaviours’ or situation.
Safety Interactions are one of the lead safety KPI’s for the company.
6.7
Management of Change (MOC)
Cristal has an established method for the management of changes in the workplace This will
minimise the risk of proposed changes creating an unacceptable risk to health, safety, assets
and/or the environment,
The change management process aims to ensure the following:

changes are identified and recognised;

consultation and communication with all the relevant parties;

careful consideration is given to managing the risks associated with any change;

due diligence can be shown to have taken place;

involvement of the right people in the change process; and

All statutory requirements are met.
Requests for changes are to be reviewed and approved by relevant personnel to ensure that all
modifications are analysed systematically and implemented in a manner that does not present an
unacceptable or uncontrolled risk.
Further information on change management can be found in the Change Management Procedure
found on SmartSolve.
7.
7.1
INDUCTION, COMPETENCE AND BEHAVIOUR
Induction
Personnel required to work on, or visit the site must complete the appropriate level of training and
induction requirements:
Site personnel including Management, Supervision and workers (employees and contractors) must
undergo the company induction which includes information on but is not limited to:

Cristal Mining Operations

HSE Management System

Risk Management and Job Hazard Analysis

Work Permits

Training and Competency

Fitness for Work

Isolation of Equipment

Camp and Accommodation requirements

Emergency Procedures
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An ID / Security pass shall be issued when a person has completed the appropriate inductions and
met pre-employment screening criteria.
Visitors are required to undertake a visitor’s induction that will explain relevant site requirements.
The visitor must be escorted / accompanied at all times by a full inducted person whilst on site.
Visitors are no permitted to perform work / tasks).
Induction refresher training is required every 3 years as a minimum or where a person has been
absent from site for a period of greater than 6 months.
7.2
Training and Competency Assessment
Cristal has established procedures and allocated sufficient resources to identify and provide the
training needs and assessment of competence of personnel on site.
Cristal will:

Identify training requirements of employees;

Ensure training complies with the National Training and Competency Assessment
guidelines;

Ensure that where required by legislation or Australian Standards such training is
conducted by a Registered Training Organisation (RTO) ( e.g. High Risk Licenses such
as forklifts, rigging etc.);

Implement a plan to ensure all workers attend relevant task training;

Maintain documented records of training and assessment;

Have approved training in the relevance to the work being performed; i.e. Working at
Heights, Isolations and Confined Space,

Ensure HSE information is regularly circulated on site via pre-start and toolbox meetings,
notice boards, etc.

Provide documentary evidence that all personnel have been assessed as competent to
safely carry out their assigned tasks.

Provide training to relevant personnel in relation to any site SOP or SMPs developed.
8.
COMMUNICATION AND CONSULTATION
Cristal will ensure clear communication and consultation with workers to facilitate positive input and
participation in HSE matters.
8.1
Daily Pre-Start Meetings
Cristal Operational departments will conduct pre-start meetings at the beginning of each shift to
discuss relevant HSE matters and planned work activities for the day. This will include cross shift
communication of identified risks and control measures implemented. The pre-start meeting will be
the centre of the workplace HSE communication, consultation and coordination.
Pre-start meeting minutes, relevant attendance records and records of notices etc. shall be
maintained. Any specific topic that may have an effect on other site activities shall be
communicated immediately following the meeting.
8.2
Toolbox Meetings
Cristal will conduct formal toolbox meetings on a monthly basis. Meeting minutes and relevant
records shall be maintained by the Safety Department. Toolbox meetings will give a regular and
formal forum for discussion on HSE matters, incidents, hazards, HSE KPI’s, safety topics,
personnel issues etc.
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Safety Alerts, Bulletins and Incident Notifications
The Cristal Senior Safety Advisor will circulate via email, relevant Safety Alerts, Bulletins and
Incident Notifications from both internal (for example Cristal Global Sites) and external (for
example Department of Trade and Investment) sources. These communications shall be discussed
at pre-start meetings and displayed at prominent positions throughout site.
8.4
Disciplinary Process
Where an individual breaches a legislative requirement, a Life Critical or other site procedure,
appropriate counselling / disciplinary action will be taken in accordance with the disciplinary
procedure. Where the breach is blatant, counselling / disciplinary action can result in dismissal /
prohibition from site.
9.
EMERGENCY PREPAREDNESS AND RESPONSE
Cristal shall establish appropriate Emergency Preparedness and Response procedures and
facilities including procurement of suitable equipment to manage an array of foreseeable
emergencies. These procedures and further information of emergency response can be found in
the Emergency Preparedness and Response Plan available via SmartSolve.
9.1
Emergency Services
Cristal shall establish good relations with local emergency services. These relations should involve
(where practicable) site familiarisation visits, communication regarding any hazardous materials or
practices, company emergency response plans and capability. Cristal safety and health
professionals shall maintain at minimum an annual meeting with the local emergency services to
ensure communication of any changes that may/will occur to the emergency response services
with regard to the mine.
9.2
First Aid and Injury Management
Cristal aims to have all of its employees trained in Senior First Aid as a minimum and shall ensure
processes are in place to provide prompt care of injured people should an injury occur.
Additionally, at the Mine sites appropriate levels of Occupational First Aid coverage shall also be
established to provide a higher level of care in the more remote area.
Cristal shall provide a sufficient quantity of suitable first aid kits for an industrial environment in
addition to plant and vehicle first aid kits.
9.2.1
Transport for Medical Assistance
If off site medical assistance is required, appropriate means of travel shall be arranged depending
on the urgency of the situation and may include (but not be limited to):

Transport via the RFDS

Transport via Ambulance

Transport via company vehicle;

Others means as necessary.
9.2.2
First Aid Rooms
Cristal has established suitable First Aid Rooms /facilities located on site for treatment of an array
of foreseeable injuries. All injuries treated at site, no matter how minor and no matter if work or
non-work related, shall be documented.
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Injury/Case Management
Cristal has established Injury and Case Management Policy’s and processes in place and the
principles apply to all site personnel (employees, contractors and visitors). The aim of injury
management is to ensure appropriate and adequate treatment is provided to injured workers to
enable a quick and efficient return to the workplace.
Cristal is committed to open lines of communication and cooperation with regard to injury
management on site as to ensure that any injured party receives the appropriate treatment and
that their return to work can be suitably managed.
Cristal has an appointed Return to Work Coordinator (RTWC) to assist with facilitating the injury
management process.
Effective injury/case management must commence immediately after the accident has occurred
and is to include;

The RTWC liaising with the patient;

Referral to the Company Doctor (where required);

Follow up, including personal off site visits (where required);

Liaising with the company’s Workers Compensation insurer

Conducting formal assessments of employee capabilities prior to returning to work;

Provision of alternate meaningful duties, where appropriate.

Discussions between the RTWC, treating physician and injured party

Discussions between the RTWC, injured party and their Supervisor regarding returning to
work.
9.3
Incident Reporting
All incidents (including near misses) regardless of how minor shall be reported and investigated
appropriately. Cristal has a documented Incident Reporting and Investigation Procedures and
many site personnel trained in incident investigation. Incidents should be reported to Cristal
Supervision immediately but no later than the shift in which it occurred. Cristal has an Incident
Report form available via SmartSolve.
Cristal has a duty to report certain incidents to the Department of Trade and Investment. A list of
these incidents is included in Appendix A of the Incident Reporting and Investigation Procedure
9.4
Injury Definitions
The following are definitions regarding the severity of injuries.
Loss Time Injury (LTI)
A work related injury or illness resulting in the employee being unable to attend their next rostered
day after the day of the injury.
Restricted Work Injury (RWI)
A work related injury or illness which results in the employee being unable to perform one or more
of their routine functions, or from working the full day on or after the next calendar day after the
illness or injury.
Medically Treated Injury (MTI)
A work related illness or injury resulting in the management or care of a patient to combat disease
or disorder, including any loss of consciousness.
MTI does not include:

visits to the physician or other licensed health care professionals solely for observation or
counselling;
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
the conduct of diagnostic Procedures, such as X-rays and blood tests, including the
administration of prescribed medications used solely for diagnostic purposes (e.g. eye
drops to dilate pupils etc.); and

First aid cases.
First Aid Injury
A work related injury or illness that requires first aid treatment but not medical treatment.
Note: Any LTI, RWI or MTI is a ‘reportable injury’ and must be reported appropriately to both the
Department of Trade and Investment and Cristal Global.
10.
INSPECTIONS, AUDITING, MONITORING AND REVIEW
Cristal shall conduct regular workplace inspections in accordance with the Workplace Inspections
procedure and maintain a schedule of the workplace inspections to be conducted and who is
responsible for carrying them out.
The Workplace Inspections Procedure and Area (housekeeping) inspections form are available via
SmartSolve.
The corrective actions proposed shall be entered into the company’s action tracking system
(Accstat) for follow up.
10.1
Inspection and Testing
Cristal shall ensure that procedures for planning and conducting inspections of plant, equipment
and processes including incoming materials and products and use only suitably qualified and
competent workers to carry out inspection and testing.
Site records are to be maintained of inspections and testing.
Cristal shall conduct regular inspections in accordance with company and legislative requirements
on (but not limited to) the following:

Plant and equipment;

Electrical installations and electrical equipment;

Rigging and lifting equipment;

Ladders and access equipment;

Scaffolding; and

Cranes, light vehicles, elevating work platforms and mobile plant.
10.2
HSE Management System and Compliance Auditing
Cristal shall conduct regular audits and workplace monitoring to verify compliance with company
statutory requirements either directly or by independent 3rd party process.
10.3
HSE Audits
Cristal shall ensure HSE compliance audits are undertaken to provide verification of the
implementation and effectiveness of the HSE Management System.
10.4
HSE Review
Cristal shall conduct regular internal HSE reviews, which shall include results of audits and
workplace inspections.
Cristal shall:
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Conduct internal HSE reviews at on a regular basis with representation from senior
management at each review session;

Maintain records of HSE management system reviews; and

Ensure corrective actions are allocated to a responsible person, documented,
implemented, monitored and closed out.
11.
Fitness for Work
Cristal shall establish procedures and processes for ensuring and monitoring personnel’s fitness
for work. The fitness for work program shall consider the possible health effects of:

general level of personal fitness and/or pre-existing medical conditions;

consumption of alcohol;

use of other drugs (prescription, pharmaceutical or illegal);

Fatigue and stress.
11.1
Drugs and Alcohol
Cristal has a zero tolerance approach to drugs and alcohol in the workplace. Cristal has a rigorous
drug and alcohol testing regime which included pre-employment testing, blanket and random on
site testing, post incident and for cause testing. This testing regime is designed to minimise the
risks to health and safety in the workplace due to the effects from drugs and alcohol. The use of
prescribed drugs also shall be reported to the worker’s supervisor so that a fitness for work
assessment can be undertaken and the medication be recorded on a confidential medical report
for use in the event of an emergency.
Persons found in the possession of, or under the influence of alcohol or non-prescription drugs at
the work site (excluding the Mine site Camp / accommodation area), will be subjected to the
company’s counselling and disciplinary procedures.
Further information on Drugs and Alcohol can be found in the company’s Drug and Alcohol
procedure.
11.2
Fatigue and Working Hours
Cristal has established a Fatigue Management Plan and Procedure on Working Hours to assist in
managing the risks associated with fatigue. The Fatigue Management Plan was developed from
industry advisory guidelines and documents information on fatigue, how to manage fatigue, roster
design and rest periods.
The Fatigue Management Plan and Working Hours Procedure can be found on SmartSolve.
11.3
Employee Assistance Program (EAP)
Cristal has established an Employee Assistance Program that is available to all workers via
telephone 1800 818 728. The anonymous service has been established to assist personnel with a
variety of issues that they may face including (but not limited to) the following:

Relationship and family problems

Grief and loss

Conflict with fellow workers

Workplace issues

Gambling

Alcohol and Drug use
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Stress and

Emotional Distress.
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Hygiene
Cristal shall ensure that its personnel and subcontractors personnel maintain high standards of
hygiene in the workplace.
Cristal shall maintain all crib rooms and work areas in a clean and tidy state and shall promptly and
appropriately dispose of waste material.
Suitable washing facilities are provided at various places throughout the workplace.
11.4
Noise and Vibration
Cristal shall manage the risk of exposure to noise and vibration hazards in accordance with current
safety legislation and shall include scheduled periodic surveys of noise exposure.
11.5
Dust, Fumes, Mists, Gases and Vapours
Cristal shall ensure exposure to dust, fumes, mists, gases and vapours is as low as reasonably
achievable and in compliance with regulatory requirements.
Respiratory protection shall comply with Australian Standards AS1715 Selection Use and
Maintenance of Respiratory Protective Devices and persons shall be trained and assessed in the
safe use, care and maintenance of respiratory protection. Respiratory protection shall be worn in
designated areas.
11.6
Chemicals and Hazardous Materials
Any chemicals or hazardous materials shall be risk assessed prior to procurement or entry onto
site. Consideration should always be given to substituting the chemical or hazardous material for a
less hazardous substance. No chemicals or hazardous materials are to be brought onto site
without a Material Safety Data Sheet.
Cristal shall ensure that personnel are trained in the use and understanding Material Safety Data
Sheets.
11.7
Radiation
Cristal shall ensure work involving the use of radiation sources and radioactive materials are
controlled in accordance with ARPANSA - Regulation: Regulatory Guides and the Radiation
Management Plan available via SmartSolve
Under no circumstances shall untrained or unauthorised persons attempt to remove, or in any way
interfere with, radioactive sources or carry out any maintenance, adjustment or modifications to
controlled radiation apparatus or remove any pipe work which has a radiation gauge mounted or
attached.
Cristal shall ensure that a Radiation Safety Officer is appointed and that all workers receive a
briefing on working with Naturally Occurring Radioactive Materials (NORMs) / Mineral Sands and
general radiation safety.
11.8
Smoking
Personnel shall not smoke in any vehicle, enclosed building nor in hazardous work areas that shall
pose a health or safety risk.
All smoking areas are to be left in a clean and tidy state and all butts placed in appropriate disposal
containers.
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Sun Protection and Awareness
Cristal shall have an active program for prevention of sun exposure and heat related illness. This
shall include but not be limited to:

provision of factor 30+ sunscreen;

acclimatisation (both heat and cold);

requirement for all personnel to wear suitable clothing and a hat in strong sunlight;

provision of ample drinking water at all times; and

provision for shade in open areas
12.
SAFETY STANDARDS
Cristal shall maintain the following work area health and safety standards as a minimum
requirement. Each of the subjects below has more information and specific detail
documented in procedures that can be found on SmartSolve.
12.1
Subcontracting and Purchasing
Cristal shall ensure that all plant, materials, equipment services purchased or hired and all
subcontracts conform to the required legislative and HSE requirements. All procurement and
subcontracting is managed by the Commercial Management Plan that can be found on the Cristal
intranet.
As a minimum, Cristal shall ensure:

All materials, equipment, plant and services to be purchased or hired are assessed
against the relevant legislative and HSE requirements;

Procedures are implemented addressing the delivery, handling, storage and disposal of
hazardous substances;

Subcontractors are assessed for suitability and display and maintain at least a
compatible Safety Management System as required of the contractor or work directly
under Cristal’s HSE Management System;

Monitor and document HSE performance of subcontractors whilst on site for compliance.
12.2
Handling, Storage, Packaging and Delivery
Cristal shall establish procedures to ensure compliance with legislative requirements for handling,
storage, packaging and delivery of products and materials.
Cristal shall:

Implement a procedure for the storage, labelling and use of hazardous substances which
shall include a register, MSDS file;

Screen new products and plant prior to entry onto site for HSE hazards; and

Ensure all vehicle, plant and equipment operators are correctly instructed, trained and
certified/licensed
12.3
Manual Handling
Cristal shall ensure that manual handling hazards are identified and managed in accordance with
company requirements and relevant Codes of Practice for Manual Handling. All workers are
encouraged to report manual handling hazards.
Cristal shall implement a manual handling awareness and training for personnel and ensure as far
as practicable that mechanical means are substituted for applicable manual handling tasks.
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Confined Space Entry
Cristal shall ensure that all confined spaces on site are appropriately signed and documented on a
Confined Space Register. All training; control and associated activities comply with the
requirements of AS/NZS 2865-Safe Working in a Confined Space, relevant legislation and
company requirements documented on the Confined Space procedure. A Confined Space Entry
Permit shall be completed prior to entry into any confined space.
12.5
Isolations and Tagging
Isolations and tagging on site shall be in accordance with the Isolation and Tagging Procedure.
Specifically, prior to any person conduction work on equipment that if started, energised or made
operational, poses a risk to themselves or others, must isolate and tag the equipment prior to
commencing work
12.6
Housekeeping
Cristal shall incorporate the housekeeping function into all processes, operations and tasks to
ensure housekeeping is an integral part of its processes.
Material stored in open areas shall be stored in a tidy manner and in appropriate containers.
Aisles, walkways, corridors, doorways, entrances, exits, etc., shall be unobstructed, free from
slippery hazards and the accumulation of combustible materials. Waste material and rubbish shall
be removed from job site areas, on a continuous basis so as to prevent a build-up of rubbish and
construction waste.
12.7
Excavations
Cristal shall ensure that excavations (other than specific mining excavations) on site are carried out
in accordance with conditions as specifically details in the Excavation Procedure and an
Excavation Permit must be raised prior to the commencement of the excavation.
12.8
Barricading
Barricading shall be erected and maintained around work areas where segregation, delineation or
protection of works is required.
Other points of note;

excavations and areas where the risk of a fall exists are to be ‘hard’ barricaded to prevent
persons from falling;

bunting shall only be used as a last resort for minor short term temporary works such as
identifying the slew radius of a crane or identifying hot work above areas;

appropriate signage and information tags shall always be used with all barricades and
bunting; and

workers are responsible for the daily maintenance and removal of all barriers
12.9
Grid Mesh, Flooring and Handrail Removal
All grid mesh and flooring removal shall be performed in accordance with the Grid Mesh and
Flooring removal procedure. Specifically, physical barricades must be erected prior to removal of
flooring as to prevent any inadvertent access / falling through the open floor or penetration.
Persons removing the flooring or handrails must be wearing the appropriate fall restraint
equipment.
12.10
Working at Heights
Where personnel are at risk of falling from height or being at risk from falling objects, effective
measures must be taken to prevent the potential of injury or damage.
All work at heights shall comply with relevant legislation and company requirements.
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Persons who are exposed to the risk of falling shall:

Participate in the risk assessment of the work.

Know and understand the control measures for fall and falling objects prevention.

Be competent and authorised in the correct use and application of control measures.

Be medically fit to work at heights.

Inform their supervisor if they have any medical condition (permanent or temporary) that
may adversely affect their competency to work safely at height.
Effective control measures include:

Eliminating the need for working at height by conducting the task on the ground if
possible.

The provision of edge protection (guardrails) systems.

Fall prevention injury prevention systems.

The use of scaffolding and/or elevated work platforms to access work areas.

A working at height’s permit system.

Training personnel who work at heights in the requirements of safe working at height
practices.

Providing personnel with appropriate equipment and PPE for the task to be conducted.
The “Hierarchy of Controls” shall be used when considering any work methods and controls for
working at height. In all cases where the use of PPE is considered appropriate, fall restraint shall
be considered as the preferred option rather than fall arrest.
12.11
Scaffolds and Scaffolding
Cristal shall ensure that all Scaffolding erection and dismantling complies with the requirements of
AS1576 Scaffolding and AS4576 Guidelines for Scaffolding and company procedures.
Scaffolding shall be controlled using the scaff-tag system and shall be inspected by a competent
person and recorded in a scaffold register.
Scaffold erection and dismantling shall only be carried out by certified competent scaffolders.
12.12
Man cages / Workbox
All workboxes (“dogboxes”) comply with AS1418.17 Design and Construction of Workboxes. A
Man Cage Permit must also be completed prior to use.
12.13
Ladders, Fixed and Portable
Ladders are to be used primarily as a means of access and egress to an area. All ladders must
comply with the relevant Australian Standard:

fixed ladders shall comply with the requirements of Australian Standard AS1657 ‘Fixed
Platforms, Walkways, Stairways and Ladders’;

portable ladders (timber) shall comply with Australian Standard AS1892-2 and AS1892-4
‘Portable Timber Ladders (including step ladders and trestle ladders)’; and

portable ladders (metal) shall comply with Australian Standard AS1892-1 ‘Portable
Ladders Metal’
Cristal shall ensure portable ladders are regularly inspected by a competent person and
documented on a register. Ladders are required to be inspected for damage and integrity prior to
use on any task.
Working from ladders shall comply with the following as a minimum acceptable standard:
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
personnel are not to be exposed to the risk of a fall from working off ladders;

use of ladders as a working platform is restricted to minor maintenance or light work

personnel working from ladders must maintain three (3) points of contact at all times
and/or be physically restrained from the risk of a fall (i.e. fall restraint PPE);

portable ladders when in use shall be secured, with rope or ladder clamps to prevent
slipping or overbalancing;

ladders shall always be placed on a firm, stable footing to prevent the ladder feet from
moving unexpectedly; portable ladders shall be placed on a substantial base at a 1:4
pitch, have a clear access top and bottom and extend a minimum of one (1) metre above
the egress landing; and portable metal ladders and wire-reinforced ladders shall not be
used for any electrical work or where contact with electrical conductors is foreseeable
12.14
Fire Protection
Cristal shall supply, install, and maintain adequate portable fire extinguishers in workshops, site
offices, plant, equipment, vehicles, and flammable storage areas.
Cristal shall ensure that all workers are instructed in the basic inspection, safe use and operation of
all relevant fire extinguishers types.
Cristal shall maintain records of inspection and maintenance of fire extinguishers for audit
purposes.
Cristal shall ensure sufficient supply and regular maintenance of fire extinguishers is carried out in
accordance with the Australian Standards listed in Table 13.22.
SAFETY STANDARDS – VEHICLES AND MOBILE PLANT
13.
Cristal shall ensure that the vehicles it uses on site are licensed, maintained in a roadworthy
condition and mechanically inspected by a trained and certified competent person.
All vehicles and mobile plant on site must conform to Cristal’s Vehicle and Mobile Equipment
Standard. Specifically:

Light vehicles must be 4WD (exemption at MSP)

Prestart checks must be conducted on work site vehicles daily

Light vehicles must be fitted with:

Flashing light

High visibility flag on pole

Seat belts

Horn

Reverse alarms

Fire extinguishers

First aid kits

Breakdown equipment for off lease use

Cargo Barriers &/or load restraints

The operation of vehicles must comply with site traffic plans
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
Mobile plant must comply and be maintained in accordance with the applicable Australian
Standards

Mobile equipment must be operated by competent and qualified persons

Mobile plant must be fitted with:

Isolation and lockout points

Flashing rotating lights,

Reversing alarms

Load charts where relevant

A horn

Seat belts

Fire extinguishers

All incoming mobile plant must be inspected and approved prior to operation

Prestart checks must be conducted daily on all mobile plant

The operation of mobile plant must comply with site traffic plans

Fire suppression systems are required on heavy earthmoving equipment as required by
the Mobile Equipment Standard available via SmartSolve.
Cristal shall ensure that its workers are authorised to drive the type of vehicle of which that
employee is in control of and under no circumstances are unlicensed persons permitted to control
vehicles on site.
Private vehicles shall not be permitted to enter the Mine site.
13.1
Vehicle Maintenance and Mechanical Inspections
Cristal shall ensure all site vehicles and mobile plant are maintained in accordance with
manufacturer’s instructions and mechanically inspected by a trained competent person on a
regular basis. Records of such inspection and repairs required/carried out shall be maintained.
13.2
Speed Limits
Drivers on site must at all times drive at a safe speed consistent with conditions. Drivers shall not
exceed the maximum speed permitted on the site or lower speeds as indicated by speed limit
signs.
Drivers shall slow down and allow sufficient clearance in congested work areas or where personnel
and plant are working in close vicinity to roads.
13.3
Cranes
Cristal shall ensure all crane use and inspection under its control is in accordance with AS2550
Crane, Hoists and Winches - Safe Use– General Requirements and AS1418 Crane, Hoists and
Winches - General Requirements (all parts relating to relevant crane type). Cranes shall carry the
current plant logbook and manufacturer’s operation and maintenance manuals at all times. Details
of maintenance history and modifications shall also me maintained.
13.4
Significant Crane Lifts
All significant lifts are conducted in accordance with the site procedure.
A Significant Lift is described as any lift:

Greater than 20t

In excess of 85% of any cranes indicated load chart SWL for any given load mass;
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
Using multiple cranes;

Involving an item of equipment that is regarded as Project critical or has or may have a
long lead time, regardless of load mass or crane capacity and/or

That is regarded as having a significant degree of difficulty regardless of load mass or
crane capacity (at the discretion of the Area Manager)
13.5
Mobile Elevated Work Platforms (EWP)
Mobile Elevated Work Platforms must:

Carry the current logbook and manufacturer’s operation and maintenance manual(s) at
all times. Details of maintenance history and modifications shall be entered in the plant
logbook;

Be operated in accordance with AS2550 Safe Use of Mobile Elevated Work Platforms
and the manufacturer’s instructions. This includes the requirement to wear and secure a
harness at all times whilst in the basket of the equipment, including when equipment is
moved;

Have a daily or pre use inspection by a competent persons

Are not used as cranes/lifting devices and must operate within their WLL.
Personnel are not to exit the basket whilst it is elevated unless there is no safer means of
access/egress and the conditions specified in AS2550 Safe Use of Mobile Elevated Work
Platforms clause 9.4 are met and the risks involved are assessed and documented.
13.6
Forklifts
Forklift requirements are as follows:

Forklifts must only be operated by competent personnel with the applicable ‘high risk’
license.

All forklifts used on site shall be fitted with a seatbelt which must be worn by the operator;

The forklift must be subjected to daily or prior to use inspections by a competent person.

Where lifting attachments are fixed to the forklift that the equipment is not loaded beyond
its design capacity; -

Attachments are securely fastened to the machine to prevent dislodgement;

Where the load is large and obscures vision, the machine must be travelled backwards or
a spotter used;
14.
SAFETY STANDARDS – FIXED PLANT AND EQUIPMENT
Cristal shall ensure all plant and equipment, including portable hand tools, are in a safe and
serviceable condition. These plant and equipment are controlled under the mechanical
maintenance plan.
14.1
Equipment Safeguarding
Equipment Safeguarding shall be implemented in order to eliminate or minimise the risk of
fatalities, injuries and incidents arising from hazards associated with contact from plant and
equipment.
The following general rules shall be implemented and followed by all personnel:

Access to equipment shall be controlled and monitored where safeguarding and interlock
systems are insufficient to protect persons from moving plant and equipment;
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
Fail-safe switches or devices shall be installed on all rotating fixed plant and hand tools
(e.g. saws, lathes, drill presses, etc.) wherever practicable;

Guards shall only be removed for maintenance and repair, and only once equipment is
isolated and locked out. Guards shall be replaced prior to equipment being put back into
service;

Procedures shall be in place for situations when safeguards on operating plant and
equipment need to be removed temporarily for any purpose;

A system shall be in place for the management of change to equipment and/or processes
to ensure the integrity of safeguarding is maintained and to determine requirements for
additional safeguarding; and

No guarding shall be modified or altered in any way except through the application of a
detailed risk assessment and management of change process.

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.
14.2
Lifting Equipment and Winches
The use of lifting gear and winches are governed by current safety legislation and Australian
Standards:
AS 1418
Cranes, hoists and winches – General requirements
AS 2550.1
Cranes, hoists and winches – Safe use – General requirements
AS 2550.5
Cranes, hoists and winches – Safe use – Mobile cranes
AS 1418.17
Cranes (including hoists and winches) – Design and construction of workboxes
AS 1418.14
Cranes (including hoists and winches) – Requirements for cranes subject to
arduous working conditions.
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.
Rigging and lifting equipment shall be inspected regularly (quarterly) by a competent person for the
purposes of determining their suitability for safe use; this inspection shall be recorded in a rigging
and lifting equipment register.
A qualified engineer shall approve non-standard manufactured lifting attachments. Non Destructive
Testing (NDT) shall be carried out as required. All lifting attachments shall be included in all Lifting
Equipment inspections.
All lifting gear shall be tagged, or otherwise identified as having undergone a 3 monthly inspection.
The colour of lifting gear tags and/or identification will be in accordance with the site tagging colour
codes.
Rigging and slinging must only be performed by qualified persons being a dogman or a rigger.
All rigging gear shall be stored off floor level and away from hazardous substances;
14.3
Welding and Gas Cutting
When carrying out welding, cutting and grinding tasks, the minimum eye protection when carrying
out the above operations shall be:

Grinding – Goggles and a face shield

Welding – Safety Glasses and full welding face shield

Oxy cutting – Oxy goggles with suitable lenses
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Special Conditions for Welding, Cutting and Grinding
The following special conditions shall apply for all welding, cutting and grinding tasks:

Prior to the commencement of hot works outside of the workshop area, a risk
assessment and Hot Work Permit must be completed.

Electric welding cables and gas welding/cutting lines in work areas, walkways and
access ways shall be protected against physical damage at all times. Where possible,
they shall be routed overhead or under elevated walkways, but in all cases routed in such
a manner as to eliminate tripping or other hazards;

Electrical welding and gas welding/cutting units are inspected and maintained in
accordance with the relevant Australian Standards;

Flashback arrestors to be fitted on the hand piece and cylinder end of oxy/acetylene
hoses;

Gas cylinders shall be stored in an upright position in appropriate cages, cradles or
trolleys and secured with a non-flammable material (e.g. chain; wire rope) to ensure
stability when being transported, stored or used on site;

Appropriate signage when transporting or storing compressed or flammable gas;

Electric welding cables and gas welding/cutting apparatus free from grease and oil. Worn
or damaged electrical welding cables with exposed wire or bare conductors shall be
replaced or discarded immediately;

Fire resistant screens are required when electric arc welding to ensure that adjacent
workers are not adversely affected by the process;

Fire extinguishers are provided at all work locations where hot work is being undertaken,
flammable gases are stored or on vehicles transporting flammable gas;

Prior to the commencement of hot works, all combustible/flammable material shall be
removed or adequately protected;

Gas cylinders shall not be transported, raised or lowered to another work level unless an
approved holder or carrier designed for the transport of gas cylinders is used;

Gas cylinders shall be kept at a safe distance and shielded from welding at cutting
operations and not be exposed to electrical circuits or heat;

Acetylene and other fuel gases shall not be stored in enclosed spaces even overnight,
e.g. vans, vessels or containers; and

Voltage reduction devices (VRD) used with all electric welding machines
14.4
High Pressure Water Equipment
Only competent personnel experienced in the handling of the equipment being used shall carry out
high-pressure water jetting operations.
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 per minute.
High pressure blasting areas shall be barricaded (red & white) and danger tape with information
tags shall be erected.
14.5
Compressed Air Equipment
Compressed air operations shall only be carried out by competent personnel experienced in the
handling of the equipment being used.
Personal protection equipment suitable to the work being done shall be worn and shall include:
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
Eye protection – Medium impact safety glasses. If dust or other airborne particles are
created during compressed air activities, goggles shall be worn.

Foot protection - safety boots with steel toecap;

Head protection - safety helmet;

Body protection - gloves and clothing having regard to the nature of work being done;
and

Hearing protection - ear plugs and/or ear muffs.
14.6
Hoses – Air, Water, Hydraulic and Gas
All hoses shall comply with the relevant Australian Standards for Air - AS2554, Rubber - AS1179
and AS1180, Hydraulic – AS3791 and Gas AS1869 and Welding and Cutting AS1335.
All hose connections shall be installed in such a manner to reduce the 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;

LPG, butane, acetylene and oxygen, hoses shall be of an approved type, complying with
AS1335 Hoses for Welding and Cutting and AS1869 Gas Hoses, easily distinguishable
and shall not be interchangeable;

All hoses to be inspected, repaired or replaced as required prior to each use
14.7
Portable Tools
Cristal shall ensure all portable tools conform to appropriate Australian Standards.
A portable tool is defined as any hand held power tool (electric, pneumatic, hydraulic or fuel driven)
that can be manually transported by one person. Excessively worn tools and tools requiring
maintenance shall be tagged and removed from the job site.
Cristal prohibits the use of portable electric hand tools in wet areas as a risk control against electric
shock. Only battery tools below extra low voltage or pneumatic tools are to be used in wet areas.
In the event that a portable electric tool is the ONLY means of performing a certain task in a wet
area, permission to use the tool must be sought from the Area Manager. A Risk Assessment and
Job Hazard Analysis must be completed and submitted with the request to carry out the work. This
Job Hazard Analysis can only be authorised by the Area Manager.
All portable tools shall be in good state of repair and safe for the user and other people in the same
area. They shall be used only for the task they were designed, and maintained in accordance with
the manufacturer’s instructions. Guarding shall be used and maintained in accordance with
manufacturer instructions.
15.
SAFETY STANDARDS – ELECTRICAL
Cristal shall ensure all electrical equipment on site complies with Australian Standards and is used,
inspected and maintained in accordance with the relevant standards. Electrical works are
controlled under the Electrical Maintenance Plan and specifically the electrical management
standard
15.1
Electrical Equipment – Inspection, Testing and Tagging Procedure
Cristal shall ensure installation and testing of electrical equipment complies with AS 3000
‘Electrical installations (known as the Australian/New Zealand Wiring Rules)’ and AS 3760 ‘In-
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service safety inspection and testing of electrical equipment’.
A portable and/or fixed RCD shall be used to protect all electrical equipment. No portable
generators are to be used on site without an inbuilt RCD.
Cristal shall ensure that only approved licensed electrical personnel carry out electrical installation,
maintenance and testing on site other than operator daily equipment testing.
Cristal shall ensure all industrial electrical equipment, including office and crib appliances, are
tested and inspected in accordance with AS3760 prior to use on site. Records of such testing and
inspection are maintained on site files.
15.2
Flexible Cords/Extension Leads
Cristal shall ensure:

Power lead lengths shall not exceed 25 meters or the recommendations set out in the
table of AS: NZS 3012.

Leads, plugs and similar equipment used on site in operating areas shall be armoured
cable that is IP 56 rated.

Connection plugs shall be of a shrouded bonded type or made of transparent material;

Power leads shall be suitably restrained, supported above ground level using either cable
stands or standard lead restraining clip;

Power leads shall not be routed along access ways, walkways or handrails unless
supported by lead restraining clip/s;

Portable RCD units shall be used to distribute power directly to power tools only and not
as an adapter to extend the length of power leads or for multiple distribution of power
leads; and

Double adapters shall not be used.
15.3
Generators and Welding Machines
Cristal shall ensure all welding machines used on site comply with the requirements of this
Management Plan and are fitted with Australian Standard compliant voltage reduction devices
(VRD).
15.3.1
Generators
Transportable generating sets shall meet the following requirements:

Comply with AS 2790 Electricity Generating Sets - Transportable, and AS 3010 Electrical
Installations – Supply by Generating Set with the additional features, as varied below. All
live parts, including ‘neutral’ parts shall be guarded and insulated, including terminals at
the back of the outlet;

Socket outlets providing non-welding power shall be IP 56 rated, with an isolating switch
that operates in all live conductors;

Single-phase outlets indicated above shall be protected by a residual current operated
circuit breaker set to trip at a maximum earth leakage of 30 mA;,

Generators shall be inspected and tested by a licensed electrical worker and tagged in
accordance with the tagging procedure and be protected from wet weather conditions at
all times; and

Earthing of generators must comply with manufacturer instructions and the requirements
of AS/NZS 3000:2000 Wiring Rules.
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ENVIRONMENT
Cristal shall take appropriate actions to protect air, water, animal and plant life from adverse effects
of activities, and to minimise any nuisance which may arise from such operations, in accordance
with all applicable laws and company environmental requirements. Cristal shall provide information
and training in the company’s environmental requirements and all personnel are to respect and
comply with these requirements. These requirements are managed under the environmental
management plan
16.1
General Environment Conditions
Cristal will ensure operations are carried out in such a way as to minimise impact upon the natural
environment and comply with best principles and practices to:

Minimise land disturbance;

Prevent pollution of any surface and ground water of natural origin and include provision
of suitable equipment, facilities and precautions to prevent the discharge of contaminants
which may pollute the atmosphere, any body of water, or land areas, or which may harm
aquatic life or other wildlife;

Protect native flora and fauna ecosystems and control the importation of weed species;

Minimise quantities of waste generated and determine its hazard rating and type;

Recycle, re-use or recover resources from waste, as far as is economically feasible;

Ensure adequate dust control during required activities;

Minimise the generation of all noise to comply with the consent requirements;

Ensure compliance with all environmental laws, regulations and rules pertaining to the
operation.
16.1.1
Dust
Cristal shall implement effective dust control as far as is practicable to ensure no adverse impact to
other personnel, the environment and/or the community. The controls shall be regularly monitored
for effectiveness Dust control will be maintained by:

Conducting work practises in a manner to minimise airborne dust

Ensuring dust suppression measures are identified and implemented

Reporting excessive dust generation

Ensuring vehicles and plant must remain on defined and stabilised routes/ work areas.
16.1.2
Weeds and Contamination
Cristal shall ensure all mobile plant, equipment and vehicles are thoroughly cleaned and inspected
prior to mobilisation and demobilisation in order to control the spread of noxious weeds etc.
16.1.3
Waste Management
Cristal shall be responsible for ensuring that the handling, storage, treatment, transportation, and
disposal of waste is executed in an environmentally acceptable manner and is in accordance with
all applicable local government and statutory requirements.
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Spillages
Cristal shall be responsible for providing and maintaining spill control and clean-up equipment.
Spillages shall be controlled in the first instance and clean-up implemented as soon as possible.
All spillages shall be reported via the incident reporting procedure.
16.1.5
Waste Disposal
Cristal shall provide sufficient rubbish receptacles and industrial disposal bins for collection of
waste and ensure that all such bins are emptied on a regular basis to prevent overfilling.
Any hazardous substances shall be disposed of in accordance with statutory requirements at
licensed facilities.
All other waste shall be disposed of also in accordance with the requirements of local Government
and statutory bodies and will be assisted by:

All rubbish being placed in closed containers - NO LITTERING

Disposal and segregation of waste as per the mining and rehabilitation plan

Purchasing in bulk from suppliers to avoid excessive packaging waste
16.2
Discharge of Liquids
Cristal shall take all the necessary precautions to minimise the impact of discharged water
containing any matter in solution or suspension which may damage the environment, including,
without limitation, visible suspended matter into waterways and areas adjacent to the site.
Cristal shall take all precautions necessary to prevent the discharge into waterways of any oils or
similar materials or of any foaming or non-biodegradable liquids. All plant and equipment
maintenance must be carried out in a suitably contained area, the draining from which shall be
provided with approved oil separation traps before discharge. Contractors shall be responsible for
regular removal of harmful matter from such traps and its disposal in accordance with statutory
requirements.
All oil or fuel spilt or leaking from any item of plant or equipment shall be cleaned up immediately, if
necessary by excavation of impregnated soil and its removal to a disposal facility or soil
remediation area in accordance with the Hydrocarbon Management Plan.
17.
COMMUNITY
Cristal shall ensure the following aspects are considered to minimise the impact of its Operations
on the local community.
17.1
Concerns of the Local Community
Cristal shall take the following actions to ensure the community is considered throughout the
Operation. The local community concerns include:

Community consultation as and when required

Safe driving and road courtesy by all;

Respect for the community and natural environment; and

Consideration of local people

Establishing a mechanism for the reporting of public complaints.
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Caring for the Environment
Cristal shall ensure the following is clearly communicated to workers and appropriate controls are
implemented accordingly: 
Dispose of your own rubbish;

Respect and care for native bush, no driving of off-road vehicles except in designated
tracks and areas

Native vegetation is not cleared or damaged without consent

A permit to clear vegetation must be submitted and approved prior to clearance

No ground disturbance without consent

Native fauna is not injured due to poor work practices

Our workers are aware of potential impact on native fauna

No deliberate harm inflicted on all native fauna

Local fire regulations are adhered to, the district is subject to extreme risk of bushfires

Obtain a hot work permit before conducting hot work

Participate in fire fighting training

Provide and maintain fire fighting equipment
17.2.1
Community Complaints
Cristal shall establish a mechanism/process for the reporting of public complaints. All complaints
will be recorded via the company’s Incident Reporting procedure and corrective actions
implemented as appropriate.
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Appendix A – Organisational Structure.
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Appendix B – Referenced and Applicable Legislation, Australian Standards
and Codes of Practice
Work Health and Safety Act 2011
Work Health and Safety Regulations 2011
Mine Health and Safety Act 2004
Mine Health and Safety Regulation 2007
AS1337 – Eye Protectors for Industrial Applications
AS1269 – Occupational Noise Management
AS1715 – Selection, Use and Maintenance of Respiratory Protective Devices
AS2865 – Safe Working in Confined Space
AS1576 – Scaffolding – General Requirements
AS4576 – Guidelines for Scaffolding
AS1418 – Design and Construction of Workboxes
AS1657 – Fixed Platforms, Walkways, Stairways and Ladders
AS1892 – Portable Timber Ladders (including step ladders and trestle ladders)
AS1892 – Portable Ladders Metal
AS1841 – Portable Fire Extinguishers – General Requirements
AS1850 - Portable Fire Extinguishers – Classification
AS2250 – Crane, Hoists and Winches - Safe Use – General Requirements
AS2550 - Crane, Hoists and Winches - Safe Use – Mobile elevated Work Platforms
AS1418 – Cranes, Hoists and Winches – General Requirements
AS1418 - Crane, Hoists and Winches – Mobile Cranes
AS1418 - Crane, Hoists and Winches – Elevated Work Platforms
AS1893 - Code of Practice for Guarding and Safe Use of Metal and Paper Guillotines
AS1219 - Power Presses – Safety Requirements
AS3000 - Wiring Rules
AS3007 - Electrical Installations
AS3012 - Electrical Installations - Construction and Demolition Sites
AS21788 – Abrasive Wheels
AS3302 - Approval and Test Specifications – Electric Fans
AS2554 – Hoses and Hose Assemblies for Air
AS1179 – Glossary of Terms for Rubber Hose
AS1180 – Methods of test for hose made from Elastomeric Materials
AS1869 – Hoses and hose Assemblies for LP Gases and Natural and Town Gas
AS1335 – Hoses and Hoses Assemblies for Welding, Cutting and Allied Processes
AS3791 – Hydraulic Hoses
AS3760 – In Service Safety inspection and Testing of Electrical Equipment
AS2790 - Electricity Generating Sets – Transportable
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AS3010 - Electrical Installations – Supply by Generating Set
AS1841 - Portable Fire Extinguishers General Requirements Series
AS1851 – Maintenance of fire protection systems
AS5062 – Fire Protection for Mobile and Transportable Equipment
AS2444 - Portable fire extinguishers and fire blankets - Selection and Location
SafeWork Australia National Codes of Practice
SafeWork Australia National Standards
SafeWork Australia National Guidance
National Transport Commission Advanced Fatigue Management Standards
NSW Electrical Practices for Construction Work 2007
NSW Codes of Practice applicable to Mining
NSW Licensing, Registration and Notification
ARPANSA
Mining Design Guidelines
REVISION INFORMATION:
Revision History
Rev. #
0
1
2
3
Date
25/10/05
12/9/06
Owner
P. Humphris
P. Humphris
Detail of Change
Original Document
Reviewed, no changes
07/05/14
J. Sulicich
19/11/2014
A. Carter
Significant changes.
*Name changed from HSEQ Manual to Mine Safety
Management Plant
*Large amount of information added to provide
information on how the HSE Management System
functions.
No changes to document content.
Document number changed from AP_ME_4.4.0 to
AP_ME_4.4.04007
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