Fatal Hazard

Protocols and
Life Saving
Behaviours
MARCH 2021
2 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Contents
SafeWork 3

Accountabilities 5

Life Saving Behaviours 6

Fatal Hazard Protocols 7

1 Energy Isolation 10

2 Working at Height 16

3 Confined Spaces and Irrespirable and/or Noxious Atmospheres 22

4 Mobile Equipment 27

5 Ground and/or Strata Failure 35

6 Electrical Safety 45

7 Emergency Response 54

8 Lifting and Cranage 59

9 Fire and Explosion 65

10 Explosive and Shotfiring 73

11 Tyre and Rim Management 78

12 Inrush and Outburst 88

13 Molten Material 94

Glossary 100

Control and Revision History 108

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
BEHAVIOURS BOOKLET
ISSUED ON: 31 MARCH 2021 STATUS: APPROVED
3 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

SafeWork
SafeWork is Glencore’s approach
to eliminating fatalities.

SafeWork is about identifying fatal hazards and managing At the heart of SafeWork are the Fatal hazard Protocols,
associated risks, improving the way we operate, adopting that along with the Lifesaving behaviours, Safety
the right behaviours, taking care of ourselves and our Standards and a set of operational safety tools, make up
colleagues, and having the courage to stop work when the core elements of fatal hazard management.
not safe. It is also about creating the right culture to enable SafeWork will only be as effective as the commitment
everyone take the right decisions when it comes to safety. we make to implement the Fatal hazard Protocols whilst
SafeWork consists of the following 9 essential elements: continuing to be vigilant regarding the health and safety
Safety Leadership of ourselves and others.

Risk Management
Fatal Hazard Protocols and Safety Standards
Life Saving Behaviours
PETER FREYBERG HEAD OF
SafeWork Planning INDUSTRIAL ASSETS
Operational Safety "Fatal Hazard Protocols and Life Saving
Incident Investigations and Reporting Behaviours remain at the heart of SafeWork
Assurance and its adequate implementation continues
to be our priority"
Action Closure and embedding Learnings
At the heart of SafeWork are the Fatal Hazard Protocols
and the Life Saving Behaviours – which are critical and
must be prioritized to eliminate fatalities as they directly
address fatal hazards at the frontline.
This booklet combines the requirements from all 13 Fatal
Hazard Protocols and the 9 Life-Saving Behaviours in
their respective latest version at the time of the release
of this booklet. The Fatal Hazard Protocols are updated
on a regular basis and as such, the requirements in this
booklet are not controlled.

1 Commitment
Glencore is absolutely committed to making SafeWork
a reality and this can only be achieved with the
combined commitment of every member of our teams
and other relevant stakeholders. We know that when
fully implemented, consistently used as part of daily
operations and championed by strong leadership,
SafeWork prevents fatal injuries.

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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4 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

SafeWork
SafeWork is Glencore’s approach
to eliminating fatalities.

2 Implementation
Managers at Glencore’s assets are required to implement
the Fatal Hazard Protocols (FHPs) in alignment with the
GLENCORE CODE OF CONDUCT ALSO STATES: SafeWork Performance Expectations for FHPs and
“Our ambition is to become a leader in the field Safety Standards.
of safety and to create a workplace free from Additional location / hazard specific fatal hazard
fatalities, injuries and occupational diseases.” protocols may be added.
"We acknowledge that we are all responsible Protocols shall be implemented through a structured
for our own safety and the safety and wellbeing process involving communication, consultation
of our colleagues, contractors and the and Training*.
communities in which we work. We expect our
people to follow health and safety instructions
and to take responsibility for their own and their
colleagues’ safety.”

"We are committed to a strong safety culture

that requires visible leadership from all levels
of line management, a high level of
engagement from employees and contractors
and a focus on hazard identification, risk
analysis and risk management."

"We recognise that all of us have the authority

to stop work if we consider it unsafe. We require
our people to be trained, competent, and fit to
fulfil their duties. No-one should commence
any task that they consider unsafe or where
the hazards cannot be controlled.”

If it is not safe,
STOP work!
No more fatalities!

* See glossary

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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5 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Accountabilities

Workforce Ensure effective reporting systems exist for

(“everyone**”) people to raise concerns;

Satisfy yourself that the FHPs are properly

Comply with SafeWork Performance
understood, adhered to by: undertaking
Expectations and FHPs requirements;
regular site visits, safety interactions, reviewing
Ask questions, seek clarification as needed; Audit* reports, ensuring corrective actions are
implemented;
Challenge any behaviour which does not comply;
Address all violations of FHPs before an incident
Take time to plan to do the job safely, including
occurs;
risk assessment;
Ensure consistency and fairness in consequence
If in doubt, stop the job; and report all unsafe
management of violations;
situations and take action.
Set the example to employees;
Supervisors Act to eliminate hazards or mitigate risks; and
(as well as “everyone”)
Inform the employees of processes for
Explain to your team that compliance is compliance reporting.
expected at all times;

Visit the worksites regularly to check compliance; All work starts with the foundations
Ensure your team understands the Emergency Response Plans are in place before
consequences of breaching requirements; work starts;
Support and coach the members of your teams A pre-job risk assessment and safety discussion
in implementing the FHPs requirements; are required at the start of every job;
Ensure your team identifies hazards and All workplaces must be safe from uncontrolled
assesses risks; hazards;
Address all violations of FHPs, before an incident No supervisor will instruct anyone to violate
occurs; or breach any FHP requirement, or condone
Set the example to employees; and inappropriate behaviours;

Act to remove or repair safety issues and provide Personal Protective Equipment (PPE) will be
feedback to the team on their status. worn where mandated;

All persons will be trained and competent in the

Managers work they conduct; and
(as well as “everyone”) Everyone has an obligation to stop unsafe work.
Regularly explain the purpose of the FHPs, Everyone has a clear understanding of the
and expectations of compliance by everyone; consequences for wilfully violating FHPs
requirements.
Recognise good safety behaviours, and tackle
non-compliance;

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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6 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Life Saving Behaviours

Life-Saving Behaviours (LSBs) are a set of critical safety behaviours intended to save lives. By following LSBs
we protect people from potential fatal consequences. LSBs have a direct link, based on previous incidents
and learnings, to behaviours broken just prior to a fatal incident occurring. They are an essential complement to the FHPs.
LSBs apply to all Glencore employees, temporary employees, contractors and visitors to a Glencore operated Asset.
Mandatory LSBs that must be implemented are:

Always come to work Never modify or over-ride

drug and alcohol free. critical safety equipment
without approval.

Always use or wear Always seek and obtain

critical safety equipment. clear approval before
Note: critical safety equipment are entering mobile equipment
items that are designed to prevent life operating zones.
threatening injuries and are referred Note: the operating zones must be
to within the Fatal Hazard Protocols defined by the Operation / Project,
or defined by the Operation / Project they typically include: 3 – 10m from
as critical, e.g. seat belts, fall restraint machinery in an underground situation,
or arrest equipment, etc. 30 – 50m from heavy mobile equipment
on the surface.

Always wear appropriate fall Never enter Danger Zones.

protection equipment when Danger Zones include: under
working above two (2) metres. unsupported roof; under suspended loads;
within barricaded or signposted no-go
areas, or within identified pinch or crush
points of machinery, confined spaces, and
other zones defined by the Operation
Only operate equipment / Project based on legislation, industry
if trained and authorised. norms and risk assessments.

Always isolate and ‘test Always report injuries

for dead’ prior to working and HPRIs.
on energy sources.

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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7 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Fatal Hazard Protocols

Introduction or will be, addressed through risk management

processes in accordance with the SafeWork
In 2013, a review of our recent fatalities, High Performance Expectations and Safety Standards.
Potential Risk Incidents (HPRIs) and serious incidents
identified the need for an intervention program to These protocols are to be read and used in conjunction
eliminate fatalities and improve our health and safety with the Glencore Code of Conduct and relevant
performance. This program is called SafeWork and one operating procedures.
of its main initiatives is to focus on Fatal Hazards.
Scope
As a result of these reviews, a number of FHPs have
been developed that establish minimum requirements These FHPs and Life Saving Behaviours apply
for the management of these hazards consistently to all employees, directors and officers, as well as
across our business. The FHPs are associated with contractors under Glencore's direct supervision,
the most common fatalities within our industry and working for a Glencore office or industrial asset
Glencore and respond to various Operations Baseline directly or indirectly controlled or operated by
/ Broad-Brush Risk Assessment*, HPRIs, Industry Glencore plc worldwide.
Safety Alerts, and the health and safety legislation that
exists across the relevant jurisdictions, as well as other
relevant information including good industry practice.

These FHPs do not replace or override local health and

safety legislation, or associated legislation and other
external requirements. The content and intent of these
FHPs is to provide minimum requirements.

In 2020 all FHP’s were reviewed, updated and

republished. Some protocols were converted to Safety
Standards and the number was limited to thirteen
of those most applicable to the operating assets.
The FHP’s may be updated from time to time on the
Glencore HSEC Intranet, so the content in this booklet
should always be checked to see if there are more
recent updates.

Context
It should be acknowledged that these protocols may
not include all of the Fatal Hazards that may exist or
be faced by our assets, but the outcomes do focus
attention on the hazards that have resulted in recent
fatalities and HPRIs.
The other hazards and associated risks are being,

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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8 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Fatal Hazard Protocols

Assurance General mandatory requirements

Assets will be required to conduct Assurance as All employees and contractors must be fully aware of
defined in the SafeWork Performance Expectations the specific Fatal Hazards in their workplaces and be
for FHPs and Safety Standards. FHPs Self-Assessment trained and competent to manage the risks associated
and Audit Workbooks are provided. with these hazards.

Variation of the protocols To achieve this:

Departments are free to contextualise and add to the Operating teams at each worksite (e.g. drilling, mining,
Protocols within their own documentation, but must processing, port operations, maintenance and offices)
retain all protocols unless they are not applicable within are to identify their respective Fatal Hazards;
the Department. Requirements must remain consistent. A risk management approach is to be undertaken
to ensure that robust control mechanisms (hard
Variations to the Protocols should be backed up by barriers, systems & procedures) are in place;
evidence in departmental, Operational or Project risk
All employees and contractors are to be trained in
assessment process. Any deviation from the FHPs must
understanding Fatal Hazards and their controls;
be formally approved by the Industrial Lead based on the
department’s deviation process and accompanied by a All employees and contractors are to understand
documented justification based on risks. their accountabilities in controlling the Fatal
Hazards to protect themselves and their fellow
workers;

Managers and supervisors are to have the control

of Fatal Hazards as part of their job description;

A Visible Field Leadership Matrix is to be

established at each operational site;

Continuous Improvement
Assets are to implement and maintain the requirements
of these protocols into their HSEC management systems.
This should follow the ‘Plan, Do, Check, Act’ process:

PLAN
Identify and develop processes and controls to meet the
requirements of these protocols, considering relevant
legal and other external requirements. This includes
(but is not limited to):

Conducting appropriate documented risk

assessments for each of the Protocols;

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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9 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Fatal Hazard Protocols

Developing a Management Plan*, procedure*, ACT
system (e.g. permit system) and / or other formal Analyse outcomes of Monitoring Program, including
risk control process, as appropriate, that identifies Audit outcomes and identify areas for continual
the individual controls and their effectiveness that improvement and maintenance of Management Plans,
are adopted to eliminate or manages the risks; procedures and permit systems. This includes:

Developing a risk prioritised treatment plan; Integrating outcomes and feedback into risk
management process, plans, procedures and
Identifying Training needs for relevant employees,
permit systems;
contractors, and visitors regarding each of the
protocols; and Using a Change Management* process for
significant planned and unplanned changes; and
Ensure disciplinary code supports effective, fair and
consistent consequence management through a Implementing and maintaining documentation in
fair treatment process. accordance with Document Control* processes.

DO The importance of an effective risk management

Develop, implement and maintain processes, controls process including Change Management is fundamental
and/or communication strategies, as appropriate, to to achieving the desired outcome of the protocols.
meet the requirements of these protocols. This includes
(but is not limited to):
Version Note
Implementing and maintaining the Management
Plans, procedures or permit systems; This version supersedes SafeWork Life Saving
Providing Training and refresher Training to Behaviours and Fatal Hazard Protocols V1-0 Booklet.
relevant employees and contractors, as identified in
the Training Needs Analysis; and However, the Fatal Hazards Protocols are reviewed on a
regular basis and the latest versions of each respective
Assessing the trainees to verify their competence.
Protocol can be consulted on the HSEC Intranet.

CHECK
Develop, implement and maintain processes, controls
and/or communication strategies, as appropriate, to
meet the requirements of these protocols. This includes
(but is not limited to):

Conducting internal Audits, reviews and / or self-

assessments to monitor compliance with the
protocols requirements against a predetermined
Monitoring Program; and

Ensuring line management understands and

accepts their accountability with respect to
consequence management and violations of
Life-Saving Behaviours and FHPs requirements.
* See glossary

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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10 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Energy
Isolation
VERSION: 2-0
EFFECTIVE DATE: 01/12/2019
11 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

1 Energy Isolation

Intent
The intent of this protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents arising
from risks associated with inadequate isolation of
Energy Sources*. Examples of Energy Sources include
electrical, mechanical, pneumatic, gravity, hydraulic,
heat, radiation, etc., and stored energy such as e.g.
electrical capacitors, springs, compressed air/gas, and
suspended loads, etc.

Related Life-Saving Behaviours

2 Always use or wear critical safety equipment.

4 Only operate equipment if trained and authorised.

5 A
 lways isolate and “test for dead” prior to working
on Energy Sources.

6 N
 ever modify or over-ride critical safety equipment
without approval.

8 Never enter danger zones without approval.

KEY ACTIONS
A risk assessment must be conducted to identify
and evaluate energy isolation related risks.

 n Action/Treatment Plan must be developed

A
to control all identified risks.
An Audit* must be conducted to identify
gaps against legal requirements, relevant
international standards, and this protocol.

 n Action Plan* must be developed and

A
implemented to meet these requirements.

 ew and emerging technical solutions are

N
identified, tested and applied to reduce or
eliminate energy isolation hazards and risks.

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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12 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

1 Energy Isolation

1.1 Risk assessment and controls

1.1.1 A risk assessment must be conducted to
with Live energy or other sources of danger.
identify the hazards, assess the risks and
These areas must be demarcated via the
implement controls related to interaction
application of a standardised system of
with Energy Sources.
barricading and signage to prevent or
control access; e.g. caution and danger tape,
1.2 F
 ixed guarding, barricades and and/or solid fencing or barricades, and signs.
signage 1.2.4 Guarding, colour coding and signage used
1.2.1 Wherever practical, access to Energy Sources, must be consistent with international
e.g. electrical conductors, rotating and standards.
moving parts, nip points must be guarded to
prevent inadvertent or unauthorised access. 1.3 Procedures and permits
1.2.2 Emergency stops must be placed at all 1.3.1 An Energy Isolation Procedure and
points where personnel may be in danger associated permits must be developed,
of entanglement with rotating machines or implemented and maintained for all relevant
other process conditions. Guarding must be Energy Sources.
provided as a first option but may not always 1.3.2 As a minimum, the Energy Isolation
be practical in some instances; these areas Procedure must include the following
should be determined by a risk assessment. requirements:
a) Application of the 12 Step Isolation
1.2.3 Assets must develop, implement and
Process (see below):
communicate a system to barricade
identified hazardous locations that are
not protected by fixed guarding and
identified as presenting a risk of contact

12 STEP ISOLATION PROCESS

Place locks
Isolate & or permits
secure

Advise
relevant
parties 3 4 Verify
isolation

2 5

1 Isolation 6
Commence
work
Check
operation

Identify
energy Complete 7 12
Restoration
sources work

8 11
Check
work 9 10 Restore
energy

Clear Remove locks

area or permits

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13 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

1 Energy Isolation

1.3.2 b
 ) Before undertaking any work on plant incorporating a second competent
and equipment, relevant Energy Sources electrical isolation verifier. Exemptions
including back feeds from generators and from this requirement may be applicable
dual supplies must be: in limited applications where specific
1. Identified and dissipated; engineering controls and isolation
2. Isolated and secured; and procedures are implemented, e.g.
3. The isolation is Verified* as zero energy. withdrawing 3.3kV plugs on a longwall.

c) Use of locks as part of the isolation process. i) For plant and equipment containing
Energy Sources that cannot be locked-
d) Isolation at the primary lockable isolation
out, e.g. “power on” maintenance tasks, a
point or points, e.g. circuit breaker,
risk-based and prioritised Action Plan must
isolator, battery isolator, valve, visible
be developed to address positive isolation
break isolator, and not a control device,
requirements.
e.g. vehicle key, emergency stop button
or conveyor lanyard. Control systems 1.3.3 The
 Energy Isolation Procedure must be
that have been specifically designed for supplemented with the following:
performing isolations with a suitable level a) Permit Systems* for Group Isolations
of integrity may be used, e.g. conveyor (Group Isolation Permit) and High
remote isolation systems, Longwall High Voltage Isolations (High Voltage Access
Integrity Isolation Systems. Permit).
e) A
 n approved process for performing b) A procedure for protection of individuals
isolations where the isolation points under an isolation system (Individual,
cannot be locked due to not being Group or High Voltage Isolation) and/
lockable type, broken handles or no or for Authorised Personnel* to assist
availability of portable devices as examples. individuals whenever the individuals
f) L
 imiting the types of tags used across the are not competent or confident in
asset to only the following types: performing their own isolation or locking/
1. Personal Identification Tags (Photo signing onto an Isolation Permit.
Type) for use with Personal Red Locks, c) Procedures for Complex Isolations*.
where required;
d) A procedure for the removal of personal
2. Out of Service Tags;
isolation locks by persons other than
3. Commissioning Tags; and
the person that has performed the
4. Information Tags.
isolation in the event that this person
g) U
 se of interlocks or physical barriers where is unavailable to remove the lock, e.g.
practical, to prevent access to Energy left the worksite without removing their
Sources that have not been isolated. personal lock for personal isolations or for
h) P
 ersonnel accessing High Voltage* lost keys under a Group Isolation Permit
conductors (greater than 1000 volts AC or High Voltage Access Permit.
or 1500 volts ripple free DC) must have
a High Voltage Access Permit in place

* See glossary

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14 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

1 Energy Isolation

1.3.3 The
 Energy Isolation Procedure must be 1.4.2 A
 ll isolation points must be clearly labelled
supplemented with the following: to identify the equipment that has or is to
be isolated, including a plant number and
e) A procedure to control the risks
description.
associated with Live Testing* or approved
“power on” maintenance activities. 1.4.3 The ON and OFF positions of an isolation
device shall be clearly and reliably indicated.
f) P
 rocesses for the use of stands, chocks,
locking pins, clamps or other methods for 1.4.4 Consideration must be given to the
securing objects from falling or moving. display of photographs and/or diagrams
at Isolation Points that have been deemed
g) A process for the isolation of light
complex to more clearly demonstrate the
vehicles, e.g. personnel carriers, road
isolation requirements.
registered vehicles, transport vehicles.
1.4.5 All Isolation Points must, wherever possible,
1.4 Isolation Points* be of the lockable type or made lockable
with a portable or specific device.
1.4.1 In determining the location of the Isolation
Points, consideration must be given to 1.4.6 A
 maintenance regime for isolation devices
practicality and accessibility. and equipment (including Isolation Points)
must be developed and documented.
All electrical isolation devices, e.g. circuit 1.4.7 For all plant and equipment, Isolation
breakers/isolators, that are located outside Points and methods must be identified and
of a switch room or substation, where documented, e.g. how and where a specific
access and operation is permitted, should piece of plant and equipment is isolated and
be installed inside a suitably IP rated the isolation Verified.
enclosure that allows for access without the
1.4.8 Lockable battery isolators must be fitted
need for a key or tool. This may be achieved,
to all plant and equipment, e.g. trucks,
depending on the installed conditions, by
loaders, dozers, excavators, lighting plants,
either:
generators, diesel pumps, diesel welders
a) Installing an extension handle designed for and labelled “Battery Isolator”. For light
the isolation device to extend through the vehicle requirements see item 1.3.3 g.
front door where environmental conditions
1.4.9 All new installations must be specified with
allow these to be installed (IP rated); or
double-pole type isolators.
b) Having the isolation device mounted
1.4.10 Consider the installation of video
inside an electrical enclosure where
surveillance cameras in substations and
it can be accessed without the need
switch rooms to record any switching
for a key or tool and an internal barrier
activities or actions, including the use of
installed to prevent access to exposed
the required arc flash PPE. This includes the
Live conductors, e.g. escutcheon cover.
use of personal “body-cam” style cameras
Examples of these installations are
to capture critical switching activities and
shown in the Glencore Installation and
confirm the effectiveness of isolations, e.g.
Equipment Guideline.
verification of zero energy.

* See glossary
TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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15 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

1 Energy Isolation

1.5 Competency and Training 1.5.4 Only

 trained, competent and Authorised
or Appointed Personnel* are to conduct
1.5.1 Assets
 must identify the competency
isolations.
requirements and associated Training* for
relevant personnel in relation to energy
isolation. This will include refresher Training 1.6 Technological surveillance
as well as the ongoing maintenance of 1.6.1 C
 ontinual surveillance of existing and
isolation competencies. Competency upcoming technologies should be
requirements include: maintained to identify new and safer
a) The familiarisation of all relevant energy isolation solutions.
personnel with Basic Isolation*, including 1.6.2 N
 ew technical solutions should be tested
identification of primary and secondary and used to minimise the need to isolate
Energy Sources and how to verify an or to make isolation simpler and/or more
isolation in line with their respective effective.
competencies. Emphasis should be given
to the “test for dead” verification for
identified Energy Sources.
1.7 A
 dditional requirements for
catastrophic (PMC 5) situations
b) A
 ll relevant personnel who are required
to isolate Energy Sources to perform Nil.
work are to be trained to conduct an
individual isolation within their own * See glossary
competency, or apply personal locks to
a group isolation permit or High Voltage
Access Permit.

c) L
 egal/regulatory competency
requirements pertaining to specific
activities and/or professions must be met.

1.5.2 Training
 packages are to be inclusive of
relevant competency standards, legislation, TOOLS (SEE GLENCORE HSEC INTRANET)
codes of practice, design criteria and site or
Tools provided include:
regional protocols, procedures and permit
systems, and include: FHP Self-Assessment Workbook,

a) Relevant isolation and emergency FHP Third Party Audit Workbook 01

procedures and use of related – Energy Isolation,
equipment, devices, PPE and other Energy Isolation Procedure template,
protective apparatus.
Group Isolation Permit,
1.5.3 Specific
 Training and assessment for
High Voltage Access Permit, and
Authorised Isolators and Permit Holders
must be conducted, including practical Energy Isolation Training Package.
application.

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16 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Working
at Height
VERSION: 2-1
EFFECTIVE DATE: 15/10/2020
17 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

2 Working at Height

Intent
The intent of this protocol is to eliminate or minimise the
potential for fatalities, injuries and incidents arising from
risks associated with Working at Height*.

Related Life-Saving Behaviours

2 Always use or wear critical safety equipment.
3 Always wear appropriate fall protection equipment
when working above two (2) metres.

4 Only operate equipment if trained and authorised

6 Never modify or over-ride critical safety equipment
without approval.

KEY ACTIONS
A risk assessment must be conducted to
identify, analyse and evaluate all hazards
associated with Working at Height such as
working over water, dropped or falling objects,
etc. and an action/treatment plan
is implemented.

When practicable, advanced technical and

engineering solutions must be applied to
reduce or eliminate Working at Height hazards.

For all identified routine tasks and/or

activities involving work above two (2) metres,
procedures* and permits* must be developed,
applied and maintained.

Competency requirements and training*

needs must be identified and a training plan
developed and implemented.

Rescue plans must be developed and

tested and suitable recovery equipment
made available.

Project management plans including Work at

Height risk management processes must be
developed and applied for major construction
or demolition projects.

* See glossary
TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
BEHAVIOURS BOOKLET
ISSUED ON: 31 MARCH 2021 STATUS: APPROVED
18 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

2 Working at Height

2.1 General requirements

2.1.1 
A risk assessment must be conducted and 2.1.10 Environmental conditions and events that
documented to identify the hazards and may affect the Worker to safely complete
assess the risks associated with Working at a task or an activity involving Working at
Height such as working over water, dropped Height hazards must be factored in
or falling objects, construction or demolition
of structures.
2.1.11 All snap hooks and karabiners shall be
self-closing and shall be capable of being
2.1.2 A Working at Height procedure meeting opened only by a minimum of at least two
the requirements of this protocol must be consecutive actions.
developed, implemented and maintained.
2.1.12 Corrosion resistant pieces of equipment
2.1.3 For routine and/or periodic tasks and/or (e.g., Anchor Points*, snap hooks, Lanyard
activities involving Working at Height, task Connectors*, etc.) must be used in
specific procedures must be developed preference to other types of material,
and used. particularly in corrosive environments
2.1.4 Before undertaking any task or activity (e.g., in process plants).
involving Working at Height, and where 2.2 H
 arnesses, Lanyards, Personal Fall-
safety procedure does not exist, a
Arrest Systems and Anchor Points
documented risk assessment must
be conducted.# 2.2.1 Full-Body Harnesses (FBH), Lanyards,
Personal Fall-Arrest Systems (PFAS),
2.1.5 Workers* conducting a task or activity
fall-restraints systems and accessories
at a height whilst outside the protection
must be appropriate to the type of work
of a fixed access platform with handrails
being conducted and meet the relevant
shall wear Full Body Harnesses (FBH)*,
recognised design standard.
and use Lanyards*/Personal Fall-Arrest
Systems (PFAS)*. 2.2.2 The operator must inspect their fall arrest
system or restraint device before use as per
2.1.6 A Working at Height Permit must be used
manufacturer’s instructions. The inspection
for Work at Heights greater than two (2)
should include checking for damage to the
metres whenever outside the protection of
webbing through burns, chemicals, etc. and
a fixed access platform with handrails, when
damage to buckles, hooks and attachment
Mobile Elevating Work Platforms (MEWP)*
hardware. The harness and Lanyard must be
or crane suspended Workboxes* are used.
within their test period (as stamped on the
2.1.7 Persons Working at Height must not harness and Lanyard).
work alone.
2.2.3 All FBHs must be fitted with a suspension
2.1.8 Persons Working at Heights must wear trauma safety strap and appropriately
appropriate head protection for the task and adjusted prior to the use of the FBH.
use chin straps.
2.2.4 Lanyards must be fitted so fall distances are
2.1.9 Where practicable, eliminate or engineer out minimised and the wearer may not fall to a
the risk of falls or use fixed access platforms, lower level without the fall being arrested.
MEWPs, Workboxes, and/or Scaffolds*.

* See glossary
TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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2 Working at Height
2.2.5 
Lanyards must have an Energy Absorber*
device when being used in a PFAS, unless
it can be demonstrated that a force of 6kN roof) a risk assessment must be conducted
will not be experienced by the user. and documented, alternative Anchor Points
and PFAS must be properly selected.
2.2.6 
When estimating the total fall distance, the
extension length of the Energy Absorber 2.2.13 Hard barricading and warning signs shall
(when fitted) must be taken into account. be installed around an area where an
opening has been created (i.e. grating
2.2.7 
Where Workers are required to detach and
removal due to maintenance purpose
reattach at height, a dual Lanyard system
or projects).
must be utilised. A person Working at
Heights must be attached to an Anchor 2.3 M
 obile Elevating Work platforms,
Point before crossing outside the protection Workboxes and Scaffolds
of a fixed access platform and remain
attached 100% of the time.
2.3.1 
MEWP and Scaffolds with complete floors,
guardrails, toe-bars, safe access and egress
2.2.8 
A Lanyard assembly must be as short as must be provided and used. Before being
practicable, its working slack length is to be used, they must be inspected and tagged
less than two (2) metres and where practical by a Competent Person.
fitted to limit the Free-Fall Distance* to six
hundred (600) millimetres.
2.3.2 
A MEWP should be controlled by an
operator in the platform. Where this is
2.2.9 
PFAS or fall-restraint equipment attached not possible (such as underground loaders)
to an Anchor Point must be used whenever an override or emergency stop provision
persons work at a height above two (2) must be accessible in the platform.
metres whilst outside the protection of
an installed (fixed) access platform with
2.3.3 
A person working from a crane suspended
Workbox must remain in visual and/or radio
handrails.
contact with the person in control of the
2.2.10 PFAS material/equipment must be tested crane or the crane operator.
and certified for use, inspected by the user
before use and destroyed following a fall or
2.3.4 
Persons working in or on boom-type
MEWPs, or Workboxes above two (2)
where an inspection has shown evidence of
metres must wear FBHs with Lanyards
excessive wear or mechanical malfunction.
affixed to an approved Anchor Point in
2.2.11 Anchor Points/Systems* must be marked the platform, or in the case of Workboxes
as tested and approved by a Competent suspended from a crane, to an approved
Person* to verify they are capable of independent point/line outside
withstanding a breaking force of 15kN,
the Workbox.
(single person Anchor) or 21kN
(two persons Anchor). 2.3.5 
Only MEWPs, Workboxes and Scaffolds
that are designed, constructed, certified
2.2.12 Where practical, Lanyard Anchor Points on
and labelled to a recognised standard
apparatus should be above the head of the
may be used.
Worker and no lower than shoulder height.
Where it is impractical to do so, (e.g., on a flat
* See glossary

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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20 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

2 Working at Height
2.3.6 
If an MEWP, Workbox or Scaffold has
been repaired or modified, it must
be recertified in accordance with the automatic device to mitigate the severity
manufacturer’s requirements; of an operator crush injury; an example is
an interlocked pressure-sensitive bar over
2.3.7  EWPs, Workboxes and Scaffolds
M
the operating controls.
are to be inspected and maintained.
Regular inspections should consider 2.4 L
 adders
use of non-destructive testing
(e.g. dye penetrant testing). 2.4.1 Working above two (2) metres from ladders
must be avoided, but when no other
2.3.8  ollowing any significant
F
practicable alternative exists, the following
environmental event (e.g. gale, storm,
requirements apply:
tornado, thunderstorm, etc.), scaffoldings
a) A
 pre-task risk assessment must be
and other such types of equipment must
carried out;
be re-inspected and re-certified.
b) A
 person may ascend or descend a ladder
2.3.9 
The use of MEWPs for undertaking without fall protection provided they are
maintenance activities on large equipment, able to use both hands and legs, maintain
including workshop and field maintenance three points of contact with the ladder,
activities must be considered. continuously to face the ladder, and take
2.3.10 The installation of fixed access platforms only one rung at a time;
on infrastructure, large mobile plant and c) F
 ixed vertical ladders greater than 6
equipment where routine maintenance metres in height must be provided with
activities require personnel to work at a protecting cage, extending a suitable
height must be considered. distance above the platform reached;
2.3.11 The installation of stairways or other man d) E
 xtension ladders must be tied off or
lifting devices for vehicle access in place footed, have an angle corresponding
of ladders for large mobile plant and to one in four (one horizontal to four
equipment must be considered. vertical), be maintained and they must
extend at least one (1) metre above the
2.3.12 Self-propelled boom-type elevating
access or work area; and
work platforms should be fitted with:
e) If a person is to work from a ladder,
a) A
 switch or warning that must be PFAS must be used unless three points
activated or accepted before the propel of contact can be maintained with
function is enabled when the boom is the ladder and the task does not
swung past 90 degrees; this is to prevent involve overreaching.
inadvertent movement of the MEWP
in the opposite direction to the propel
2.5 F
 alling or dropped objects
control lever movements. An alarm 2.5.1 Whenever a task or an activity involves
only is not a satisfactory control; working a height, risks associated with
b) A form of secondary guarding or crush falling or dropped objects must be
protection such as a protective guard identified, assessed and controlled.
structure over the operator or an

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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21 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

2 Working at Height
2.5.2 When the risks cannot be eliminated,
controls must be developed, implemented
and maintained to prevent objects from 2.7.5 Crane suspended Workboxes may only
falling or being dropped. be used by persons who have been trained,
are competent and have been authorised
2.5.3 Barricades must be erected below work
to do so.
areas to protect Workers from falling objects.

2.5.4 Signage and PPE requirements for 2.8 A

 dditional Requirements for
personnel working in areas with a risk Catastrophic Risk (PMC 5) Situations
of dropped or falling objects must be 2.8.1 Where major construction or demolition
developed and applied. works are planned and multiple persons
2.6 Rescue are at potential risk:
a) T
 he risk assessment must be updated
2.6.1 Site specific rescue plans and procedures
on a regular basis;
for rescue from height and/or from water
must be developed, implemented b) A
 project management plan must
and maintained. be developed which includes the order
of activities, inspection requirements,
2.6.2 Appropriate rescue equipment must
accountabilities and controls be
be provided, ready for use and regularly
applied; and
inspected.
c) A
 project manager must be appointed
2.6.3 Competent rescue teams must be ready to manage activities in accordance
to intervene at any time. with the plan.
2.6.4 All applicable legal requirements pertaining
to fall from height emergency rescue plans
and procedures must be satisfied.

2.7 C
 ompetency and training
2.7.1 Training needs and competency
requirements pertaining to Working at
Height risks, equipment, procedures and
permits must be identified and reviewed
on a periodic basis.

2.7.2 A training plan including periodical refresher

training must be developed, implemented
TOOLS (SEE GLENCORE HSEC INTRANET)
and maintained.
Tools provided include:
2.7.3 Competency must be assessed on a periodic
FHP Self-Assessment Workbook,
basis, and as legally required.
FHP Third Party Audit Workbook
2.7.4 MEWPs may only be used by persons who 02 – Working at Height, and
have been trained, are competent and have Working at Height Work Permit.
been authorised to do so.

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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22 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Confined Spaces
and Irrespirable and/or
Noxious Atmospheres
VERSION: 2-0
EFFECTIVE DATE: 01/01/2020
23 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

3 Confined Spaces and Irrespirable

and/or Noxious Atmospheres

Intent
The intent of this protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents
arising from risks associated with personnel entering
or working in a confined space or an area with the
potential for an irrespirable or noxious atmosphere.

Related Life-Saving Behaviours

2 Always use or wear critical safety equipment.

4 Only operate equipment if trained and authorised.

5 A
 lways isolate and “test for dead” prior to working
on Energy Sources.

6 N
 ever modify or over-ride critical safety equipment
without approval.

8 Never enter danger zones without approval.

KEY ACTIONS
A risk assessment is conducted to identify
confined space and irrespirable/noxious
atmosphere risks and an action/treatment plan
is implemented to control identified risks.

All identified confined spaces and areas/

workplaces with potential for irrespirable/
noxious atmosphere are documented in
a register.

 rocedures and permits are developed

P
and used to manage confined spaces and
irrespirable/noxious atmosphere risks.

 n Audit* is conducted to identify gaps against

A
legal and international standards requirements
and an Action Plan* is developed and
in areas with potential for irrespirable/noxious
implemented to meet these requirements.
atmosphere commensurate to employees and
 raining* including refresher course are
T contractors competency.
provided to all employees and contractors on
Apply advanced technical and engineering
relevant procedures and permit systems.
solutions wherever practical to reduce or
 rovide supervisory monitoring of activities/
P eliminate hazards related to confined spaces
tasks taking place in confined spaces and and irrespirable/noxious atmosphere.

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
AND LIFE SAVING HUMAN RIGHTS VERSION: 2.0
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24 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

3 Confined Spaces and Irrespirable

and/or Noxious Atmospheres

3.1 C
 onfined Spaces
3.1.1 A documented risk assessment must 6. E
 stablishment of ventilation needs,
be conducted to identify the hazards, i.e. natural or forced;
analyse and evaluate the risks associated
7. Identification of the need to use self-
with confined space entry.
contained breathing apparatus;
3.1.2 All existing confined spaces must be
uniquely identified, signposted and recorded 8. P
 rovision and use of safety harnesses
in a register that must be maintained and fitted with life lines to rescue
updated as appropriate. personnel in the case of an incident.
3.1.3 The specific hazards and associated risks Where the life line poses an additional
for each confined space are to be assessed risk, an alternative means of rescue
and evaluated. must be established and available at
3.1.4 A confined space procedure and a confined the location;
space entry permit must be developed, 9. A
 ccess to the confined space entry
implemented and maintained. permit at the task/activity location;
3.1.5 The confined space procedure must include 10. S
 ign-in and sign-out of personnel
the following minimum requirements: entering the confined space;
a) A Work Permit must be prepared and
11. N
 omination and identification of a
authorised prior to entering a confined
competent stand-by person(s), who
space;
shall be present at the entry point for
b) A documented risk assessment must
the duration of the work;
be conducted and included within the
Permit; 12. D
 efined communication methods
to be used between the stand-by
c) Conditions of entry must include:
person(s) and personnel within the
1. Isolation of Energy Sources; confined space;
2. Establishment and maintenance 13. Identification of the appropriate
of oxygen levels required for the specification for the equipment to
duration of the task; be taken into or used within the
3. Identification of contaminants, confined space;
temperature extremes, 14. B arricading and sign-posting
concentrations of flammable requirements; and
substances, and any other hazards
15. A
 n area/task specific rescue
that may be harmful;
Management Plan*; provision and
4. P
 rovision and use of multi-gas accessibility of suitable rescue
continuous monitoring detection equipment (including self-contained
and alarm equipment for the breathing apparatus) and competent
duration of the task/activity; rescue personnel.
5. That actual gas levels are regularly
tested and recorded for the duration
of the confined space activity;

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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25 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

3 Confined Spaces and Irrespirable

and/or Noxious Atmospheres

d) That atmospheric monitoring

equipment must be of an approved
d) Provide a process to determine
type, listed on a register, and be
atmospheric conditions prior to
inspected, tested, calibrated and stored
entry of the area;
in accordance with the manufacturer’s
specifications; and e) 
Provide continuous monitoring
for the presence of atmospheric
e) That atmospheric monitoring
contaminants including multi-gas
equipment can only be used by
detection and alarm equipment;
personnel who have been trained,
assessed as competent, and authorised. f) 
Provide sufficient stationary monitors
in areas with process equipment that
3.2 Irrespirable/Noxious Atmospheres transport or could produce noxious gas;
3.2.1 
Determine suitable types, fit test g) 
Develop withdrawal conditions (Trigger
requirements and locations where breathing Action Response Plans - TARPs) for the
apparatus wearing or carrying is mandatory presence of atmospheric contaminants;
3.2.2 
Routine access to Operational Areas* with h) 
Provide emergency equipment
the potential to generate irrespirable/ (including suitable breathing apparatus
noxious atmospheres must be subject and communication) for personnel who
to a scheduled atmospheric inspection/ may be exposed to the irrespirable or
Monitoring Program*. noxious atmosphere;
3.2.3 
Areas that have not been classified as
i) 
Develop, maintain and implement
confined spaces and that are not part
an area/task/activity specific rescue
of any scheduled inspection/Monitoring
plan including suitable and easily
Programme but where an irrespirable/
accessible rescue equipment
noxious atmosphere can potentially occur,
and Competent Persons.
must be identified.
3.2.4 
Before entering any such areas,
a documented risk assessment must
be conducted and controls identified
and implemented.
3.2.5 
If personnel are required to enter an
area where a risk of irrespirable/noxious
atmosphere occurrence exists,
the asset must:
a) Develop and apply a procedure and/or
permit systems to access and conduct
any task/activity in such an area;
b) Provide for barricading and
signposting to prevent inadvertent
access to these areas;
c) Develop and apply procedures
that minimise the risk of exposure to
personnel, e.g. ventilation requirements

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26 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

3 Confined Spaces and Irrespirable

and/or Noxious Atmospheres

3.3 T
 raining and Assessment
Requirements
3.3.1 Identification of Training needs, competency
requirements, and maintenance of
competency requirements of relevant
persons in relation to confined space entry
and recovery, irrespirable and noxious
atmosphere and use of atmospheric
monitoring equipment.
3.3.2 Provide regular chemical awareness Training
related to chemicals/gases process safety
and related occupational health and safety
hazards.
3.3.3 Training needs are to be inclusive of relevant
competency standards, legislation, codes
of practice and site or regional protocols,
procedures and permit systems; and
3.3.4  Provision of adequate Training, and
competency assessment using practical
and/or simulated methods.

3.4 Additional Requirements for

Catastrophic Risk (PMC 5) Situations
3.4.1 
Where the risk of widespread exposure to
irrespirable/noxious gas releases is possible:
a) Consider the need for fresh air refuge
bays; and
b) P
 repare emergency alarm,
communication and evacuation plans.

TOOLS (SEE GLENCORE HSEC INTRANET)

Tools provided include:

FHP Self-Assessment Workbook,

FHP Third Party Audit Workbook 03 – Confined

Spaces and Noxious/Irrespirable Atmospheres, and

Permit 06 – Confined Space Entry Permit.

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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27 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

Mobile
Equipment
VERSION: 2-0
EFFECTIVE DATE: 23/03/2020
28 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

4 Mobile Equipment

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents arising
from risks related to mobile equipment.

Related Life-Saving Behaviours

1 Always come to work drug and alcohol free.
2 Always use or wear critical safety equipment.
4 Only operate equipment if trained and authorised.
6 Never modify or over-ride critical safety equipment
without approval.

7 Always seek and obtain clear approval before

entering mobile equipment operating zones.

8 Never enter danger zones without approval.

KEY ACTIONS
Conduct a risk assessment of mobile
equipment collision and pedestrian
interactions for your asset.
 evelop a Transport/Traffic Management Plan*
D
and apply associated procedures.

Identify and introduce fatigue management

and collision avoidance technologies.

Develop equipment specifications and

procurement criteria.

 onitor that controls continue to deliver

M
all required outcomes.

* See glossary

TITLE: FATAL HAZARD PROTOCOLS ISSUED BY: GROUP HSEC AND ID: G-S-PTC-0001
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4 Mobile Equipment

4.1 General requirements

4.1.1 
A risk assessment must be conducted steering to the wall when parking
and documented that identifies mobile on grades in underground mines;
equipment interaction risks and their
controls for: d) 
The safe refuelling of the
mobile equipment;
a) Vehicle to pedestrians;
b) Vehicle to vehicle, including heavy e) S
 topping mobile equipment
to light vehicle; when boarding or dismounting;
c) V
 ehicle interactions with fixed structures f) Loading and unloading of mobile
and the operating environment. equipment methods detailing:
1. L
 oad security and stability;
4.1.2 
A Transport/Traffic Management Plan or
equivalent must be developed for surface 2. P
 recautions to be taken
and underground locations which: when tipping loads.

a) Meets or exceeds regulatory and legal g) 

Mobile equipment limitations including
obligations; the maximum loads that may be carried
b) Documents the means to minimise risk or towed;
required when working with or around h) Expected operator responses to mobile
mobile equipment; equipment faults, alerts and alarms;
c) Details how the controls from the i) Stability related hazards when
risk assessment are implemented operating ancillary equipment such
and maintained; as for forklifts, scissor lifts and similar
d) Confirms how the status of controls items, including vehicles with quick
are monitored. detach systems (QDS);
j) Transport of personnel rules
4.1.3 
Site rules and procedures which must
and procedures covering:
be referenced in the Transport/Traffic
Management Plan for mobile equipment 1. O nly mobile equipment
must include: with designed and approved
a) Mobile equipment being used seating, including seatbelts or
within approved design parameters; other restraints devices, can be
b) Operator prestart equipment used to transport personnel;
inspection and technology checks, 2. S
 eat belts and/or restraints must
based on original equipment be worn where fitted;
manufacturer or approved engineering
3. P
 ersonnel must never be transported
advice, and operating requirements;
in workbaskets, buckets, or any other
c) Method of fundamentally stable parking machine locations without seating.
of mobile equipment, e.g. park brake, An exception may apply to tramming
chocks, spoon drains, humps (between approved mobile lifting equipment
front and rear axles), turning vehicle where the operator is secured with
a safety harness.

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4 Mobile Equipment
k) Speed limits by equipment type,
location and conditions;
l) Managing changes in road surfaces; system must be applied which
includes:
m) Operating around fixed structures,
such as conveyor and bin trestles, 1. E
 ducation and awareness for Workers;
building supports, power poles etc.; 2. S
 hift roster design;
n) Loading from bins, if relevant;
3. D
 efined hours of work and rest
o) Entering potentially explosive requirements, including travel time
atmospheres, if relevant; and a process to manage additional
p) Access to Operational Areas* including hours of work;
Positive Communication* methods;
4. A
 dvice and support for supervisors
q) Minimum PPE requirements including including fatigue call-ups during shift
high visibility clothing; and how to manage fatigued persons
r) Identification and communication from the workplace.
of mobile equipment sight lines and
4.1.4 
A plan for the introduction of technology
blind spots;
to support existing fatigue management
s) Provision of walkways and means
approaches must be developed including:
of maintaining clearance from
pedestrians and other vehicles; a) A baseline assessment of existing
mobile equipment fatigue controls;
t) Give way requirements for mobile
equipment operators and pedestrians; b) Assessment of the potential benefits
of technology to support or replace
u) Managing road repair works,
existing fatigue management controls
including grader operations;
for mobile equipment operators;
v) Radio (or other communications)
c) Establishing functional and performance
call up protocols where used;
requirements of the technology to
w) Procedures for approaching mobile
achieve desired outcomes.
equipment;
4.1.5 Mobile equipment related potential
x) Procedures for towing;
emergency scenarios must be identified
y) Parking in Operational Areas including and emergency response procedures
the means of isolating of equipment must include equipment and response
and activity from danger of collision requirements, e.g. fire response, trauma
during breakdowns, emergencies, infield first aid, extrication of trapped or pinned
servicing, refuelling and maintenance; personnel; power line contact and
z) Handheld mobile phones must potential Tyre Explosion*, etc.
not be used when operating
mobile equipment;
aa) An effective fatigue management

* See glossary

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4 Mobile Equipment

4.2 Mobile Equipment specification

and maintenance
m) Fire suppression;
4.2.1  s a minimum, the following
A
must be in place: n) Roll Over Protection System (ROPS);
a) M
 obile equipment specifications o) F
 alling Object Protection System (FOPS)
must be prepared by knowledgeable that exceed the maximum expected
and experienced people who are object force, e.g. when loading in pit
familiar with production and operating or from under an ore or reject bin;
environment demands; p) Internal load barriers that protect
b) M
 obile equipment specifications operators and passengers;
must be applied when: q) Mobile equipment reversing alarms;
c) Purchasing new or used equipment; r)  tability requirements for equipment
S
d) Transferring equipment to site; fitted with quick detach systems (QDS);
e) Hiring equipment; s)  tability requirements for ancillary
S
equipment such as forklifts, scissor
f) Assessing contractor equipment.
lifts, etc.
4.2.2  s a minimum, mobile equipment
A
t)  mergency escape and rescue for
E
specifications, with reference to Glencore
credible emergency scenarios e.g.,
procurement standards, must be
managing void hazards for dozers
established for:
working on stockpiles with underground
a) Operator access and egress;
reclaim hoppers which require:
b) Maintainer access;
1. T
 he fitting of tilt switches;
c) T
 owing hooks/lugs designed
2. Installation of laminated glass while
to handle expected loads;
maintaining an emergency escape;
d) Brakes;
3. T
 he installation of oxygen generating
e) Steering; self-rescuers.
f) Tyres; 4.2.3. M
 obile equipment maintenance processes
g) Head lights and clearance lights; must include:

h) Indicators, warning lights, horns and a) O

 perator pre-use inspections including
alarms of sufficient volume to be heard highlighted critical “No Go” items;
in the operating environment; b) M
 ethod of notifying and managing
i)  ehicle identification numbers (unique,
V equipment failures during operations;
clear and visible) for Surface Operations*; c) S
 cheduled inspection, servicing and
j) Mirrors and cameras (where fitted); maintenance programs for mobile plant
and support equipment,
k) Communications equipment;
e.g. radio communication system
l)  here implemented, operator
W including networks; and key systems,
proximity alerts, advisory and e.g. proximity detection systems,
intervention technology; brakes, tyres and lubrication;

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4 Mobile Equipment
d) Cause analysis of serious and recurring
failures of the equipment in order to
avoid repetition and exposure. f) The design and use of bumper blocks
at underground dump locations such
4.3 E
 stablishing a safe operating as open stopes and ore passes;
environment g) Maximum grade;
4.3.1 Assets must establish minimum dimensions h) Curvature and line of sight;
and conditions for roadways and mobile
i) Pavement shape and material;
equipment work areas within their
j) Guideposts spacing relative to
Transport/Traffic Management Plan
the distance required between
that specifies:
travelling vehicles;
a) Surface Operations road width normally
k) Guidepost reflector specification, e.g. red
of at least three times the width of the
on driving side and white on off side;
widest vehicle regularly using two-way
l) Signs and barriers;
haul roads;
m) Lighting standards;
b) The construction and maintenance of
safety berms or windrows alongside n) Intersections designed as far as practical
roadways edges or areas where there is with a ninety-degree angle of approach;
a sudden change in terrain e.g., drop off, o) Vehicle parking requirements that
water body, or other hazard. The safety include parking distances from other
berms or windrows must be constructed equipment and structures;
using suitable (solid) materials, be of a p) Dust control;
height, density and profile to enable an q) Lightning and other extreme weather
effective barrier. The minimum height event precautions;
required is half the Wheel* height of
r) The protection of fixed structures,
largest vehicles using road;
including overhead power lines,
c) The design and use of safety buildings, refuelling areas, elevated
berms or windrows for delineation structures, bins, etc. during mobile
and segregation, e.g. at intersection equipment operations;
approaches, corners, etc. so as not
s) Loading from a reject or ore bin detailing
to impede visibility;
requirements for access, loading and
d) Physical barrier design and locations equipment design minimum standards
used to protect against access to including preventing any unprotected
unprotected benches or trenches, mobile equipment cabin from
and to underground draw points and entering the material loading zone
open voids such as the overcuts of under a loading bin;
mined out Stopes
t) The approach to bridges and tunnels
e) Road Maintenance practices that will must clearly signpost the maximum
maintain a proper road surface (e.g. height and width, and if relevant the
snow removal, sanding, managed maximum load capacity of vehicles
roadway watering for dust control, etc.) that may transit;

* See glossary
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4 Mobile Equipment
u) Operational practises that
prevent vehicles from entering
or operating in explosive (e.g. methane move to a position of safety,
rich) atmospheres i.e. a defined distance or location.
This means:
4.4 M
 obile equipment interfaces with
i) T
 he vehicle must stop;
pedestrians and other equipment
ii) T
 he operator must acknowledge
4.4.1 As a minimum, the following must
the pedestrians’ presence and allow
be established and included within the
the pedestrians to walk past the
Transport/Traffic Management Plan:
vehicle before continuing.
a) Travelling and clearance distance
c) Workplace design and operational
between equipment and people;
practice that manages mobile
b) Workplace design that, as far as practical, equipment interactions where practical
eliminates the interaction between using:
pedestrians and mobile equipment, or
1. S
 eparation of light and heavy vehicles
assists in maintaining awareness using:
using segregated roads;
1. S
 egregated or dedicated walkways for
2. U
 se of remote bays, portable
pedestrians protected by windrows,
remote stands designed to withstand
bunds or other physical barriers;
vehicle contact, and sensors that stop
2. Delineation of no-go and danger equipment when allowable proximity
zones for pedestrians; distances are breached for remote
3. Pedestrian crossings in high controlled mobile equipment
pedestrian traffic areas; 3. P
 ark up areas with one-way traffic
4. Horn signals to indicate vehicle flow and segregated parking areas
operation prior to starting the for heavy plant and equipment,
vehicle, before forward movement, light vehicles and pedestrians;
and before reversing (except in 4. E
 stablishing park up areas with
operating environments where spoon drains, humps (between front
this may create a hazard); and rear axles) or some other method
5. Establishing protocols for to prevent uncontrolled movement
persons who work around operating of vehicles;
mobile equipment to have Positive 5. E
 stablishing one-way traffic in
Communication with the equipment high traffic areas, or installing
operator, e.g. cap-lamp signals in an centre berms or windrows;
underground, in a surface mining
6. T
 he installation of one-way block
environment at least one member
lights or other control system for
of the work party has an operating
high traffic intersections and drifts
two-way radio;
in underground mines;
6. S
 topping vehicles on underground
7. A
 pplying Positive Communication
roadways when pedestrians cannot
where the caller and receiver identify

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4 Mobile Equipment
vehicle and clearly respond, before:
i). Entering an active work area;
of buses from heavy vehicles or the
ii). Overtaking. requirement to stop operation of heavy
4.4.2. A review and planning exercise must vehicles when buses pass;
be conducted to introduce collision d) Critical controls must be identified
warning and avoidance technology and monitoring and verification
for priority equipment. processes must be implemented
as per Glencore’s Catastrophic and
4.5. Training and Competency
Fatal Hazard Management Guideline.
4.5.1. Personnel who operate or work around
mobile equipment must be trained,
competent and authorised. A Training
Plan must be developed and include:
a) Criteria for selecting and appointing
mobile equipment operators. This
must include a physical assessment
of capability to reach an operator all
controls;
b) Training* needs based on work role,
site rules and procedures, licensing
requirements, Original Equipment
Manufacturer (OEM) guidance and
other recognised standards;
c) Competency assessment criteria,
with records retained;
d) A periodic review and update of
competency requirements, Training
needs, Training content and methods.

4.6 A
 dditional Requirements for TOOLS (SEE GLENCORE HSEC INTRANET)
Catastrophic Risk (PMC 5) Situations Tools provided include:

4.6.1 Wherever there is a potential for a FHP Self-Assessment Workbook,

catastrophic incident related to mobile FHP Third Party Audit Workbook
equipment, e.g. transportation using buses: 04 - Mobile Equipment
a) A risk assessment must be conducted VIIS tool (MS Access database) and
to identify specific hazards and controls; Guideline for Mobile Equipment Control
b) In-vehicle monitoring systems must Implementation.
be used to monitor driver behaviour;
c) Controls must consider the separation
* See glossary

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Ground and/or
Strata Failure
VERSION: 3-0
EFFECTIVE DATE: 01/08/2019
36 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

5 Ground and/or Strata Failure

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries, incidents and other
harm arising from risks related to ground or strata failure
caused by ground disturbance or natural causes, in
mining and non-mining environments.

Related Life-Saving Behaviours

6 Never modify or over-ride critical safety equipment
without approval.

8 Never enter danger zones without approval.

KEY ACTIONS
Gather and interpret applicable technical data
required to identify hazards and to derive safe
and sustainable designs.

Develop designs to minimise or reduce the

level of geotechnical/Ground Control* risks.

 onduct a risk assessment of proposed designs

C
and specific geotechnical/Ground Control
hazards.

Conduct a gap analysis against local legal

requirements and relevant international and
local practices; implement the actions
required following that analysis that adopts
the highest standard.

Develop, implement and maintain a Ground/

Strata Management Plan* including
procedures and controls with reference
to relevant Glencore guidelines and
risk assessments.

 rovide information, instruction and Training*

P
on Ground/Strata Failure awareness, risks
and controls, and conduct competency
assessments. Provide supervision Communicate and test triggers for stopping
commensurate to competency or capability. work, and for evacuation.

Develop inspection and monitoring systems, Undertake planned and systematic inspection
including slope/strata movement technologies. and monitoring to verify control effectiveness.

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5 Ground and/or Strata Failure

5.1 General
5.1.1 Prior to commencing any design or c) In situ stress data – overall magnitude
operations plan, sufficient technical data and direction of the natural stress field
must be collected, analysed and interpreted. resolved into the principal and minor
The requirement for further data review horizontal stresses and the vertical stress;
and collection shall be assessed throughout
d) Structural information (e.g. faults with
the life of the operation using a risk-based
dip and dip direction) and rock fabric
approach.
(joints and other defect characterisation;
5.1.2 Geological exploration and characterisation
dip, dip direction, roughness, infilling,
must take place before and during mining
persistence, etc.) data with spatial
to provide key information on the geological
location are required to adequately
parameters of the orebody and surrounding
characterise and interpret the rock
host rock and to inform the associated
mass behaviour; and
technical fields. The requirements are:
e) Incorporation of the outcomes from
a) A geological data base as the verified
clauses 5.1.4 (Surface and Ground Water)
repository for relevant geological data;
and 5.1.6 (Seismicity).
and
5.1.4 Where pore pressure, surface water
b) A geological model that includes
flow or other hydrogeological/hydrological
detailed lithology, weathering and
parameters are key components of any of
alteration zones as well as mineralisation
the credible failure mechanisms that are
structures – for example splitting and
governing the design then the following
coalescing zones, intrusions (dykes, sills,
are required:
etc.) and major structural defects such
a) Surveys of surface water catchment
as joints, faults or shear zones.
areas and flow must be undertaken
5.1.3 The geotechnical engineering work
before and during mining to assess the
programme must include identification
impacts to mining and geotechnical
of the parameters required as inputs to
risks. This includes surface flows
the geotechnical/Ground Control design
associated with changes to topography
methods being applied. The following list
as a result of mining activities (e.g.
must be considered as inputs and if not
excavated ramps, berms, dumps, etc.);
used, have an assessment documenting
b) Surveys of groundwater behaviour
the reason:
must be undertaken before and
a) Specific provision in the planning and
during mining to determine the
execution of the geological exploration
key parameters;
programme for the collection of the
required geotechnical data; c) Groundwater characteristics that
could impact on ground supports,
b) Testing of physical properties to
e.g. corrosion of roof bolts
adequately characterise the rock
mass, e.g. slake durability, uniaxial d) A fit for purpose hydrogeological/
compressive strength, triaxial strength, hydrological model must be created
shear strength, cohesion, friction angle, and maintained;
Young’s modulus and Poisson’s ratio, etc.;

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5 Ground and/or Strata Failure

e) A hydrogeological/hydrological 5.2 H
 azard Identification
monitoring scheme for surface and sub-
and Risk Assessment
surface water pore pressures must be
5.2.1 The following general requirements apply:
created and maintained; and
f) Installation of appropriate monitoring a) Ground Control/geotechnical hazards
and alarm systems on ground water will be assessed on a Potential Maximum
monitoring devices or locations. Any Consequence (PMC) basis;
devices in “critical monitoring” should b) Slopes and Excavations* are to be
record and transmit at a time interval assessed as having at least a PMC4
that allows appropriate corrective or (fatal) consequence;
avoidance action to be taken. c) Slopes and Excavations are to
5.1.5 If hydrogeological/hydrological factors are be rigorously assessed to determine
not key components of any of the plausible PMC5 exposures, e.g. places where
failure mechanisms this must be confirmed, people congregate or ramps with
justified and signed off by the appropriate high vehicular traffic use; and
senior manager.eg Chief Mining Engineer d) Relevant assessment tools referenced
or Technical Services Manager, etc. in this Protocol must be used to assist
5.1.6  here seismic impacts are assessed as
W in classifying slope risks and identifying
being key components of any plausible suitable controls (see Tools section).
failure mechanisms then the following 5.2.2 A risk assessment of the geotechnical
provisions will apply: and Ground Control hazards must be
undertaken and documented to underpin
a) A background study on local and
the development of a Ground/Strata Control
regional seismic behaviour will
Management Plan. It must address the four
be undertaken and updated at
main technical areas; geology, geotechnical
predetermined intervals as mining
engineering, hydrogeology/hydrology
progresses;
and seismicity. The Risk Assessment
b) A seismic monitoring network will be
must consider, as relevant:
designed and established to record the
local seismic behaviour; a) The current/proposed mine
design and layout;
c) Actual seismic behaviour will be
reconciled against anticipated seismic b) Ground Control and geotechnical
behaviour; failure modes and all the factors that
can influence or bring about instability,
d) Design methods (see clause 5.3.2) that
e.g. the maximum dimensions of
incorporate seismic behaviour will be
unsupported spans or bench/face/
applied; and
Batter* heights;
e) Where systematic ground support
c) Exposure of personnel to failure
(see clause 5.3.7) is applied, the
modes and any potentially
selection of support elements will
unstable environments;
specifically consider their behaviour and
characteristics under the influence of
seismic events.

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5 Ground and/or Strata Failure

d) Existing and proposed systematic

ground support systems; and
i) Any other unforeseen change
e) The role of the ground support/
that may arise.
geotechnical design as a control against
5.2.4 Trigger Action Response Plans (TARPs)
the hazards of falls of ground, inrush and
must be developed and applied, and:
wind/air blast or rock/coal burst.
a) Include a “Red”, STOP trigger
5.2.3 A Change Management* process must be
for all Critical Monitoring Modes*,
in place and applied. Key changes that must
e.g. displacement, pore pressure or
be recognised and managed include:
changes in the seismic environment,
a) Significant variations to mine plans (see
that causes people to be evacuated
definition), sequences and designs, e.g.
from the hazardous area;
any UG Excavation* dimensions, ramp
b) Trigger levels are to be based on a
locations, slope angles;
sound engineering analysis. This can
b) Major equipment or mining
be empirical if the data is site based;
methodology changes;
c) The monitoring system supplying
c) Unforeseen changes in geology,
the trigger level data must be accurate
geotechnical engineering, hydrogeology/
and reliable;
hydrology and or seismicity that fall
d) The data must be communicated in
outside of the range of parameters
an effective time frame to allow actions
considered in the Design Process;
to be undertaken;
d) The development of failure mechanisms
e) Where a “Red” STOP level may be
not considered in the design process;
activated, the trigger level data needs
e) Changes or amendments to the Ground/
to be communicated in a timely
Strata Control Management Plan;
manner to allow an orderly, calm and
f) Major environmental events either not safe evacuation of affected personnel;
considered in the design or which occur
f) The effectiveness of the evacuation
at a level greater than that considered
process must be tested on a planned
in the design e.g., earthquakes or major
and systematic basis (minimum
rainfall events;
annually); and
g) The occurrence of failure or
g) The actions triggered at the lower
unacceptable instability e.g., repeated
“Yellow” and “Orange” levels need to
occurrences of “Orange” or “Red” (STOP)
be designed wherever possible to bring
Trigger Action Response Plan (TARP)
the undesirable ground behaviour
trigger levels; and
back to a level in accordance with the
h) Changes in key personnel including requirements of this Protocol and local
contractors and consultant, e.g. legal requirements, applying whichever
Production Manager, Technical Services achieves the highest health and
manager, independent peer reviewer, safety standard.
Appointed Geotechnical Engineer
or Appointed Hydrologist.

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5 Ground and/or Strata Failure

5.3 S
 lope and Excavation Designs
5.3.1 Design processes will set out and provide escalation of sign off level with increased
governance on the steps required in the consequence level; and
mine design. The process will include steps l) Recognition of design changes or non-
that provide for: conformance to design during mining
a) Designs and peer reviews being triggering a design review including a
undertaken by Competent Persons; full re-appraisal of the new risk situation
b) The technical data (see clause 5.1.1) arising from modifications to the design
being used is accurate and up to date; and the subsequent reiteration of the
c) The design methods (see clause approval and sign off process.
5.3.2, 5.3.3 & 5.3.4) being applied are 5.3.2 The following design method requirements
appropriate to the deposit, the likely apply to both underground and surface
or credible failure modes and the mines:
mining method; a) Each site will demonstrate that the
d) The range of input parameters is design methods being applied to the
realistic, credible and documented; Slopes and Excavations are appropriate
e) Recognition of external factors, e.g. an to the geotechnical environment and
out of pit dump or a flood event, that the mining method being applied;
could create a loading mechanism; b) The design cases to be considered
f) The proposed design recognises the must include the worst most reasonably
geotechnical hazards and minimises the foreseeable credible case that can be
risk of geotechnical and Ground Control identified for the site and location;
failures to a level in accordance with the c) Each Ground Control or geotechnical
requirements of this Protocol and local design should be supported by two (2)
legal requirements; appropriate design methods e.g. One
g) Verification that the necessary design method could be empirically based
acceptance criteria (see 5.3.5) have been and the second method could be a
applied and that their threshold values numerical method;
have been met; d) Each Ground Control/geotechnical
h) Full documentation of the data used design will demonstrate that it meets
in a design and the calculations and design acceptance criteria for the
assessments made as part of the design; Slope or Excavation that it applies
i) Recognition of a design not meeting the to for the failure mechanisms or
minimum acceptance criteria and the means of instability being designed for;
design not being able to proceed, i.e. a e) If failure of a component of the design
STOP criterion; e.g., a slope or a pillar is acceptable or
j) Recognition of, and specific treatment even expected during the lifecycle then
for PMC 5 risks; that will be identified in the design;

k) Verification of sign off level being in

accordance with the level of risk and

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5 Ground and/or Strata Failure

f) Designs will include the requirements

for monitoring and inspection post
underground mining activities, natural
execution; and
and man-made voids and any other
g) Designs will comply with all local
credible causes.
legal requirements and where there
5.3.4 The following requirements apply to
is a difference between the local
Ground Control design for surface mines:
requirements and this protocol the
higher requirement should be applied a) Provision of controls (e.g. benches and
5.3.3 The following requirements apply to Ground catch berms) to address the Rock Fall
Control designs for underground mines: hazard so that any falling material will
not expose personnel or equipment
a) The design of underground mine pillars
below to undue risk; and
and mine pillar systems including crown
b) Provision of adequate controls
pillars will address and consider:
e.g. berms or windrows) to prevent
1. An assessment or calculation of pillar personnel and equipment being
strength vs maximum potential load exposed to edge failure.
(vertical or lateral) or critical span;
5.3.5 Pre-determined acceptance criteria
2. The Factor of Safety (FoS) and/or the must be established for designs prior to
Probability of Failure of the pillar or mining and documented in the Ground/
the pillar system; Strata Management Plan. For high risk or
3. The minimum width: height ratio of PMC 5 situations, the acceptance criteria
the pillar that can be demonstrated to may be different (more stringent) than
be an acceptable risk of an individual for normal conditions.
pillar or the pillar system not failing or a) The minimum Factor of Safety
becoming unstable; and expected in static 2D Limit of
4. A
 ny pillars intended to have a Equilibrium methods is 1.2;
capability to yield, e.g. for rock b) For PMC5 scenarios or where the static
burst risk mitigation, will be clearly 2D Limit of Equilibrium Factor Safety
identified as such and will have becomes or is planned to be <1.2 then
specific Design Acceptance Criteria the Design Process (clause 5.3.1) must
which will be supported by an provide for off-site sign off; and
independent peer review. c) Performance based and pseudo static
b) Where rock burst or coal burst 2D Limit of Equilibrium based designs
conditions are included in the credible will need to develop and justify specific
failure mechanisms, then the ground Design Acceptance Criteria based on
support design method will include a peer review accepted geotechnical
controls to specifically address this risk. engineering assessment.
The provisions of clause 5.1.6 (Seismicity)
must be addressed and accounted for in
such designs; and
c) Designs will consider controls to manage
the impacts of surface subsidence from

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5 Ground and/or Strata Failure

5.3.6 Mines will determine and document

criteria (which also meets local legislative
b) Where the next planned line
requirements) within the mine design to
of systematic support cannot be
minimise the risk of entrapment by falls
installed from behind the last installed
of ground.
line of systematic support then the
5.3.7 For underground mines, the support design following applies:
must include:
1. T
 he design must be accompanied by
a) The physical properties of the a procedure that demonstrates that
ground support components (for the method of work is safe and does
example strength and deformation not pose an unacceptable risk; and
characteristics) under static and, where
2. T
 he design must be supported by
applicable, dynamic loading;
an independent design review.
b) The sequence and timing of support
installation; 5.4 Management
 Requirements
c) The support density (for example bolt 5.4.1 All Ground Control management design
spacing or shotcrete thickness); processes will meet or exceed the
d) The maximum Excavation dimensions requirements of local legislation. Where
and distance that can be mined before the requirements in this protocol are higher
support is installed; and or not covered by legislative requirements
e) The frequency and method of testing then the protocol requirements must still
rock bolts, cables and other support be applied
elements for effectiveness. 5.4.2 Civil engineering undertakings will be
5.3.8 Systematic ground support systems will be subject to the requirements of engineering
designed and specified such that the next design codes and standards. Locations
row of support can be installed without a undertaking civil engineering Excavations
person going beyond or past the last row of or creating engineered slopes will:
installed support. a) identify the most appropriate design
a) Where ground conditions are such that codes and standards
there is a demonstrated safe case for b) apply those standards to the design; and
spacing of systematic ground support c) execute the design and subsequent
at a spacing where the next row of service life of the Excavation or Slope
systematic support cannot be installed in accordance with the requirements
from behind the last completed line of the codes and standards.
of systematic ground support then d) Use Excavation Works Permits prior
the justification and acceptance of the to commencement of work
risk associated with that system must
be signed off by the Chief Operating
Officer or equivalent of that asset and
communicated to relevant persons.

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5 Ground and/or Strata Failure

5.4.3 Regular, direct, and iterative communication

processes must be established, maintained
5.4.8 In accordance with Glencore’s Critical
and documented between geotechnical/
Control process, all sites will address the
hydrological specialists, mine designers,
Geotechnical/Ground Control failures by:
planning and operations personnel and
other relevant personnel. a) Identifying Critical Controls each of
which must include a STOP condition
5.4.4 A Ground/Strata Control Management Plan
which is implemented through both
must be developed, implemented and
Performance Standards and TARPs; and
maintained to provide an overall framework
to control and govern the provisions of this b) Reporting the results of critical control
Protocol. inspections and verifications. The results
must also be reviewed and analysed by
5.4.5 The Ground/Strata Control Management
Competent Persons in accordance with
Plan and the effectiveness and
the Glencore Catastrophic Hazard and
completeness of its implementation
Critical Control Management Guideline.
must be reviewed at least annually.
5.4.6 A Technical Governance process must 5.5 Inspection, Monitoring and
be in place to review: Reconciliation
a) The performance of Excavations, Slopes 5.5.1 All Ground Control designs must include
and support systems compared to provisions for the inspection and monitoring
design expectations; of both the performance of the design and
b) Inspection and monitoring results and the degree of deformation that takes place
the occurrence of potential hazards; within the rock mass.
c) The application and effectiveness of 5.5.2 Inspections and monitoring processes
controls; and must be able to detect deformation in
d) The overall effectiveness of and a sufficiently timely manner that a fall of
conformance to normal site Ground ground or slope movement can be detected
Control processes and procedures, e.g. quickly enough to allow personnel to be
the Ground Control review meeting. alerted and evacuated from the area.
5.4.7 The requirements pertaining to 5.5.3 Inspection and Monitoring processes
independent external reviews set out in must include:
the Independent Review of Geotechnical a) The means or methods of detecting
Designs Guideline must be reviewed hazards or change;
and addressed. b) A schedule of inspections and
monitoring, including accountabilities;
c) Documentation requirements; and
d) Effective communication of results
to all relevant personnel

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5 Ground and/or Strata Failure

5.6 Special Provisions for PMC5 Risk

Situations
5.6.1 The requirements set out in the Surface
Slope Design and Management Guideline,
the Slope Stability Monitoring Guideline
and the Independent Review of Geotechnical
Designs Guideline will apply for risks
identified as PMC 5.

5.7 R
 oles, Responsibilities, Training
and Resources
5.7.1 Assets must employ or engage sufficient
and adequately experienced, technically
qualified and Competent Persons to
undertake the tasks required in this Protocol.
5.7.2 The competence requirements must
be documented.
5.7.3 Key appointments include; person in charge
of production, person in charge of mine site’s
technical work, exploration geologist, mine
geologist, design geotechnical engineer,
independent review geotechnical engineer,
hydrologist (where required) and mine
planning engineers. TOOLS (SEE GLENCORE HSEC INTRANET)
5.7.4 Persons appointed to the above Tools provided include:
positions may be company employees
FHP Self-Assessment Workbook,
or consultants/contractors.
FHP Third Party Audit Workbook 05 –
5.7.5 A Training Plan including regular
refreshment periods and review of Ground/Strata Failure,
material will be prepared and provided for Independent review of geotechnical
mineworkers to identify, control and report designs Guideline
on ground/strata failure hazards and related
Slope Stability monitoring Guideline
risks, and methods of control.
5.7.6 Adequate resources (including budget) Surface Slope Design and
allocation must be made for the acquisition management Guideline
of required technical data, interpretation Slope Stability Monitoring Needs Assessment,
and analysis of that data, design process
Slope Stability Monitoring Tool, and
and subsequent monitoring and
reconciliation processes. Permit 12 – Excavation Works Permit.

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Electrical
Safety
VERSION: 3-0
EFFECTIVE DATE: 15/10/2020
46 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

6 Electrical Safety

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents arising
from risk associated with contacting energised electrical
conductors or exposure to faulty electrical systems; these
can result in secondary hazards such as arc blast, fire or
ignition of explosive atmosphere.
This document should be read in conjunction with the
Glencore Electrical Installation and Equipment Guideline.
Assets may impose higher standards than those set out
in this Protocol to address requirements such as local
legislation.

Related Life-Saving Behaviours

1. Always come to work drug and alcohol free.
2. Always use or wear critical safety equipment.
4. Only operate equipment if trained and authorised.
5. Always isolate and ‘test for dead’ prior to working on
energy sources.

6. Never modify or over-ride critical safety equipment

without approval.

8. Never enter danger zones without approval.

9. Always report injuries and HPRIs.

KEY ACTIONS
 nly trained, competent and authorised or
O
A risk assessment must be conducted to
appointed personnel may conduct
identify, analyse and evaluate all electrical
electrical work.
source related risks.
Provide training on the relevant and
 evelop and implement an Electrical
D
applicable standards and assess the trainees’
Engineering Control Plan (EECP) to manage
competency and understanding.
and control the identified risks.
Assign accountability for implementing
Implement electrical standards highlighted
and maintaining these processes.
in the EECP for the identified risks using the
Glencore Electrical Installation and Equipment Monitor that controls continue to deliver
Guideline as a source of specific requirements. the required outcomes.

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6 Electrical Safety

6.1 General requirements

6.1.1 
A documented risk assessment must be c) 
Management of the energy involved
conducted to identify the hazards, assess during testing, i.e. control versus power
the risks and implement controls related to circuits and the additional precautions
the risks associated with electrical sources. that need to be applied;
6.1.2 
An Electrical Engineering Control Plan
d) 
Use of required test equipment;
must be developed, implemented and
maintained to: e) 
A suitable and approved method
of verifying the correct operation of
a) 
Address the identified risks in 6.1.1 above,
test instruments using a known source
b) 
Provides an overall framework (e.g. battery-operated test units; placing
to control and govern the provisions the probes on exposed live busbars that
of this Protocol. are not IP2X rated is not considered
an acceptable means of testing
c) 
Include the Life cycle management
an instrument);
process for plant and equipment
f) 
Completion of a documented risk
6.1.3 Isolation procedures and associated
assessment (e.g. JSA) or procedure
permits must be developed, implemented
for all live testing tasks;
and maintained for the management of
electrical installations including their g) 
A process for approval to undertake live
energy sources. testing (live testing permit or similar);

6.1.4 An assessment of overhead power lines must h) 

The assignment requirement for
be conducted, and a system implemented a safety observer where the risk
to control the risks associated with working assessment identifies the need;
in close proximity including prevention of i) 
PPE requirements; and
contact by personnel or equipment.
j) 
Supervision requirements.
6.2 S
 ystems and Processes
6.2.2 
There must be a process implemented
6.2.1  nless specifically approved, there should be
U for the management and safe use of
no “Live Testing” undertaken in any electrical portable electrical tools. The process must
installations that are energised above extra consider the asset’s specific environmental
low voltage. A live testing process and conditions, as well as inspection and
system of approval for this type of testing testing requirements. Use of battery or
needs to be developed and implemented. pneumatically operated tools are preferred,
This must include as a minimum: where practicable.
a) 
That live testing will only be a last resort
when there are no other practical means
to complete the task;

b) 
Competency and training for the
personnel involved;

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6 Electrical Safety
6.2.3 
Assets must develop a process for the
restoration of power and specifically detail
the necessary steps which must be taken d) Preservation of the scene;
before resetting any tripped circuit breakers, e) Barricading the area;
e.g. earth leakage, short circuit and overload, f) Notification to relevant supervisors/
or replacing blown fuses on all electrical managers; and
systems above extra low voltage. This process g) Investigation of the cause and corrective
should also include a register for recording actions.
any trips, particularly on high voltage
installations. 6.2.8 A labelling standard must be implemented
and maintained to fit appropriate
6.2.4 
A study must be completed to calculate
identification and warning labels on all
the specific arc flash hazard at switchgear
electrical installations.
and electrical panels and identify where
the use of appropriately rated personal 6.2.9 There must be a system implemented
protective equipment for electrical work and maintained for the specification and
may be needed. layout of all electrical distribution networks,
including single line diagrams, asset services
6.2.5 
The appropriate personal protective
drawings for any high voltage overhead
equipment category rating (refer NFPA
power lines or high voltage underground/
70E) must be identified for all electrical
buried cables, system fault level calculations,
installations and signposted accordingly.
equipment details, electrical protection
The use of engineering controls to mitigate
settings and discrimination curves.
the hazard must be considered (e.g. arc
fault detection relays, HRC fuses, remote 6.2.10 There must be a system implemented and
switching). maintained to control the risks associated
with excavation where electrical cables may
6.2.6 
Assets must develop a system to manage
be present.
any high voltage overhead power lines and
cables including clearances from plant 6.2.11 A maintenance management system
and equipment, as well as maintenance applicable to all electrical equipment must
and inspection requirements. This must be developed, implemented and updated. It
include condition monitoring/inspection must include maintenance and inspection
of the joints and terminations by either a requirements as well as inspection timing.
visual inspection or using approved test 6.2.12 A commissioning process must be
equipment such as thermographic cameras. developed and implemented to inspect
6.2.7 
The steps for the management of electric and test all electrical installations
shock must be developed, implemented energised above extra low voltage after any
and maintained; and include as a minimum: construction, alterations or repairs have been
a) That all electric shocks must be reported; undertaken and prior to placing the plant or
b) Isolation of the power supply; equipment back into service. Inspection and
test results must be recorded and verified by
c) First aid treatment of personnel;
relevant supervisors prior to completion of
the task.

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6 Electrical Safety
6.2.13 There must be a process for removing
electrical equipment from service if
not fit for use or purpose, e.g. a defect be fitted with phase barriers and
management system and the placing shrouds on both the line and load
of an Out of Service tag on the defective sides of the circuit breaker/isolator as
equipment’s applicable isolation point(s). specified by the manufacturer. Any
busbar installations to and from these
6.3 I nstallations and Equipment circuit breakers must be appropriately
designed with short circuit and arc fault
6.3.1 Electrical installations, including wiring and mitigation included, e.g. insulation,
earthing must be specified, and maintained segregation distances, and phase
in compliance with relevant legislation, barriers etc.;
standards, codes of practice and any other
d) Minimum approach distances to
external requirements applicable to the
live electrical conductors must be
country/location of the asset.
documented and signposted, this
6.3.2 Assets must have a documented electrical must be based on the IEC/NEMA/
installation standard detailing the specific SAI or country standards applicable
electrical requirements for installations. to the location of the asset. Where
Guidance for developing these standards no standards are applicable, and
may be obtained from the Glencore conductors are not IP2X rated, then:
Electrical Installation and Equipment 1. A
 minimum approach distance
Guideline. This standard must include, of 500mm must be maintained
as a minimum: FOR installations up to and including
a) Provision of protection against dangers 1000V AC or 1500V DC;
arising from contact with parts of the 2. A
 clearing distance of at least 2.0
electrical installation that are live in metres must be maintained with
normal operation. This must be achieved all HV installations energised with
using one or more of the following Voltage of up to and including
methods: 132kV (applicable only to accredited
personnel with an observer);
1. Insulation;
e) All spare wiring and electrical cables
2. Barriers or enclosures; must be treated as live, adequately
3. Obstacles; insulated, and tagged to notify others
of the status, i.e. spare, redundant,
4. Placing out of reach.
damaged; multiple spare cores may
b) 
All electrical installations and be fitted with a heat shrink boot
equipment must be at least IP2X rated arrangement in lieu of individual cores;
in relation to any accessible exposed
electrical conductors energised above
extra low voltage;
c) All circuit breakers/isolators must

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6 Electrical Safety
f) 
An earthing system must be provided
to ensure that all mains-fed electrical
equipment, and all conductive parts h) All electrical equipment including
of that equipment, other than active enclosures, motor control centres,
conductors, are connected in order to: distribution boards, junction boxes etc.
must be installed in a position where
1. E
 nable automatic disconnection of
they can be easily accessed
supply in the event of a short circuit
and provide a safe work area for
to earth fault or excess earth leakage
personnel. A minimum distance of
current in any part of the installation;
600mm from the arc of the door must
2. P
 rovide an effective and reliable low be kept clear in front of these enclosures;
impedance fault path capable of
carrying earth fault and earth leakage i) 
All electrical installations must be fitted
currents without danger or failure with permanent type labels indicating:
from thermal, electromechanical, 1. P
 lant or identification number;
mechanical, environmental and
2. Plant description and what it supplies;
other external influences or another
approved system that achieves an 3. W
 here plant is supplied from or
equivalent level of safety; and isolated at;

3. M
 itigate any differences in potential 4. D
 anger sign indicating the maximum
across any exposed conductive parts voltage found in the enclosure;
by having adequately sized earth 5. D
 anger sign indicating that only
bonds in place. authorised personnel are permitted
g) Switch rooms and substations access;
must have as a minimum: 6. D
 anger sign indicating to isolate
1. A single line drawing showing elsewhere prior to opening door or
all high voltage cables and removing cover where exposed live
switchgear on display; conductors are not IP2X rated behind
them; and
2. A single line high voltage drawing
showing all points of isolation 7. E
 lectric shock/resuscitation in switch
available on the electrical distribution rooms and substations.
system for that installation/location
on display;
3. A
 single line drawing showing all
points of isolation available for the
Low Voltage electrical distribution
system for that installation/location
on display;
4. Electrical drawings available for the
specific electrical installation.

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6 Electrical Safety
j) 
All electrical switch rooms and
substations must be locked and
inaccessible to unauthorised personnel. including LV trailing cables, and they
To enable removal of power in the event must be set to trip at a maximum
of an emergency, an external emergency of 500mA.
stop device(s) must be incorporated
b) 
All final sub circuits rated up to and
unless this creates a greater risk than
including 32A, including general
it mitigates. A risk assessment must be
purpose outlets and lighting circuits,
undertaken to support the decision if an
must have earth leakage protection
external emergency stop is not provided
provided, which is set to trip at a
at an installation.
maximum of 30mA.
k) 
Provision for managing Extra Low c) These devices must be suitable for the
Voltage installations must be application and settings documented
implemented and maintained and in the asset’s electrical protection
include mechanical protection, support standard. Where it is not practical, for
and segregation of all wiring from safety reasons or where opening a circuit
mechanical services, e.g. brake lines, fuel could cause a greater danger than the
lines, hydraulic lines. Battery cables must trip itself, i.e. lifting magnets, exciter
be individually mechanically protected circuits etc. these must be supported by
and supported along their entire length. a documented risk assessment and any
The installation of electrical protection other safety measures implemented as
devices and appropriate isolation an outcome.
devices, e.g. battery isolator/s, must form d) Testing of electrical protection devices
part of this documented standard. must be conducted at pre-determined
6.3.3 
A fault level and protection study must be intervals recommended by either
completed and documented to determine the manufacturer, relevant country
the asset’s electrical protection requirements standards, or risk based depending
and, as a minimum, must ensure that all on the asset’s requirements. Test results
faults must be cleared in the minimum must be recorded and retained for
possible time and all fault clearing times a period specified in the document
must be within the fault withstand control system.
capability of the equipment. 6.3.5 Certified explosion protected electrical
enclosures and equipment must be installed
6.3.4 
Electrical protection devices, including
where located within potentially explosive
overload, earth leakage and short circuit
atmospheres and/or as described by
protection, suitable for the application, must
standards applicable to the location
be installed on all final distribution circuits
of the asset.
energised at low voltage.
a) Earth leakage protection devices must
6.3.6 All extension leads outside an office
environment must be of robust construction
be installed on all distribution circuits,

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6 Electrical Safety
suitable for the installed conditions in an
industrial environment. The preferred leads
are the screened type, which are fitted with of cable being joined. The cables must be
IP56 plugs and sockets. The screen in the tested to the required standards and a test
extension leads must be connected to the sheet produced for the completed joint or
earth terminal at both the plug and socket splice prior to energisation.
ends of the lead.
6.3.9 
Any cables above extra low voltage,
6.3.7  here must be a process for managing
T excluding trailing and reeling cables must be
welding machines and associated installed and arranged to minimise damage
accessories that includes as a minimum: due to impact or interaction with mobile
a) Installation of a Voltage Reduction equipment. Inspections must be conducted
Device (VRD) on all Manual Metal Arc on a regular basis.
Welding machines;
6.3.10 Any cables that are energised above extra
b) Cables must only be joined using the
low voltage must be designed for the
approved plug type arrangement;
environment in which they will be used and
c) The ground/earth return clamp must be installed. Trailing cables on machines and
taken as close as practicable to the work cables submerged in water are examples of
area and effectively attached; this requirement.
d) 
Welding machines must be maintained
to a standard as described by the
6.4 C
 ompetency and Training
manufacturer and any standards 6.4.1 
Assets must identify competency
applicable to the location of the asset, requirements and associated training for
i.e. IEC/NEMA/SAI standards etc.; relevant personnel in relation to electrical
safety. This must include refresher training
e) 
Welding leads must be inspected
as well as ongoing maintenance of electrical
prior to use by the person using the
competencies. Competency requirements
equipment; and
include:
f) 
Welding leads must be inspected a) Appointment of Person/s with
formally on a risk-based time period appropriate electrical qualifications are
and tagged to indicate they have been to develop and review the standards
inspected by a competent person, e.g. and procedures for the installation,
monthly. commissioning, maintenance and repair
6.3.8 
All high voltage power cables (excluding of electrical plant and installations;
aerials) must be insulated, terminated b) Appointment of Person/s to supervise
and only joined/spliced using approved the installation, commissioning,
methods available from recognised maintenance and repair of electrical
manufacturers and by competent and plant and installations;
authorised personnel; this must provide the c) Persons appointed to do electrical work
correct insulation properties, IP rating, and must meet local legislation competency
phase segregation as approved for the type prerequisites;

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6 Electrical Safety
d) The identified training must meet
competency requirements, legislation,
codes of practice, design criteria and
asset or regional protocols, as well as
relevant procedures and permit
systems; and
e) Only trained, competent and authorised
or appointed personnel are to conduct
electrical work.

6.5 A
 dditional requirements for
Catastrophic Risk (PMC 5) Situations
Nil

TOOLS (SEE GLENCORE HSEC INTRANET)

Tools provided include:

FHP Self-Assessment Workbook,

FHP Third Party Audit Workbook 06 –

Electrical Safety

Electrical Installation and Equipment

Guideline, and
Electrical Engineering Control Plan (EECP)
Template.

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Emergency
Response
VERSION: 2-0
EFFECTIVE DATE: 01/04/2020
55 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

7 Emergency Response

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents arising
from risks associated with inappropriate response to
an emergency.

Related Life-Saving Behaviours

None.

KEY ACTIONS
Conduct a risk assessment to identify likely
events that could result in an emergency and
determine controls.

Develop an Emergency Response Plan.

Develop and implement triggers for

withdrawal, evacuation, Emergency Response
Crisis Management Team notification.

Include emergency warning and/or alarm

systems to notify Workers, visitors or the public
as applicable of a need to evacuate

Provide emergency response and

escape equipment.

Establish protocols and structure for

Emergency Response Teams and
support functions.

Implement response arrangements with

external support agencies and mutual
assistance from adjacent operations.

Provide and maintain effective

communications systems for management
of emergencies.

Provide regular competency-based emergency

response Training* for all personnel.

* See glossary

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7 Emergency Response

7.1 General Requirements

7.1.1 Assets must identify all potential j) Access to rapid medical support and
emergencies they may be exposed to and evaluation services, particularly related
the associated risk analysed and evaluated. to injuries related to electric shock,
Where possible, these risks are to be asphyxiation, burns, caustic chemical
monitored for early warning. contact, high pressure fluid injection and
7.1.2 An Emergency Response Plan (ERP) must crush injuries;
be developed, implemented and maintained k) Rapid, effective and robust
to minimize the consequences of potential communication systems, devices and
emergencies, as a minimum it must include: procedures for initial notification of
a) Clearly defined procedures for the personnel of an emergency, and for
reporting an emergency event and ongoing two-way communication
initiating an emergency response; during emergencies for key personnel;
b) Triggers to notify the Crisis l) Control of site access and restriction of
Management Team; re-entry to the affected areas;
c) Responses to, and containment of m) Duty cards that clearly identify
identified emergencies; responsible persons duties, functions
d) Triggers for withdrawal of people from and reporting relationships;
a mine, asset or part thereof, or the n) Protocols and structure for Emergency
local community; Response Teams, and support functions;
e) Processes to avoid any further injuries, o) Provision of an adequate number of
fatalities, rescue team casualties, Competent Persons to provide an
or damage; appropriate emergency response
f) Procedures and equipment for at all times;
evacuation including escape ways, p) Service agreements and communication
guidance systems and route marking, mechanisms with external emergency
self-escape and aided rescue; agencies for the provision of aided
g) Provision of first response equipment rescue where available;
including firefighting, first aid, trauma q) Mutual assistance agreements must
kits readily accessible and clearly be established for rescue/emergency
signposted; assistance with adjacent operations
h) Defibrillators must be available and and local authorities where it can be
maintained at all assets, and strategically of benefit;
positioned based on a risk assessment; r) System for the notification of internal
i) Provision of adequate emergency and external stakeholders, including
equipment including escape and rescue next of kin;
apparatus such as “Jaws of Life” and air
lifting bags, transport/response vehicles;

* See Glossary.

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7 Emergency Response

s) Provision for the establishment and

maintenance of a suitably equipped
emergency control centre where duration capability to escape to a Place
communication facilities, and other of Safety.
relevant information are available 7.2.3 Self-rescuers must be worn at all times
including duty cards, emergency contact whilst underground or in other defined
lists, hazardous chemical inventories at-risk areas. Any conditions of exemption,
and plans showing the location of such as entering certain locations of
emergency equipment and services; restricted access shall include details of how
t) Processes to accurately monitor the the device will remain readily accessible
number and location of persons in a is to be approved in writing by the Senior
mine, part of mine or other asset type Site Manager.
using systems such as tag boards,
7.2.4 Self-contained refuge bays of a capacity
electronic tagging, telephone and
equal to or greater than the number of
radio communications with log sheets
people in the area must be provided at any
etc. immediately prior to and during
location where extensive distances or the
an emergency;
work environment may impede the ability
u) Identification, maintenance and sign
for self-escape to the surface. A system
posting of emergency muster points
must be in place to prevent greater than
and processes to verify that all personnel
that number of people entering beyond
have been accounted for;
that point.
v) Conditions for and management of
re-entry to a workplace and the safe
7.2.5 The design specifications, contents,
inspection and maintenance requirements
resumption of normal operations
of refuge bays (portable or fixed) must
after evacuation including systems for
be documented.
ongoing control.
7.2.6 A system to immediately notify every Worker
7.1.3 The ERP must be revised regularly, and
of the need to evacuate must be established.
consider emergency simulation exercise and
This could include systems such as flashing
actual incident investigation findings.
lights and alarms, personal telephone,
7.2 U
 nderground (or other Defined radio, beepers, or the introduction of
Risk Areas) distinctive smells (stink gas) into the
ventilation systems.
7.2.1 Primary and secondary means of escape
must be identified, clearly signposted 7.2.7 All underground coalmines must establish
and include route marking or lifelines, provisions and a procedure for sealing,
and/or other aids for escape in low the mine or part of the mine, allowing
visibility conditions. for re-entry into at least one mine entry
and introduce periodic full range testing
7.2.2 All underground Workers and visitors must of such facilities.
be provided with Certified Self-Rescuers*
of the oxygen generating type with tested 7.3 Training and Competency
7.3.1 Practical Training must be provided in the
* See Glossary.

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7 Emergency Response

donning of self-rescuers and breathing

apparatus on at least an annual basis
for all users.

7.3.2 Training needs and competency

requirements of employees, contractors
and visitors in emergency response must
be identified and adequate Training,
regular refresher Training and assessment
to verify competency must be provided.

7.3.3 Emergency Response Team members

and ERP Duty Holders must be trained for
potential events including protracted or
complex emergencies.

7.3.4 Emergency simulation exercises must be

scheduled so that all Workers are included
at least annually to test the effectiveness of
the asset’s emergency response, apparatus
and evacuation capabilities.

7.4 A
 dditional requirements
Catastrophic risk (PMC 5) situations.
7.4.1 Emergency warning and/or alarm systems
must be established to notify Workers,
visitors or the public as applicable of a
need to evacuate. Such systems must
be tested and verified as effective on
a scheduled basis.

TOOLS (SEE GLENCORE HSEC INTRANET)

Tools provided include:

FHP Self-Assessment Workbook,

FHP Third Party Audit Workbook
07 – Emergency Response.

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Lifting and
Cranage
VERSION: 2-0
EFFECTIVE DATE: 15/10/2020
60 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

8 Lifting and Cranage

Intent
The intent of this protocol is to eliminate or minimise the
potential for fatalities, injuries and incidents arising from
risks associated with lifting and cranage activities.

Related Life-Saving Behaviours

2. Always use or wear critical safety equipment.

4. Only operate equipment if trained and authorised.

6. Never modify or over-ride critical safety equipment

without approval.

8. Never enter danger zones without approval.

KEY ACTIONS
Conduct a risk assessment to identify hazards
associated with lifting and cranage activities.

Develop a Lifting and Cranage Procedure.

Confirm Lifting Plant is certified for use and

Lifting Equipment is inspected, maintained
and fit for purpose.

 learly identify and demarcate lift areas, drop

C
zones and exclusion areas and never enter
under or near a suspended load.

Regularly inspect, check and label Lifting

Plant and Equipment.

Develop and implement lift plans and

permits for complex or complicated lifts
and use qualified Riggers and Dogmen.

Communication systems and protocols

must be developed and followed for all lifting
and cranage activities.

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8 Lifting and Cranage

8.1 General Requirements

8.1.1 A risk assessment must be conducted and h) Establishment and compliance with
documented to identify the hazards and communication protocols, including
assess the risks associated with lifting and communication devices, for visual and
cranage and for the development of a Lifting non-visual load, lifting and personnel
and Cranage Procedure. access control;
8.1.2 A Lifting and Cranage Procedure must be i) Tag lines must be used where a load
developed, implemented and maintained. requires steadying or guidance and
As a minimum, it must include: to prevent personnel entering the
load zone;
a) A process to verify that the Lifting
Plant (crane, forklift, MEWP) is subject j) Records of Lifting Equipment in a
to an engineering design process and register and subjecting it to routine
certified; and the associated Lifting inspection and maintenance. Shackles,
Equipment is fit for use and purpose; light weight slings and eye bolts
(<1 tonne) are exempt from the register
b) If Lifting Plant or Equipment has
but must be subjected to inspection
been repaired or modified, it must
before use;
be recertified in accordance with the
manufacturer’s requirements; k) Labelling and preferably colour coding
Lifting Equipment to indicate its Safe
c) The requirement for pre-use inspections
Working Load (SWL) and to verify that
to verify that rigging equipment, the
it is within the inspection period;
load weight, hooks and safety devices to
be used by operators are checked prior l) SWL and radius limits that the crane
to the lift being undertaken; and associated Lifting Equipment must
not exceed. Loads are to be slung by
d) The demarcation, access restriction and
competent persons, and the cranes are
signposting of the lift area and potential
not to be operated at speeds that could
drop zone;
de-stabilise the load in the event of a
e) Prohibition of persons entering an area
sudden stop;
under a suspended load, under any
m) Consideration of weather conditions
circumstances;
with adjustment of lifting activities due
f) At least twenty (20) metres clearance
to adverse weather or environment
of cranes and Lifting Equipment from
conditions; and
power lines (clearance to be measured
n) Prohibition of use of towing equipment
using machines fully extended
for lifting activities.
capabilities) unless a risk assessment is
conducted and documented to identify 8.1.3 A permit is required for complex lifts, such as:
controls to allow for operations within
a) Multiple crane usage;
twenty (20) metres;
b) Over facilities, buildings or restricted areas;
g) That the Lifting Plant operator must
c) Over or adjacent to power lines;
remain at the controls whilst the load
is suspended;

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8 Lifting and Cranage

d) At or more than 90% of the must only be carried out with a specifically
crane’s or Lifting Equipment’s designed, certified and clearly marked
SWL, including testing of cranes (including working load limit) Workbox
for recertification purposes; or platform suitable for lifting persons.
e) When the work area is not visible Tools and equipment for use by persons
from the crane operator’s cabin; must be restrained.
f) Lifting people in a Workbox; and 8.2.2 Workboxes used for lifting persons with a
g) Potential shifting or dynamic loading. crane shall have two separate mechanisms
for preventing the Workbox from falling; one
8.1.4 A Lift Plan (Rigging Study) must be of which shall be fail-safe.
developed and implemented for complex
lifts and contain or reference: 8.2.3 Workbox access gates must open inwards
and include a safety catch.
a) A documented risk assessment that is
communicated to the work party; 8.2.4 A MEWP should be controlled by an
b) Lift data, e.g. equipment weight, rigging operator in the platform. Where this is not
weight, height of lift, equipment surface possible (such as underground loaders) an
area and centre of gravity, etc. override or emergency stop provision must
be accessible in the platform.
c) Equipment data, e.g. manufacturer,
model, size, boom length, jib length, load 8.2.5 Fall arrest equipment shall be worn by
block, material size, etc. persons in a Workbox used with a crane and
d) Rigging data, e.g. sling diameter, length, attached to a point separate to the Workbox.
sling configuration, capacity, hook type, 8.2.6 A rescue plan shall be prepared for all
shackle size and capacity, etc. personnel lifts as part of the lift permit. All
e) Lift computation, e.g. boom length, equipment required to implement the
radius of lift, equipment capacity, size of rescue plan shall be readily available prior
outrigger footplates and wind speed, etc. to and during the lift. Rescue plans shall be
f) Risks associated with power lines, crane practised at regular intervals.
travelling route, ground stability and 8.3 Cranes
agreed communication methods;
g) Evidence to verify that the crane 8.3.1 Crane hooks must be fitted with a positive
operators, Riggers and Dogmen were safety latch.
involved in the development of the Lift 8.3.2 Overhead cranes must be fitted with
Plan and/or were consulted before the appropriate stops (e.g. over-travel stops).
Lift Plan was finalised; and
8.3.3 Fixed lifting devices/cranes must conform to
h) The permit, documented risk an appropriate engineering design standard
assessment and Lift Plan must be and be subject to routine structural integrity
approved and signed by the relevant testing.
authorised person.
8.3.4 A Vehicle Loading Crane must not be able to
8.2 Lifting of Persons be rotated over the location of the operator
positioned at the controls.
8.2.1 Lifting of personnel with cranes or forklifts

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8 Lifting and Cranage

8.3.5 Loads being carried by mobile cranes in

transit must be secured so that they cannot
swing and cause toppling of the crane. be defined and visibly displayed in the
work area.
8.3.6 Mobile cranes must be positioned so that
they are on a firm level base sufficient for 8.5.5 If an operator’s vision is restricted, additional
the crane and load. Inclinometers and controls must be implemented, e.g. operate
warning devices must be installed and used in reverse, use an escort on the ground,
to ensure that a crane cannot topple when inspect and assess the travel route.
slewing a load. 8.5.6 If a forklift is to be used to lift unusually
8.3.7 Load cells in the visual range of the crane shaped or long items, specific attachments
operator or a load limiting device should be should be provided, designed and certified
used if the load weight is unknown. to an approved engineering standard. Use
of such attachments must also consider the
8.3.8 An Anti-Two-Block Device or limit switch
impact on forklift stability and load capacity.
that includes audible and visual alarm
systems should be fitted to a crane and 8.5.7 Forklifts must be fitted with: a seatbelt that
must be fitted whenever persons are lifted in must be worn by the operator when in
a Workbox. use, reversing alarm, fire extinguisher, and
flashing light.
8.4 Loads
8.5.8 Areas where forklift operation is permitted
8.4.1 Designated lift points should be provided on must be clearly and physically delineated or
equipment that is lifted on a regular basis. demarcated. Forklift operation is excluded in
8.4.2 Lifting procedures must include the areas where the ground is uneven, the grade
inspection of fixed lifting points. too steep, the road in poor condition and in
pedestrian zones, including walkway.
8.4.3 Loads that are lifted on a regular basis
should be identified and display the
component weight.

8.4.4 Loads must be stable and secure prior to

lifting.

8.5 F
 orklifts
8.5.1 Forklifts must only be operated by a
competent and authorised person(s).

8.5.2 The operator must not exit the machine with

a suspended load.

8.5.3 Forklifts must be fitted with a load cell or

load limiting device.

8.5.4 The maximum load height (or number of

stacked packages) carried by forklifts must

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8 Lifting and Cranage

8.6 Training and Competence

8.6.1 Training needs and competency
requirements of employees and contractors
in relation to all aspects of general lifting and
cranage must be identified and adequate
Training, regular refresher Training and
assessment to verify competency
must be provided.

8.6.2 Competency requirements for more

complex lifting activities must be identified.
The crane operator, Rigger and Dogman
must be assessed as competent and
appointed to conduct the work.

8.6.3 MEWPs may only be used by persons who

have been trained, are competent and have
been authorised.

8.7 Additional Requirements for

Catastrophic (PMC 5) Situations
Nil

TOOLS (SEE GLENCORE HSEC INTRANET)

Tools provided include:
FHP Self-Assessment Workbook,
FHP Third Party Audit Workbook
08 – Lifting and Cranage, and
Permit 03 – Complex Lifting Permit.

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Fire and
Explosion
VERSION: 2-0
EFFECTIVE DATE: 20/08/2020
66 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

9 Fire and Explosion

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents arising
from risks related to unplanned or uncontrolled fire
or explosion.

Related Life-Saving Behaviours

2. Always use or wear critical safety equipment.
4. Only operate equipment if trained and authorised.
6. Never modify or over-ride critical safety equipment
without approval.

KEY ACTIONS
Conduct a risk assessment to identify potential
fire and explosion risks and determine controls.

Develop a Fire and Explosion Management Plan*.

Develop and implement Procedures and

actions for first response and triggers for
withdrawal to a place of safety and
emergency response.

Provide, maintain and periodically test fire

escapes, emergency escape lighting and/or
route marking for evacuation.

Install, test, calibrate and maintain, fire

detection, monitoring and alarm systems in
appropriate locations and on relevant plant
and equipment, including evacuation routes
and emergency exits.

Install and maintain manual and/or automatic

fire suppressions systems in high-risk locations,
plant and mobile equipment.

 evelop and implement Management Plans

D
and Procedures for additional control where
there is an ignition risk from electrical arcing, Provide regular competency-based fire
lightning, friction, spontaneous combustion or Training* for all personnel.
incompatible substances – such as chemicals
or molten or reactive metal - or explosion risk
from volatile fuel or dust. * See glossary

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9 Fire and Explosion

9.1 G
 eneral Requirements

9.1.1 A fire and explosion related risk assessment response/rescue equipment must be
must be conducted and documented to maintained to support inspection, testing
identify the potential hazards, risks and and maintenance of the equipment.
controls. It must consider:
a) Sources of ignition; 9.1.5 A warning system must be provided
b) 
The presence of combustible or on enclosures that could contain toxic
flammable material; extinguishants released from automatic
fire suppressions systems – to prevent
c) 
The presence of explosive gases and
unauthorised entry and potential
atmospheres;
asphyxiation.
d) 
The storage and treatment of
incompatible and hazardous substances. 9.1.6 Portable fire extinguishers of a suitable
capacity must be installed and safely
9.1.2 
A Fire and Explosion Management Plan
accessible:
must be developed, implemented and
maintained and, as a minimum, include: a) 
On mobile equipment; and

a) 
Fire and Explosion prevention measures, b) 
Within close proximity (normally 20m)
including ignition source exclusion zones and where applicable, upwind of all fire
and contraband controls; risk locations.

b) 
Fire and Explosion detection, alarms, 9.1.7 
Integrated fire detection and suppression
warning systems and controls; systems (e.g. deluge, water, chemical, gas,
c) 
Trigger Action Response Plans (TARPs) etc.) must be provided corresponding with
based on the relevant detection systems, the risk to people and equipment. Examples
triggers and hazardous conditions; include: major mobile equipment, Motor
d) 
Fire Fighting Equipment, including type, Control Centres (MCC), electrical sub-
location, availability of adequate water stations, transformer compounds, conveyor
supply and pressure; belt drives and winches, hazardous goods
storage areas, fuel and lubricant storage
e) 
References to related Management
depots, hoist rooms, fan houses, compressor
Plans or Procedures, e.g. Spontaneous
rooms, offices and other buildings.
Combustion and Combustible Dust
Suppression Management Plans. 9.1.8 
Inspection, testing, calibration, maintenance
9.1.3 
Fire and explosion detection, monitoring and replacement of fire and explosion
and alarm systems must be installed in detection, alarm and suppression systems
appropriate locations, and on relevant items must comply with the manufacturers’
of plant and equipment, e.g. heat or smoke specifications, asset Procedure/s and
detectors, gas detection systems, audible be included in the asset’s maintenance
and visual alarms, stench gas alarm management system.
system, etc.
9.1.9 
A Permit System and back-up process
9.1.4 
A register of fire monitoring, detection, must be used whenever a fire or explosion
suppression, firefighting and emergency detection, monitoring or suppression system
is offline.

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9 Fire and Explosion

9.1.10 Up-to-date copies of the Fire Fighting

Control Plans (i.e. showing the location of
fire equipment, hydrants, escape routes, may be reduced to 30 minutes if the job
etc.) must be displayed in prominent can be completely cooled with water and/
locations, e.g. control rooms, muster areas, or a thermography camera is used to ensure
lunchrooms, supervisor stations, office areas, no ignition source remains.
evacuation points, electrical substations and a) 
Hot Work on major equipment including
workshops, etc. draglines, shovels, excavators, drills and
other equipment completed outside of
9.1.11 Procedures that clearly define the
a workshop (work on buckets, ground
actions to be taken on discovering a fire
engaging tools and Jewellery* can be
or an explosion risk must be developed
excepted where the risk is assessed
and communicated.
and controlled);
9.1.12 Fire escapes, emergency escape lighting b) 
Work in multi-level process plants,
and/or route marking must be provided, buildings or equipment where hot
and periodic evacuation drills conducted material or sparks are able to fall below
in accordance with Emergency or outside the work area;
Response protocols. c) 
Hot Work in areas determined by
risk assessment as presenting a risk
9.1.13 Hot Work must be controlled with
of immediate or delayed ignition.
the following:
a) 
Designated Hot Work Locations
9.1.16 Machine components that could cause a
fire or explosion must be identified, e.g.
(DHWL)* must be established where
turbo chargers, batteries, ignition sources
required for regular hot work activities;
close to fuel sources, cables, fuel lines and
b) 
A Hot Work Permit System must be
hydraulic hoses that can rub, chafe and
implemented and utilised for:
fail. Where practical, protection should
1. H
 azardous Hot Work within a be implemented to minimise the fire risk
DHWL where flammable or explosive associated with these components, e.g.
materials have been introduced, such shielding, shrouding, clamping to reduce
as a fuel tank or chemical products; movement, internal porting of hydraulic
2. All Hot Work outside lines, and/or establish exclusion zones.
a designated DHWL. 9.1.17 Incompatible substances that can
9.1.14 A Fire Watcher* must be considered for potentially ignite or explode when brought
all Hazardous Hot Work. into contact must be identified and specific
management and control measures
9.1.15 A mandatory continuous fire watch must be developed and implemented, e.g. oxygen
maintained at the following locations where exposure to titanium or carbon steel.
Hazardous Hot Work is conducted. A Fire
Watcher must be present during and for at 9.1.18 Where an explosion risk can occur, the
least two hours after completion of asset’s Engineering Management Plan
the hot work. The post-work fire watch

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9 Fire and Explosion

must include standards for the purchase,

installation, commissioning, use, calibration
and maintenance of equipment (e.g. cooling mechanisms, such as
flameproof/intrinsically safe electrical nitrogen or ester-based oils;
equipment and diesel engine systems). c) 
Detection and protection of overpressure
9.1.19 Where there is a risk of spontaneous conditions within the transformer;
combustion, frictional ignition or flammable d) 
Temperature protection;
gas being present, issue specific controls, e) 
Regular maintenance and testing of
processes and Procedures must be electrical installations (included as part
developed, implemented and maintained of the relevant asset’s Engineering
for each of the hazards. Management Plan); and

9. A
 dditional Requirements for f) 
Installation so that it is directly, or able
to be, ventilated to the return airway
Underground (or other Defined
where practicable.
Risk Areas*)
9.2.5 
Where a flammable gas risk exists,
9.2.1 
Where ignition of gas and dust can
the controls must include:
be initiated, a documented technical
hazard assessment (i.e. sampling and a) 
Setting of threshold levels for
laboratory testing) must be made to the monitoring of gases;
determine the potential for occurrence b) 
Appointment of Competent Persons
and mitigating controls. to monitor and take action when an
alarm is triggered;
9.2.2 
Refuelling stations and battery charging
c) 
Recording, verification and escalation
stations, major maintenance workshops,
of all alarm events;
DHWL, permanent tyre and lubricant
storage areas must be designed and d) 
An inspection regime for monitoring
equipped to minimise and contain the gas levels in intake and return airways
impact of a fire, adequately ventilated and if and where people are required to work;
underground, ventilated to a return airway. e) 
Provision of flammable gas monitors for
electrical machinery and diesel vehicles;
9.2.3 
Appropriate Procedures must be established
to manage and provide security for low flash f) 
Installation of ventilation structures, e.g.
point chemicals and fuel (<61ºC) stoppings, seals, ventilation fans, that are
whilst underground. designed, rated, constructed and verified
to a standard that is adequate for the
9.2.4 
The prevention and mitigation of electrical risk potential;
transformer fires must be addressed and
g) 
A Ventilation Management Plan
consider relevant Codes of Practice
and Procedures that document how
and include:
ventilation is to be provided to remove,
a) Installation and testing of electrical
dilute and control explosive levels of
protection systems;
mine gases;
b) 
A risk-based transition to the use
of fire resistant or non-flammable

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9 Fire and Explosion

h) 
Electrical and diesel equipment that
is designed, approved, installed, used,
inspected and maintained to operate e) 
Procedures for the examination,
safely, e.g. explosion protected or sampling and testing of roadway dust
intrinsically safe apparatus; to ensure the incombustible content is
i) 
The prohibition of smoking, smoking within acceptable limits. The methods
related products, or other non-approved for sampling must incorporate a
device capable of creating a spark or combination of spot and strip samples
flame which can ignite flammable gas; taken over set frequencies of time
depending on location.
j) A real time gas monitoring and analysis
system for intake and return airways; and 9.2.7 
Where a frictional ignition risk exists,
k) 
A tube bundle system for monitoring the controls must include:
and analysing gas concentrations in a) Verification that drums, picks and water
sealed or abandoned areas, or areas sprays used on cutting machines are
of the mine requiring monitoring during designed to eliminate or minimise the
a power failure, e.g. longwall return, main potential of a frictional ignition event;
ventilation shaft.
b) Use of adequate water and sprays
9.2.6 
Where a combustible dust hazard exists, for suppressing sparks associated
the controls must include: with cutting;
a) 
The minimisation of combustible dust c) An inspection and maintenance
generated by the cutting and transport program that demonstrates the
of material using water suppression effectiveness of the water sprays and
and/or scrubber systems and the that the picks, sprays and drums are
design of equipment; maintained to an appropriate standard;
b) 
The removal (or rendering inert) d) Ventilation of the cutting area to
of accumulations of potentially remove or dilute any accumulation
explosive dust; of flammable gas;
c) 
Procedures and methods for e) Appropriate fire extinguishing
the application of limestone dust or equipment maintained close to the face
other explosion inhibitor in quantities or work area;
that will prevent the propagation of f) Face cutting Procedures that minimise
a dust explosion in the mine; the risk of frictional ignition, particularly
d) 
The means by which the limestone around the intersection of gas
dust or other explosion inhibitor is to drainage holes;
be applied to surfaces that have been g) Bolting Procedures and equipment
recently mined. The means by which that minimise the risk of frictional
limestone dust or other explosion ignition, particularly over-spinning
inhibitor is introduced into the return or heat generation; and
airway in close proximity to the working
face; and

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9 Fire and Explosion

h) Condition monitoring (including

the use of thermal imaging where
appropriate) of rotating plant that has b) 
Lightning mitigation studies considering
the potential to heat under friction, e.g. mine infrastructure such as conveyors,
belt rollers, idlers, pulleys, drive drums. pipelines, communication cables and
electricity cables that enter the mine;
9.2.8 
Where a spontaneous combustion risk
c) 
Identification of all possible surface
exists, the controls must include:
connection points;
a) The development of a Spontaneous
d) 
Removal of all conductive cables, pipes
Combustion Management Plan,
and other structures from areas that will
that includes: prediction, detection,
become sealed if these items are greater
sealing and inertisation;
than 20 metres in length;
b) Formal determination of
e) Installation of specified gaps between
spontaneous combustion
conductive sources; and
propensity and characteristics;
f) Prohibition of shot firing during times
c) The analysis of bag samples using
of potential lightning activity.
a gas chromatograph;
d) Trigger Action Response Plans (TARPs)
for indicators and ratios of spontaneous
combustion;
e) A Procedure for managing and
removing stowage from the mine;
f) A real time gas monitoring and analysis
system for intake and return airways,
specifically located on the return air side
of potential spontaneous combustion
hazards; and
g) A tube bundle system for monitoring
and analysing gas concentrations in
sealed or abandoned areas of the mine.

9.2.9 
Where a risk from lightning-initiated gas
ignition exists, a Lightning Management
Plan is required and must include:
a) 
A lightning risk assessment with the
participation of a subject matter expert
which considers:
1. T
 he electrical resistivity of the ground/
strata at the operation;
2. C
 onductive boreholes that enter the
workings.

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9 Fire and Explosion

9.3 T
 raining and Competency

9.3.1 Identify Training needs of employees and

contractors in relation to fire and explosion,
and the provision of assessment to verify
competency.

9.3.2 Provide specific Training, assessment,

authorisation, and appoint personnel to
fulfil roles defined in the Fire and Explosion
Management Plan.

9.3.3 Specific competencies must be

obtained by persons to be authorised
to work on explosion protected or
intrinsically safe equipment.

9.4 A
 dditional Requirements for
Catastrophic Hazard (PMC 5) Situations
9.4.1 Create separate zoning and monitoring
of gaseous areas.

9.4.2 Provide specialist firefighting equipment

for relevant hazardous locations such as low
and high expansion foam and applicators;
and inertisation capability for underground
coal mines.

9.4.3 Provide specific monitoring and

management of high-risk dust generating
areas such as coal bins and bunkers or other
locations with potentially explosive dusts.

9.4.4 Apply fire engineering design solutions

to high-risk facilities that store large volumes
of fuels, large quantities of explosives, or
radioactive materials etc.

TOOLS (SEE GLENCORE HSEC INTRANET)

Tools provided include:
FHP Self-Assessment Workbook,

FHP Third Party Audit Workbook 09 – Fire and Explosion

Management of Oxygen Related Hazards

Guideline, and

Permit 05 – Hot Work Permit.

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10

Explosive and
Shotfiring
VERSION: 2-1
EFFECTIVE DATE: 31/03/2021
74 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

10 Explosive and Shotfiring

Intent
The intent of this protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents that
arises from risks associated with the use of explosives,
detonators and shotfiring equipment.

Related Life-Saving Behaviours

2. Always use or wear critical safety equipment.

4. Only operate equipment if trained and authorised.

6. Never modify or over-ride critical safety equipment

without approval.

8. Never enter danger zones without approval.

KEY ACTIONS
Conduct a risk assessment to identify hazards
associated with explosives and shotfiring and
determine controls.

Develop an Explosives and Shotfiring

Management Plan*.
Establish procedures*, Training* and
authorisations (where required) for storage,
issuing, transport, handling, loading and using
explosives, detonators and related equipment.

Establish and implement specific controls

such as exclusion zones, communication
systems, inspections, isolation and fume
control requirements.

Develop underground specific controls related

to flammable gas levels, non-sparking tools,
isolation and clearance zones.

Develop procedures and controls for Hot

Ground* and/or Reactive Ground* including
detection and management.

Ensure regular competency-based Training

and endorsement for Appointed Shotfirers*
and assistants.

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10 Explosive and Shotfiring

10.1 G
 eneral requirements

10.1.1 A risk assessment must be conducted to be in control of the vehicle used

and documented to identify the hazards to transport explosives;
and assess the risks associated with the h) Appointment of a suitably qualified
storage, issuing, transport, handling, person to design blasts;
loading, and use of explosives, detonators
i) Design and verification processes
and related equipment.
to manage drilling, loading, stemming
10.1.2 An Explosives and Shotfiring Management and tie-up;
Plan must be developed, implemented and j) Blast designs that minimise the risk
maintained. As a minimum, it must include: of fly rock injury to persons or damage
a) Purchasing and providing only approved to structures and property;
explosives, detonators and shotfiring k) Regular analysis (as a minimum
equipment, (i.e. permitted by a statutory annually), testing and characterisation
body), manufactured and maintained to of ground/soil to identify the potential
a recognised quality standard; for Hot Ground and/or reactive materials
b) A Site and Magazine Security Plan to within the working area (in accordance
prevent unauthorised access or use of with a recognised code of practice).
the explosives and detonators that are Where identified, procedures are
transported to and stored on site; to be developed, implemented and
c) Establishment of the competency maintained for loading of explosives
and authorisation (licensing in some into Hot or Reactive Ground;
jurisdictions) requirements for persons l) Procedures and controls for the type,
involved in explosives issuing, receival, loading, loading sequence and sleep
handling and shotfiring, including those time of explosives in wet, Hot or
specified in relevant legislation; Reactive Ground;
d) Storing of explosives and detonators m) Establishment of exclusion zones,
separately in safe and secure locations, communication mechanisms, radio
in licensed or approved locked transmission silence and procedures
magazines or reload compounds; for pre-blast inspection, clearance
e) A documented and traceable system and sentry placement for the safety
for the control and allocation of of person(s), plant and equipment
magazine keys; during blasting, including surrounding
potentially affected neighbours;
f) An inventory system for recording
stock movements including delivery, n) Consideration of weather reports and
issue and return; conditions to plan exclusion zones and
blast times, with particular consideration
g) Provision of vehicles or other methods
of environmental impacts, blast fumes
to transport explosives and detonators
and electrical storms;
separated and safely on site. Only
Authorised Personnel* are permitted

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10 Explosive and Shotfiring

o) Procedures for barricading and sign

posting loaded or sleeping shots
to prevent unauthorised entry and/ technology, such as detonation systems
or to prevent inadvertent access by and explosive types depending on the
person(s), plant and equipment; type of application;
p) Assignment of responsibility for x) Equipment likely to be affected by
clearing the shot affected area blasting is evacuated or located in
to the Shotfirer or another a safe area to avoid projectile or blast
responsible person; wave damage.
q) Requirement that no shot may be
10.2 U
 nderground
fired until the clearance is confirmed
by the relevant Shotfirer or other
(or other Defined Risk Areas*)
responsible person; 10.2.1 Where shotfiring is to be conducted in an
r) Preventing exposure to blast fumes underground mine, the following additional
and procedures for specific medical controls must be included:
responses for blast fume exposure; a) Provision and use of non-sparking,
s) Releasing the blast area following purpose designed tools for detecting
a blast – such as wait time cracks in coal seam drill holes;
periods, inspection requirements, b) Provision and use of non-sparking,
communication and all-clear purpose designed tools for loading,
signals/notification; measuring, delivering, tamping
t) Managing, investigating and reporting explosives or stemming;
misfires, shotfiring related incidents c) Elimination of flammable gas from
and for the recovery and disposal of the vicinity and prohibition of blasting
undetonated explosives; if flammable gases reach 10% of the
u) Disposing of or destroying unused, Lower Explosive Limit (LEL) or as
deteriorated, damaged or out of specified in legislation;
date explosives, conforming with d) Removal of explosive dust or
the manufacturers’ guidelines; confirmation that incombustible
v) Development and utilisation of an content is greater than 85%;
appropriate database for records e) Where electric detonation is used
associated with blasts, including blasting cables and wires shall be
for example: hole location and kept clear from power, lighting and
depth, loading charts, tie-up communication cables, and where
details, environmental conditions, practical remove power from electrical
photographs/videos, blast vibration, equipment in the vicinity other than
noise and dust measures; electrical equipment and circuits used
w) Maintaining technology watch to for the handling, preparing, charging
keep abreast of latest developments and firing an explosive, whilst explosives
and innovations in blasting are being prepared, charged or fired;

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10 Explosive and Shotfiring

f) Limitation of delay detonation duration

to less than 250 milliseconds, where
explosive gas or dust may be present;
g) Identification of potential paths of blast
pressure, such as other drill holes; and
h) Verification of adequate clearance of the
mine or adjacent workings.

10.3 T
 raining and competency

10.3.1 Identification of Training needs and

competency requirements of relevant
employees and contractors, the provision of TOOLS (SEE GLENCORE HSEC INTRANET)
adequate Training and assessment to verify
Tools provided include:
competency, ideally utilising a formalised
standard of competence. Training must FHP Self-Assessment Workbook, and,
cover all aspects of shotfiring, receival, FHP Third Party Audit Workbook
issuing, storage, transport, handling, 10 – Explosive and Shotfiring.
management of misfires, emergency
response, disposal/destruction of explosives,
security and sentry duties.

10.3.2 Training must include, where relevant,

detection of Hot or Reactive Ground and
the management of premature reaction/
detonation events.

10.3.3 Where available consider the use of

remote Training options such as virtual
reality Training.

10.4 Additional requirements for

catastrophic (PMC 5) situations
10.4.1 Specialist blasting processes and designs
must be developed where blasting must
occur near large gatherings of people or
sensitive structures.

10.4.2 General public access and spectators

must be restricted for mine blasting
and demolition.

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11

Tyre and Rim

Management
VERSION: 2-1
EFFECTIVE DATE: 06/11/2020
79 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

11 Tyre and Rim Management

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents arising
from risks related to tyre, Rim* and Wheel Assembly*
fatal hazards.

Related Life-Saving Behaviours

2. Always use or wear critical safety equipment.

4. Only operate equipment if trained and authorised.

6. Never modify or over-ride critical safety equipment

without approval.

7. Always seek and obtain clear approval before entering

mobile equipment operating zones.

8. Never enter danger zones without approval.

KEY ACTIONS
 ecord the types of mobile equipment
R
operating at your site, detailing Wheel
Assembly design and Rim diameter
(see Section 11.8).

Conduct a risk assessment to identify and

evaluate tyre and Rim related risks and
confirm their controls.

Develop, implement and maintain a Tyre and

Rim Management Plan* that applies to on-site
and off-site activities.

Include relevant requirements of this protocol

within the plan and apply them to equipment,
facilities and how work is carried out.

Assign accountability for implementing and

maintaining these processes.

Provide Tyre and Rim management Training*

and awareness information for persons at risk,
assess their competency and understanding.

* See glossary

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11 Tyre and Rim Management

11.1 G
 eneral requirements

11.1.1 A risk assessment must be conducted and 11.1.4 The Plan must be reviewed:
documented to identify the hazards and
a) After high potential tyre, Rim
assess the risks associated with tyre and Rim
and Wheel Assembly incidents;
management considering:
b) Before significant operational changes,
a) Catastrophic disassembly during
e.g. engagement of tyre maintenance
inflation, deflation, handling, or while
contractors, deployment of new
in service;
mining equipment, changes to haul
b) Moving and storing tyres, Rims and distances etc.
Wheel Assemblies;
c) Before the introduction of new
c) Failure of load bearing plant and technology for operations or
equipment, e.g. jacks and stands; maintenance, e.g. battery powered
d) Pedestrian interactions with tyre equipment or robot technology for
handlers and other mobile equipment Wheel Assembly removal; and
e) Wheel Assembly pyrolysis explosions, d) On a regular basis, at least annually.
caused by hot work with tyres still
mounted, mobile equipment fires, tyre 11.2 Rules and Procedures
operating parameter exceedances, 11.2.1 The rules and procedures for tyre
contact with power lines or struck maintenance equipment and components
by lightning; must include requirements for:
f) Tyre Bursts*, e.g. side wall Zipper Failure*;
a) Finding and applying reference
g) Loss of a Wheel* from operating mobile resources for:
equipment; and
1. Operating tyre pressures;
h) Occupational illness or chronic
injury exposures for tyre service and 2. A
 ssessing acceptable tyre wear
maintenance personnel. and damage while in service;
3. M
 anufacturer (OEM)
11.1.2 A Tyre and Rim Management Plan must be
recommendations for Wheel
developed, implemented and maintained
Assembly and wheel nut torque
that addresses the identified risks, and
settings; and
meets or exceeds regulatory and legal
obligations for tyre and Rim management. 4. W
 heel Assembly component
tolerances, e.g. lock rings.
11.1.3 The Plan must include or reference the
b) Inspection and technology checks of
processes and controls that prevent or
equipment and plant, based on OEM
mitigate risks including:
advice and operating site requirements;
a) Site rules and procedures;
c) Pre use tool and plant checks;
b) Tyre and Rim Management service
d) Using specialist tools, plant and
provider rules and procedures;
equipment, e.g. jacks, stands, jacking
c) Manufacturer (OEM) tool, plant and plates, bead breakers, nut runners, tyre
equipment guidance; and presses, compressors, tyre handlers,
d) Recognised standards. torquing tools etc.

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11 Tyre and Rim Management

11.2.2 The rules and procedures for tyre

maintenance work processes must include
requirements for: that must be mounted to the hub of
mobile equipment before inflating to
a) Loading, unloading and transporting
operating pressure;
tyres and Rims;
b) Shifting and storing tyres, Rims, 4. T
 he position of mobile equipment
components and Wheel Assemblies during inflation to operating pressure,
including site location, stacking height, e.g. behind a blast barrier;
and anti-roll storage; 5. R
 emote monitoring from outside
c) Wheel Assembly tasks covering: the line of fire during inflation to
operating pressure;
1. Personal protective equipment
requirements by task step; 6. N
 ever inflating a tyre being clamped
by a tyre handler as this can result in
2. C
 leaning, identifying and
structural failure of the clamp.
matching components;
e) Safe inflation for Wheel Assemblies
3. Inspecting and identifying
with 24-inch or less Rims covering:
components for damage,
e.g. corrosion pitting, wear, 1. U
 sing a designed, rated and correctly
deformations and cracks; installed tyre inflation cage;

4. Identifying defects on new, 2. M

 onitoring inflation from outside the
used and repaired tyres such as line of fire using a long air hose fitted
perishing, de-lamination inside or with a dump valve capable of rapidly
outside, wavy tyre walls, and sidewall deflating the tyre;
damage to Casings* that may lead 3. C
 arrying out site approved integrity
to Zipper Failures. tests for potential Zipper Failures;
5. Labelling and isolating rejected 4. R
 e-inspecting Wheel Assemblies for
components; defects before removal from inflation
6. C
 onfirming that multipiece cage, e.g. tyre bulges, inadequate
wheels are correctly assembled seating, incorrect component
before inflating. assembly, etc.

d) Safe inflation covering: f) Deflating tyres before releasing tension

on the Rim fastenings for split Rims,
1. Staged inflation to handling pressure
divided Wheels and multi-piece Rims:
with multiple lock ring seating checks;
1. D
 eflate to zero for demountable
2. S
 afe handling, transport and storage
Wheel Assemblies that are secured
pressures based on Wheel Assembly
by cleats;
type, e.g. single piece Wheels and
Wheel Assemblies with 24-inch or 2. N
 ominated handling pressure
less rims are usually stored at (typically 35 kPa or 5 psi) for Wheel
operating pressure; Assemblies with discs secured by
wheel bolts;
3. Identifying Wheel Assembly types

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11 Tyre and Rim Management

3. N
 ever deflate a tyre being clamped
by a tyre handler as this can cause
a loss of grip. tyres, tyre or Rim damage, and loose or
g) Cleaning and inspecting mobile absent fasteners, nuts and wheel studs;
equipment covering: b) Optimising tyre life;
1. Load or hang up in truck tray; c) Tyre emergency response covering tyre
heating, equipment fires, contact with
2. R
 ocks trapped in dual Wheel
power lines, and lightning strikes:
Assemblies.
1. N
 otifying, parking up and exiting
h) Mounting and unmounting Wheel
equipment with compromised tyres;
Assemblies from mobile equipment;
i) Re-inflating in service tyres that have 2. Q
 uarantine distances of a minimum
lost pressure: of 300 metres for potential Tyre
Pyrolysis* explosions.
1. T
 yres below 70 percent operating
inflation pressure must be deflated, 11.3 Equipment, plant and tools -
demounted, stripped and inspected; specifications and maintenance
2. F
 or dual assembly positions,
11.3.1 As a minimum, the following site
if one tyre is below 70 percent
processes must be in place for specifying,
operating inflation pressure then
selecting, approving and tracking the
the companion Wheel Assembly
operational use of tyres, Rims, and Wheel
must also be deflated, demounted,
Assembly components:
and inspected.
a) Tyre, Rim and component specifications
j) Hot work on Rims or fasteners – the tyre are prepared by knowledgeable and
must be completely removed before experienced people who are familiar
heat is applied; with site production and operating
k) Planning for and carrying out non- environment demands.
routine tyre service and maintenance The specifications must consider:;
tasks, e.g. working unusual Rim sizes or
1. W
 here the mobile equipment will
fitting tyres provided by a new supplier;
be operated (operation type, road
l) Tyre maintenance area management surface and condition, gradient and
and housekeeping; profile, turn radii, and climate);
1. Controlling access to tyre 2. H
 ow the vehicle will be operated (e.g.
maintenance areas; average and maximum speeds, average
2. M
 anaging pedestrians during and maximum wheel load, tonne
tyre handler and other mobile kilometres per hour, weight distribution,
equipment operations. cycle length empty and laden, shift
duration, and number of cycles per shift);
11.2.3 The rules and procedures for mobile
3. M
 anufacturer (OEM)
equipment operators must include
recommendations for Wheel
requirements for:
Assembly components, tyre size
a) Prestart inspections for under inflated
and ratings;

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11 Tyre and Rim Management

4. M
 anufacturer (OEM)
recommendations for non-
destructive testing (NDT) of Rims; and for Rim diameters greater than 57 inches
to reduce maintenance requirements;
5. Specialist mobile equipment
requirements, e.g. use of solid b) Use of tyre chains;
or non-pressurised tyre fill for c) Nitrogen inflation;
elevating equipment. d) Specialised tyre handling modules
b) Tyre, Rim and component specifications for underground equipment to
apply when: minimise manual handling;
1. P
 urchasing new or used tyres, Rims e) Working beyond manufacturer
and Wheel Assembly components; or tyre supplier recommendations
for tyre operating parameters only
2. Inspecting new-to-site rubber tyre
when there is:
mobile equipment, e.g. equipment
hires or contractor equipment; and 1. F
 ormal written approval specifying the
approved conditions of operation; and
3. R
 eturning repaired or reconditioned
tyres to service. 2. P
 ermanent tyre label that identifies
the tyres that have been operated
c) Multipiece Wheel Assembly
beyond standard manufacturer
components are stamped or branded
(OEM) or supplier recommendations.
with a unique serial number and
manufacturing date; 11.4 Monitoring, Servicing
d) Repaired or reconditioned tyres are not and Maintenance
used as steering tyres and repairs must
be inwards facing. 11.4.1 The following processes must be in place
for specifying, selecting and approving
11.3.2 There is an inspection and approval for use tyre service and maintenance
step, carried out by competent and equipment, plant and tools:
experienced personnel, that confirms a) Tyre servicing and maintenance
repaired, reconditioned, NDT tested, or new equipment, plant and tool specifications
to site tyres, Rims, and Wheel Assembly are prepared by knowledgeable and
components meet specifications and are experienced people;
registered, before going into service.
b) Training and instructions on how to use
a) The register tracks and records the equipment, plant and tools provided
the operational and maintenance by the manufacturer or supplier are part
history of site tyres, Rims and Wheel of the specification;
Assembly components. c) Tyre service and maintenance
11.3.3 When required for operating environment specifications for equipment, plant
demands, mobile equipment tyre, Rim and and tools apply when:
component specifications are extended to 1. P
 urchasing new or used equipment,
include: plant and tools;
a) Using double gutter Wheel Assemblies

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11 Tyre and Rim Management

2. T
 ransferring equipment, plant or tools
to site;
3. Hiring equipment, plant or tools; and 11.4.4 There must be site processes to check that
Wheel Assemblies fitted to operating mobile
4. A
 ssessing contractor equipment,
equipment remain fit-for-use and includes:
plant and tools.
a) Pre-use inspections of mobile
11.4.2 There is an approval step, that confirms equipment by operators of;
new to site tyre service and maintenance
1. T
 yre condition;
equipment, plant or tools meet
specifications before going into service. 2. W
 heel Assembly attachment,
As a minimum, this applies to: consider using wheel nut tension
indicators on light vehicles.
a) Jacks and jacking plates
b) Scheduled in-field inspections and
(rated for all types of plant);
servicing of tyres by experienced and
b) Tyre inspection stands
Competent Persons.
(rated and matched to site plant);
c) Work platforms; 11.4.5 The installation of tyre pressure and
d) Tyre handlers confirming they are: temperature sensor systems that measure
and log tyre operation trends and issues
1. Fitted with fall back arrest arms;
must be considered. When used they should
2. Relief valves in tyre handler arms. be supported by:
e) Truck mounted tyre handlers; a) Information and Training on expected
f) Fitting tools, including hydraulic presses, operator response if there are local alerts
soft hammers, levers, etc. and alarms;
g) Inflation and deflation tools and b) Remote monitoring.
equipment including, PPE, connections,
gauges, remote fill points, deflation
noise suppressors, and dump valves;
h) Torque and torsion devices such as
pneumatic percussive spanners and
torsion wrenches;
i) Inflation cages for Wheel Assemblies
with Rim diameters up to 24 inches;
j) Inflation compressors, nitrogen sources,
air valves, lines and fittings.

11.4.3 There must be a site process to confirm

that fit-for-purpose tools, plant and
equipment are available for tyre service
and maintenance personnel, before they
commence their work;

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11 Tyre and Rim Management

11.5 Establishing a Safe Operating

Environment
11.5.3 Equipment duty cycles are established
11.5.1 Knowledgeable and experienced and managed within safe tyre operating
people approve the location, design parameters, e.g. tyre load speed rating as
and construction of permanent site tyre Tonne Kilometre Per Hour (TKPH)*;
maintenance areas that include:
11.5.4 Changes in operating conditions affecting
a) A level concrete slab that:
tyre integrity are identified and managed.
1. C
 an fit the largest item of mobile
equipment operating at site;
11.6 I nterfaces during Tyre Servicing
2. H
 as adequate foundations for 11.6.1 The following processes must be in place
maximum point loading during to the manage interactions between tyre
jacking and using safety stands; service and maintenance personnel and
mobile equipment:
3. Has suitable drainage.
a) Supervision, Training and procedures
b) A general layout that:
for all tasks that require personnel on the
1. Allows efficient access control; ground to work alongside a tyre handler,
2. M
 inimises mobile equipment forklift or truck crane;
interactions; b) A traffic Management Plan for the tyre
service and maintenance area that
3. C
 onsiders line of fire for catastrophic
includes:
wheel disassembly;
1. S
 egregated or dedicated walkways for
4. Provides adequate parking for tyre
pedestrians protected by windrows,
handler, mobile equipment, service
bunds or other physical barriers;
trucks, and light vehicles; and
2. A
 ccess control and the delineation
5. P
 rovides adequate laydown, storage
of no-go and danger zones for
and parts staging areas for tyres and
pedestrians;
Wheel Assembly components.
c) Suitable lighting for: 3. D
 emarcated zones used during
inflation and deflation.
1. Inspection and assembly areas; and
c) Procedures and Training on how to
2. Other work and storage areas. service or repair mobile equipment tyres
d) Adequate ventilation requirements for in production areas that include:
inflating or deflating nitrogen filled tyres
1. P
 arking equipment away from traffic,
when required.
people, and other hazards with a clear
11.5.2 Road networks are designed and area to perform the task;
maintained, including loading and dumping 2. Area lighting for the task;
areas to minimise acute tyre damage;
3. D
 emarcation and ongoing
communications with operations;

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11 Tyre and Rim Management

4. C
 onfirming that the surface under a
vehicle can support the load without
subsidence. 11.7.3 Training for personnel who routinely
access Operational Areas* that includes:
11.7 T
 raining and Competency
a) Awareness of catastrophic wheel
11.7.1 Tyre service and maintenance personnel, disassembly and Tyre Explosion line
mobile equipment operators, maintenance of fire;
and logistics personnel must be trained, b) Expected bystander emergency
competent and authorised. A Training Plan response, notify, do not approach,
must be developed and include: retreat 300 metres when rubber
a) Criteria for selecting and appointing tyre mobile equipment:
tyre service and maintenance 1. Is on fire and the operator
personnel, mobile equipment operators, has evacuated;
maintenance and logistics personnel;
2. H
 as contacted power lines; and
b) Tyre, Rim and Wheel Assembly hazard
management Training needs analysis 3. May have been struck by lightning.
based on work role for: 11.7.4 Training is competency assessed
1. P
 ersonnel who carry out tyre servicing and records are kept.
and maintenance activities;
11.7.5 There is an authorisation, appointment
2. Mobile equipment operators;
or licensing step, before trained and
3. Mobile equipment maintainers competent tyre fitters carry out servicing
and other maintenance staff, or maintenance work that is not
e.g. boiler makers; directly supervised.
4. Logistics personnel.
11.7.6 Only trained, competent and Authorised
c) Training content prepared by competent Personnel* can carry out tyre servicing
and experienced personnel based on: and maintenance tasks.
1. Site rules and procedures;
11.7.7 All other personnel working in or visiting
2. T
 yre, Rim and Wheel Assembly
tyre maintenance and storage areas
supplier and manufacturer guidance;
are supervised.
3. Manufacturer (OEM) guidance for the
safe and productive use of tools, plant 11.7.8 There is a periodic review of awareness
and equipment used for servicing and information, competency requirements,
maintaining tyres; and Training needs, Training content
and approaches.
4. Recognised standards.

11.7.2 All personnel, employees, contractors, 11.8 Requirements – Wheel Assembly

and visitors receive awareness information Design and Rim Diameter
or Training relevant to their work role.
11.8.1 For mobile equipment with up to and

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11 Tyre and Rim Management

greater than sixty-one (61) centimetres

(24 inches) diameter Rims, all
requirements apply. and authorised (see 11.7 Training and
Competency);
11.8.2 Where the Rims in use are all sixty-one
j) Inspection, integrity checks and
(61) centimetres (24 inches) in diameter
service approaches for Zipper Failures
or less then at least these protocol
(11.1.1 f, 11.2.2 c-4, 11.2.2 e-3 and e-4, and
requirements apply:
Definitions).
a) The rules and procedures for tyre
maintenance equipment and 11.9 A
 dditional Requirements for
components must include requirements Catastrophic Risk (PMC 5) Situations
for finding and applying reference
11.9.1 Wherever there is a potential for a
resources (see 11.2.1 a-1, a-2, a-3, a-4);
catastrophic incident related to tyre and
b) Rules and procedures for tyre Rim management, e.g. location of tyre
maintenance work processes must maintenance area, tyre failures on buses
include requirements for loading and etc. the following requirements apply:
unloading (see 11.2.2 a) and shifting a) A risk assessment must be conducted
and storing (see 11.2.2 b); to identify specific hazards and their
c) Rules and procedures tyre maintenance controls; and
work processes must include b) Critical controls must be identified, and
requirements for Wheel Assembly tasks monitoring and verification processes
(see 11.2.2 c-1, c-2, c-3, c-4, c-5, c-6); must be implemented as per Glencore’s
d) Safe inflation for Wheel Assemblies with Catastrophic and Fatal Hazard
24-inch or less Rims (see 11.2.2 e-1, e-2, e-3, management Policy.
e-4);
e) The use of a designed and certified
inflation cage (see 11.2.2. e-1 and 11.4.2 i);
f) Deflating tyres before releasing tension
on the rim fastenings for split Rims,
divided Wheels and multi-piece Rims
(see 11.2.2 f and 11.8 Definitions);
g) No hot work on Rims unless tyres have
been removed; (see 11.1.1 e and 11.2.2 j); TOOLS (SEE GLENCORE HSEC INTRANET)
h) Some 24 inch or less Wheel Assemblies
can be handled, transported and stored Tools provided include:
at the cold operating pressure (see 11.2.2 FHP Self-Assessment Workbook, and,
d-2);
FHP Third Party Audit Workbook
i) Tyre service and maintenance 11 – Tyre and Rim Management, and
personnel, mobile equipment FHP Third Party Audit Workbook 11 – Tyre
operators, maintenance and logistics and Rim Management for off-site Supplier.
personnel must be trained, competent

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12

Inrush and
Outburst
VERSION: 2-0
EFFECTIVE DATE: 15/10/2020
89 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

12 Inrush and Outburst

Intent
The intent of this protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents
arising from risks associated with an Inrush of water,
gases or materials which flow when wet either in a
surface or underground mine and/or risk associated
with an Outburst*, rock or Coalburst* event in an
underground mine.

Related Life-Saving Behaviours

2. Always use or wear critical safety equipment.

6. Never modify or over-ride critical safety equipment

without approval.

8. Never enter danger zones without approval.

KEY ACTIONS
Conduct a risk assessment to identify potential
Inrush, Outburst*, Coalburst or Rockburst* risks
and determine controls.

Develop an Inrush*, Outburst, Coalburst or

Rockburst Management Plan as applicable.

Develop and implement procedures and

actions for first response and triggers for
withdrawal to a place of safety and
emergency response.

Establish and implement monitoring and

analysis systems for identifying potential
sources or conditions for Inrush, Outburst,
Coalburst or Rockburst.

Implement protocols and approval processes

(Permit to Mine*) for mining within identified
Inrush, Outburst, Coalburst or Rockburst
potential zones.

Apply mining design and methods that

Establish provisions for maintaining knowledge
mitigate the severity of and isolate or protect
of Outburst, Coalburst and Rockburst
people from potential Inrush, Outburst,
mechanisms, prevention and protection.
Coalburst or Rockburst situations.

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12 Inrush and Outburst

12.1 Inrush requirements

12.1.1 An Inrush risk assessment must be regulators and the potential for Inrush
conducted and documented to identify material to inundate or impact adjacent
potential Inrush sources. Issue specific risk working areas;
assessments must also be conducted for f) Trigger Action Response Plans (TARP)
each of the potential Inrush sources that give that define risk-based responses to
regard to the accuracy of the plans of the manage or react to changes of Inrush
mine, future mining operations, geological indicators;
conditions and potential changes.
g) Annual review of the Inrush
12.1.2 An Inrush Management Plan* must be Management Plan and associated
developed, implemented and maintained Inrush control zones and location
and include: plans; or review prior to the mine being
a) Review and verification of original extended into any new area;
and updated plans and other records h) Reference to the Permit to Mine process;
(including those held by statutory i) Associated emergency response
authorities) for accuracy and to identify provisions and procedures.
any potential Inrush sources that may
exist either adjacent to, or in the near
12.1.3 Inrush control zones (i.e. stand-off distances
or solid barriers) must be established and
vicinity of the mine workings, e.g.
maintained between mine workings and
current, proposed or disused mine
each potential Inrush source.
workings, surface waters, stockpiles,
tailings dams, reclaim tunnels or 12.1.4 Mine plans, and/or, Inrush Control Zone
aquifers, etc.; Plans must show the nature and thickness
b) Detailed literature reviews that identify of the separating barrier, as well as the
and evaluate all past information related presence of any faults, dykes, intersecting
to the potential of an Inrush risk for all boreholes in the Inrush control zone.
new mine projects or the acquisition of
an existing mine; 12.1.5 Man-made barriers (e.g. bulk head or dam
c) Where appropriate, a technical walls) that are installed to contain an Inrush
assessment by a competent professional source are designed, constructed and
to determine the nature and magnitude maintained to an approved/recognised
of potential Inrush sources and a record engineering standard and include
of assumptions and engineering consideration of the competence and
calculations; interface with the surrounding parent
material.
d) Identification and provision of Inrush
control zones (width as prescribed or by 12.1.6 Processes and systems for the monitoring
engineering design) between potential of potential Inrush sources including
Inrush sources and mine workings; water pressure, volume, gas content and
e) Evaluation of the impact of an Inrush composition (as relevant) must be in place
event on seals, stoppings and/or when an Inrush potential exists.

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12 Inrush and Outburst

12.1.7 Abandoned or disused surface to seam/

orebody boreholes must be fully sealed and
locations recorded on a plan. 12.2.2 An Outburst and Coalburst risk assessment
must be conducted and documented
12.1.8 Operational surface to seam boreholes/ to identify the potential for Outburst or
orebody in areas that could flood, must have Coalburst in an underground coal mine
provisions for monitoring and temporary and give regard to the accuracy of the plans
sealing. of the mine, future mining operations,
experiences at adjacent mines and
12.1.9 Mines must assess the potential risk
geological and gas related conditions.
of Inrush from adjacent workings and
implement appropriate controls. 12.2.3 Where an Outburst or Coalburst risk
has been identified an Outburst and/
12.1.10 If mining is to occur within an Inrush control
or Coalburst Management Plan must be
zone:
developed, implemented and maintained
a) An engineering design, risk assessment,
and include:
justification and Permit to Mine must
be approved prior to mining within an a) Identification of geological conditions
established Inrush control zone (within and indicators of potential Outburst or
a prescribed solid barrier) and outline Coalburst;
the sequence of operation, survey b) Pre-drilling and coring to identify the
controls, inspections and any other gas content, composition, pressures and
controls to be applied; desorption characteristics of the coal;
b) In-seam drilling, with sufficient drill hole c) Provision of gas drainage to minimise
coverage or overlap, in advance of the the risk of an Outburst or Coalburst;
mining direction must be implemented d) Development of TARPs that define risk-
so that mine workings do not based responses to manage or react to
inadvertently intersect an Inrush source; changes of Outburst indicators;
c) When working within an Inrush e) Requirement that no mining can occur
control zone, affected personnel must in an Outburst or Coalburst prone area
be informed of the hazards, risks and without approval under a Permit to Mine
controls; and copies of relevant plans process;
and permits must be provided. f) Requirement that gas concentration
12.2 O
 utburst and Coalburst levels must be at a pre-determined
acceptable level before a Permit to Mine
requirements
and approval to mine can be issued;
(underground coal mines)
g) Procedures that detail mining
12.2.1 As knowledge of the mechanisms that sequences, manning levels gas
cause Outbursts and Coalburst is still monitoring requirements and other
evolving to some extent, mines should health and safety precautions that
maintain a process of currency with the must be followed; and
development of industry expertise. h) Emergency response provisions and
procedures.

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12 Inrush and Outburst

12.2.4 The minimisation of risk of Outburst and

Coalburst should follow the principles of:
a) Prediction – consideration of history b) Development of TARPs that define risk-
and recording of seismic activity, stress based response to manage or react to
monitoring, geological and geotechnical changes of Rockburst indicators;
factors, gas reservoir mapping, c) Requirement that no mining can occur
monitoring, observation, mining in a Rockburst prone area without
method, mine design and mine layout; approval under a Permit to Mine process;
b) Prevention – gas drainage, changes to d) Procedures that detail mining
mine layout and geometry of pillars sequences, manning levels and other
and roadways, de-stressing, operational health and safety precautions that must
controls such as mining rate or cutting be followed; and
sequence; and e) Emergency response provisions and
c) Protection – physical barriers between procedures.
the face and operators, automation, safe
12.3.4 Sound engineering design principles must
standing zones, provision of rescue, first
be applied to the development of mine
aid and evacuation equipment.
workings, ground support and ground
12.3 R ockburst requirements monitoring provisions in Rockburst prone
(underground metalliferous mines) areas.

12.3.1 As knowledge of the mechanisms that 12.3.5 The minimisation of risk of Rockbursts
cause Rockbursts is still evolving to some should follow the principles of:
extent, mines should maintain a process a) Prediction – consideration of history
of currency with the development of and recording of seismic activity,
industry expertise. geological and geotechnical factors,
stress monitoring, observation, mining
12.3.2 A Rockburst risk assessment must be
method, mine design and mine layout;
conducted and documented to identify
the potential for Rockburst in deep b) Prevention – changes to mine layout
underground metalliferous mines and give and geometry of pillars and roadways,
regard to the accuracy of the plans of the de-stressing, operational controls such
mine, future mining operations, experiences as mining rate or cutting sequence;
at adjacent mines and geological conditions. exclusion strategies and remotely
operated equipment; and
12.3.3 Where a Rockburst risk has been identified c) Protection – physical barriers between
a Rockburst Management Plan must be the face and operators, burst-prone
developed, implemented and maintained support, automation, safe standing
and include: zones, provision of rescue, first aid
a) Identification of geological conditions and evacuation equipment.
and indicators of potential Rockburst;

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12 Inrush and Outburst

12.4 Additional requirements for

catastrophic (PMC 5) situations
12.4.1 No further requirements applicable.
12.5 T
 raining and competence
12.5.1 Identification of Training needs and
competence requirements of relevant
employees and contractors in relation to
Inrush, Outburst, Coalburst or Rockburst
and the provision of adequate Training and
assessment to verify competency.

12.5.2 Regular attendance and participation by

mine and sector specialists at industry
related symposia and workshops, related
to the development of Outburst, Coalburst
and Rockburst knowledge and technology.

TOOLS (SEE GLENCORE HSEC INTRANET)

Tools provided include:

FHP Self-Assessment Workbook, and,

FHP Third Party Audit Workbook

12 – Inrush and Outburst.

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13

Molten
Material
VERSION: 2-0
EFFECTIVE DATE: 20/08/2020
95 FATAL HAZARD PROTOCOLS AND LIFE SAVING BEHAVIOURS

13 Molten Material

Intent
The intent of this Protocol is to eliminate or minimise
the potential for fatalities, injuries and incidents
arising from risks associated with the processing
or handling of molten material inclusive of tapping,
transportation and smelting operations.

Related Life-Saving Behaviours

2. Always use or wear critical safety equipment.
6. Never modify or override critical safety
equipment without approval.

8. Never enter danger zones without approval.

KEY ACTIONS
Review all the requirements of this protocol.

I dentify the requirements that are applicable

to your molten material handling and
processing facilities.

 or each applicable requirement, identify the

F
related business and operational processes as
well as the expected outcomes.

 onfirm that the processes and outcomes

C
meet business needs and comply with the
requirements of this protocol.

Assign accountabilities for maintaining and,

if necessary, improving these processes.

 onitor the processes to ensure they

M
continually produce the required outcomes.

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13 Molten Material

13.1 Design
13.1.1 The design specifications of new or 13.2.2 Water supplies to handling and processing
modified facilities must be the object of a facilities must be dedicated systems (e.g.
risk assessment and the hierarchy of controls jacket cooling) and, where possible, access
should be applied with administrative to water tapping points must be restricted
controls considered as last resort. or eliminated. Water system should be
monitored to identify leakages.
13.1.2 The design of molten material facilities
must be subject to formal and periodic 13.2.3 Processing and handling areas must
reviews using recognised risk assessment be designed to contain any spillage that
techniques (e.g. hazard and operability may occur and to allow safe clean up
study - HAZOP). The outcomes of these and disposal.
reviews together with recommendations
must be documented and communicated 13.2.4 All surfaces that contact molten
as appropriate: material must be coated, prepared
or be of a composition that prevents
13.1.3 Inrush control zones (i.e. stand-off distances
exothermic reactions.
or solid barriers) must be established and
maintained between mine workings and 13.2.5 Barriers, safeguards and signage
each potential Inrush source. must be installed to prevent personnel
a) Use of appropriate construction getting into contact with molten material
materials; and hot surfaces.
b) Bypass systems;
13.2.6 To prevent explosions, contamination
c) Containment areas; or other harmful reactions, procedures
d) Refuge stations; must be established and maintained to:
e) Monitoring systems and equipment; a) Receive, segregate and store
f) Alarms and early warning systems; charge materials;
g) Firefighting systems; and b) Assess charge materials adequacy
h) Water management systems. and/or quality and identify inappropriate
and/or wet charge materials;
13.1.4 Molten material handling and
c) Feed the furnaces; and
processing equipment must be
designed to “fail-to-safe” in the event d) Dry and remove water remnants
of power failures and interruptions. from pots and ladles.

13.2.7 Programmed maintenance systems

13.2 Handling and Processing
for handling and processing equipment
13.2.1 Only Authorised Personnel* should be and facilities must be developed,
allowed in handling and processing areas implemented and maintained.
and access to these must be monitored and
controlled. Where possible, a well-defined 13.2.8 Monitoring systems must be maintained to
process must be used to monitor and ensure that operating status and conditions
control access. are known at all times.

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13 Molten Material
13.2.9 All processing and handling activities
must be subject to a risk assessment.
processing areas. Where this is not possible,
13.2.10 Management of change must specifically sufficient protection measures must
address the implications for the processing be implemented to keep personnel safe
and handling of molten material. in the event of an emergency.

13.2.11 Changes and/or modifications to facility 13.4 C

 ritical Equipment
structures, plant, equipment and materials,
and associated protective systems must 13.4.1 Critical components and their
be subject to formal management of maintenance needs must be clearly defined
change processes. and documented.

13.2.12 The safe operating parameters for 13.4.2 Remote and automatic systems to shut
molten materials processing and handling down plants must be in place to avoid
must be defined by Competent Persons operators’ exposure to harmful substances
and understood by all relevant personnel. or other risks that may exist in the
Physical and system indicators as well processing area.
as limit values for safe operation must
13.4.3 Dedicated and clearly demarcated roads
be established and communicated
and rail systems must be used to transport
as appropriate.
molten material.
13.2.13 Accurate and up-to-date drawings
13.4.4 Tapping and casting processes must be
of handling and processing facilities
remotely controlled and operated. When
must be kept and be accessible to all
this is not feasible, a risk assessment must be
relevant personnel.
carried out to define appropriate operating
13.2.14 Handling and processing facilities conditions, practices and measures to
must be equipped with ventilation, control risk.
fume extraction and emergency venting
systems to reduce personnel exposure
13.5 P
 rocedures
to dust, fumes and gases. 13.5.1 Procedures must be developed and
maintained for all molten material
13.3 Emergency Response processing, handling and disposal activities
13.3.1 Emergency response plans must be and/or operations. They should cover:
maintained and an annual simulation a) Response to loss of containment;
exercise conducted. b) Safeguarding mobile equipment;

13.3.2 Emergency response facilities must include c) Tapping molten material from furnaces;
specialised first-aid and pre-hospitalisation d) Cooling and use of water;
trauma care equipment. e) Specification and provision of personal
protective equipment (PPE);
13.3.3 There must be at least two separate
f) Control of charge material;
emergency exit points in all molten material

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13 Molten Material
g) Defining competency standards and 13.6 R
 esponsibilities and Training
skill requirements;
h) Transfer of molten material;
13.6.1 Competency standards and responsibilities
for relevant roles (employees and
i) Storage and preheating of charge
contractors) must be defined, documented
material and tools;
and assigned.
j) Operation of casting machines;
k) Operation and maintenance of launders; 13.6.2 A competency-based Training and
l) Operation and maintenance of molten assessment programme including clear
material ladles; learning outcomes must be developed,
maintained and implemented. Before being
m) Operation and maintenance of
involved in or exposed to molten material
granulation facilities;
handling and/or processing, operational
n) Operation and maintenance of disposal
and maintenance personnel must have
sites;
been assessed as being competent.
o) Operation and maintenance of furnaces;
p) Use of liquid and gaseous fuels and 13.6.3 Refresher Training and/or an awareness
furnaces and ladles; programme on the risks associated with
molten material handling and processing
q) Repairs on an operating furnace;
and their management should be
r) Housekeeping;
provided for.
s) Emergency isolation of services;
t) Blasting in an operating furnace; 13.6.4 Everyone (employees and contractors)
u) Operation of overhead cranes; must follow Training on emergencies and
be capable of responding and fulfilling their
v) Response to a power failure event; and
responsibilities competently in the case
w) Firing-up and shutting-down furnaces.
of an emergency.
13.5.2 Where the systems used to transport
13.6.5 The above programmes together with the
molten material are shared with other
competency standards, leaning outcomes
activities, the risks (e.g. collision and spillage)
and Training needs must be reviewed on a
must be assessed and controls established.
periodic basis and updated as necessary.
13.5.3 A formal communication process
13.6.6 To ensure PPE provides the best possible
(e.g. GCOM) must be used to share
protection, they must be selected by
and pass relevant technical and safety
ways of a risk-based approach and their
related information, including changes
maintenance and use must be managed.
in operation status, between shifts.
13.6.7 The workplace observation programme
must include operations of molten material
equipment and systems.

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13 Molten Material

13.6.8 All relevant personnel must follow Training TOOLS (SEE GLENCORE HSEC INTRANET)
on the health hazards associated with their
Tools provided include:
work environment.
FHP Self-Assessment Workbook
13.6.9 The asset management team must
maintain a fitness for work policy and a 13 - Molten Material Management, and
programme addressing the use of drug
and alcohol, fatigue and heat stress. Molten Metal Workshop (Best Practice Portal).

13.7 A
 dditional Requirements for
Catastrophic (PMC 5) Situations
13.7.1 Whenever an operation involving
molten material induces a risk exposure
to catastrophic consequences
(i.e. five of more fatalities):
a) An assessment must be conducted
to identify the specific risks and the
associated controls; and
b) Critical controls must be identified
and subject to monitoring and
verification processes.

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Glossary

Action Plan Basic Isolation

A documented plan of actions to achieve a specific An isolation, not involving High Voltage, with no more
goal or goals which details responsible people and than three (3) isolation points and no more than six (6)
completion dates. people in the work crew. As an example, a piece of mobile
plant with a battery isolator, an air valve, and body up
Anchor (ISO 22846-2)
support rope, as their task isolation points, with less than
A fixture or place for the attachment of lines or persons.
six people, would be considered a basic isolation.
Anchor Point (ISO 22846-2) Broad-Brush Risk Assessment
An attachment point at an anchor for anchor lines
(BBRA)/Baseline Risk Assessment
or persons.
A general risk assessment of an area or a process consistent
Anchor System (ISO 14567) with the Glencore Risk Management Framework.
An assembly of multiple anchor devices with one
Casing (in the context of Protocol 11 -
or more PPE attachment points.
Tyre and Rim Management)
Anti-Two-Block Device (not used) Structure and components of a radial ply tyre.
An anti-two-block device is an electrical sensing device
that is installed on a crane to prevent the lower load
Certified Self-rescuer
block or hook assembly from coming into contact with Certified to at least one of the following standards:
the upper load block or boom point sheave assembly. EN 13794, AUS/NZ 1716, SANS 1737/10338, NIOSH.
Consists of a weighted ring around the hose line, the Change Management
ring is suspended on a chain from a limit switch that The process of clearly identifying, assessing and
is attached to the boom tip, and if the hook assembly managing the planned and unplanned changes that
(sometimes referred to as a ‘headache ball’) touches the occur within our activities, operations and facilities.
suspended weighted ring, the switch opens and an alarm
sounds in the cab to warn the operator to stop hoisting. Coalburst
A rapid propulsion of a significant volume of coal from a
Appointed or Authorised Personnel face or rib into the mining area, (caused by a combination
A person authorised in writing by the Manager or their of rock mass strain energy, seismic energy and gas
delegated representative to carry out specific duties, pressure, likely associated with depth) and may results in
such persons being trained and deemed competent for a rapid closure of a roadway.
the purpose of the clauses in which the term is used. An
example is Authorised Isolators and Permit Holders. Competent Person
A person having the appropriate experience, knowledge,
Audit skills and capability.
Third- or second-party formal assessment of a process,
system, activity or other element of the business against Complex Isolation
set criteria such as legal requirements, site procedures or An isolation that has more than three (3) isolations points
these Protocols. or more than six (6) people in the work crew.

Batter
The inclined section of a bench.

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Confined space Designated Hot Work Location (DHWL)

Means an enclosed or partially enclosed space that: A DHWL is a fixed and approved location designed for
• is not designed or intended for human occupancy conducting hot work with a minimal risk of fire, and is
except for the purpose of performing work; clear of all flammable materials and maintained in that
state, e.g. boilermaker’s shop. It includes provision of
• has restricted means of access and egress; and
adequate firefighting equipment.
• may become hazardous to an employee entering
it due to:
Document Control
Formal process for managing documentation, i.e. version
its design, construction, location or atmosphere,
number, review date, owner, approver.
the materials or substances in it, or
Electrical Work
any other conditions relating to it.
Work that includes:
Some examples of confined spaces are: manholes, connecting electricity supply wiring to electrical
sewers, boilers, tunnels, pipelines, wells, fuel tanks, equipment or disconnecting electricity supply wiring
ballast tanks, storage tanks, tank cars and tank trucks, from electrical equipment, or
vats, process vessels, septic tanks, sewage lift stations, installing, removing, adding, testing, replacing,
silos, boots in grain elevators, trenches, and ventilation repairing, altering or maintaining electrical
and exhaust ducts. Although some of these are easily equipment or an electrical installation.
recognized as confined spaces, others may not be.
Energised (or Live)
A confined space does not include a mine shaft or the
Connected to an Energy Source or subject to hazardous
workings of a mine.
induced or capacitive electrical Voltages.
Connector (ISO 10333-5) Energy Absorber (ISO 10333-2)
A device, which is used to assemble a PFAS by enabling Component designed to dissipate the kinetic energy
two other components or subsystems to be physically generated during a fall, and which limits the arresting
connected. A connector has an opening guarded by a forces applied to the personal fall-arrest system, anchor
self-closing gate with a self-locking feature. device and user.
Critical Monitoring Mode Energy Sources
Constant monitoring and analysis of a specific, high Electrical, mechanical, pneumatic, gravity, hydraulic, heat,
consequence hazard to predict failure such that radiation and stored energy such as electrical capacitors,
personnel can be evacuated prior to failure. springs, compressed air/gas and suspended loads.
Defined Risk Area Excavation (underground)
Refers to a location other than underground where the Includes but is not limited to shafts, drifts, raises,
risk is such that similar controls need to be established for headings, drives, cut-throughs, ramps, declines, longwall
the safety of personnel. Where such risk/s are identified panels and all forms of stopes.
within an asset’s risk assessment, the controls are to be
documented and applied.
Fire Watcher
The role of the fire watcher is to continuously monitor
for a fire outbreak and must not be given other duties or
leave the location unless replaced.

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Free-Fall Distance (ISO 14567) Hazardous Hot Work

Total vertical distance through which a Worker could fall Hot work is hazardous if it requires work on or within:
from the start of the fall to the onset of the arrest. 15 metres of flammable liquids, gases, dusts,
Full Body Harness (FHB) (ISO 10333-1) or other flammable or explosive substances;
Component of the body-holding device which connects a Fuel or oil tanks or hydraulic components;
person into a personal fall-arrest system. A chemical, fuel, oil or gas storage area;
The FBH may comprise straps, fittings, buckles or other
A battery charging area;
elements suitably arranged and assembled to support
the body of a person and to restrain the wearer during a An explosive storage area;
fall and after the arrest of a fall. A confined space;
The FBH may incorporate other fittings which permit its
Exposed drill patterns; and
connection into other types of safety systems such as a
work-positioning system. Areas determined by risk assessment
to be hazardous in nature.
Ground Control
A generic term relating to the application of all forms of High Voltage Access Permit
rock mechanics, strata control, geotechnical engineering A formal documented process used for High
and support design that may be or would ordinarily be Voltage Isolations where persons may be exposed
expected to be carried out in the mine whether it be to bare conductors.
surface or underground, coal or metalliferous.
Hot Ground (Elevated Temperature)
Stability (in the context of Protocol 5 - Material that is above 55oC.
Ground/Strata Failure)
Refers to the stability of ground including in-situ Hot Work
strata, bedrock, weathered material, soil, embankments, Any work that involves burning; welding, cutting, brazing,
benches, highwalls, low walls, dumps, stockpiles flame soldering or grinding of metals; using fire- or spark-
and trenches. producing tools, or other work that produces a source
of ignition.
Group Isolation Permit
A formal documented process used for isolation when: Incident Energy
A measure of thermal energy at a working distance
The individuals doing the work are not confident
from an arc fault. The unit of incident energy is cal/cm2.
that they can competently carry out the isolation as
an Individual Isolation; or
Indirect Contact
It has been decided that the risks and/or complexity Contact with a conductive part that is not normally live
involved in the work make it necessary to use a but has become live under fault conditions.
Group Isolation Permit; or
The work does not involve High Voltage (if it does, it Ingress Protection (IP) classification
is called High Voltage Isolation and requires a High A degree of ingress protection in accordance with
Voltage Access Permit). international standards.

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IP2X Lanyard (ISO 10333-2)

A 12.5mm diameter object or finger size should not be Finished length of flexible material, which in conjunction
able to gain access to exposed live conductors without with an energy absorber is used as a connecting
one of the following conditions being met: subsystem in personal fall-arrest system.
The use of a key or tool is required to access the Lock ring
enclosure; or Part of a Wheel or Rim which retains the components
The door is interlocked with the power supply to when a tyre is mounted to the Wheel/Rim Base.
prevent the door from being opened whilst the
Lifeline
power supply is ON; or
A rope or other material attached to a harness and of
There is a secondary barrier or cover fitted internally sufficient length used to recover an unresponsive person
to cover any exposed conductors and prevent a to safety, from a position of safety
person from inadvertently coming into contact.
Live Electrical Work
Inrush Electrical work while the circuit is energised above Extra
Rapid ingress of water, gases or materials which Low Voltage.
flow when wet either into a surface or underground
Live Testing
mine workings.
(in the context of electrical safety)
Integrity testing of wheel assemblies A last resort process where it cannot be done any
- up to sixty-one (61) centimetres other way, using both approved test instruments
(24 inches) diameter rims and test methods to measure Voltage or current values,
as an example, without isolating the supply and
Inflation in a suitable tyre inflation cage to a pressure
maintaining a distance outside the “near” zone.
of 120% of the tyre’s recommended minimum cold
operational inflation pressure and left for 20 minutes It would not be considered to be Live Testing when:
to confirm tyre integrity. Post integrity testing the tyre The power supply is isolated to allow test probes to
is reduced to its recommended cold operating be attached at the test point, the person conducting
pressure for storage or fitting. the test stands clear, i.e. outside the “near zone”
where conductors are not IP2X rated, and the power
Isolated is restored to allow the values to be observed; or
Disconnected from all possible sources energy supply
Tong type instruments (ammeters) or induced
and rendered incapable of being energised without
Voltage detectors, are being used, where the
premeditated and deliberate action.
terminations are rated IP2X or outside the near zone,
Isolation Point from any exposed live conductors; or

A point that has been identified as the lockable isolator Testing for zero energy, i.e. using an approved Testing
for an identified Energy Source for a specific piece of method to verify an isolation has been effective.
plant or equipment. There is to be NO Live High Voltage Testing undertaken
at all, i.e. using handheld probes to test for a Voltage
Jewellery source. (This excludes permitted “phasing” where Safe
Miscellaneous items used to attach the dragline bucket Work Procedures have been developed using approved
to the hoist ropes. test equipment)

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Management Plan Operations Engineering

Formal process for management of a particular Management Plan
activity, task or are of the business which articulates Formal process for management of engineering
management activities and roles and responsibilities. practices, in particular as it relates to design, install,
commission, use, maintenance and decommissioning.
Mobile Elevating Work Platform
- MEWP (ISO 16368) Outburst
Machine/device intended for moving persons, tools A rapid ejection of a significant volume of (often
and material to working positions, consisting of at least pulverised) coal from a coal face or rib into the mining
a work platform with controls, an extending structure area, (caused by a combination of gas content,
and a chassis. composition and gas pressure).

Permit System
Mobile Equipment
Formal system required for specific tasks or activities,
Includes all self-propelled tyred, tracked equipment
i.e. working in confined space, Working at Heights, hot
including light and heavy vehicles (trucks excavators,
work etc., whereby a permit has to be issued prior to
loaders, draglines, graders, dozers etc.), ancillary
commencing work.
equipment (forklifts, scissor lifts, elevated work platforms,
tyre handlers, etc.), and trains/locomotives Permit to Mine [May be referred
to as Authority to Mine (ATM)]
Molten Material
Formal system and approval process required for
Metal or slag in a liquid state.
mining to be allowed to take place in an area, whereby
Monitoring Program a permit has to be issued through a formalised process
Agreed program to regularly monitoring and measure incorporating multi-disciplinary sign off, to mine workers
the effectiveness of specific aspects of controls, and supervisors prior to commencing mining activities.
procedures and Management Plans.
Personal Fall-Arrest System – PFAS
Near (in context of Live Testing) (ISO 10333-2)
Proximity to exposed energized conductors where there Assembly of interconnected components and
is a possibility of either of the following coming within subsystems, including a FBH worn by the user, that
500mm of the energized exposed conductors above when connected to a suitable anchor device will arrest
Extra Low Voltage. a fall from a height.
A person’s body.
A PFAS minimises the fall-arrest forces, controls the total
Any object which a person may be carrying or
fall distance so as to prevent collision with the ground or
touching during the course of the work, that is not
other relevant obstruction, and maintains the user in a
designed for use on energized conductors operating
suitable post-fall arrest attitude for rescue purposes.
at that Voltage.

Operational Areas Place of Safety

Any areas where production activities are undertaken. An approved location where a source uncontaminated
air is available such as a refuge bay, refuge tent or other
guaranteed source of fresh air. The place must also offer
protection from environmental factors such as fall of
ground, flooding or extremes of temperature for the
expected maximum duration necessary.

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Positive Communication Rim

Includes the active communication between both mobile The outer circular part of a Wheel or a rim where
equipment operators and/or pedestrians where the caller the tyre is fitted. Rims can be either single-piece or
and receiver identify one another, their intentions and multi-piece. The part of the tyre assembly that uses
clearly respond. a taper seat arrangement to affix to the Wheel
motor or hub of an earthmoving machine.
Primary Isolation
An isolation where only approved “whole of energy” Rim Base
type isolators are used for isolation purposes, i.e. circuit Part of the Rim that is attached to the hub.
breakers, isolators, battery isolators, valves, visible break
devices. These are known as the main isolation point to Risk of Exposure
remove the necessary energy from plant and equipment. The measure of potential future loss resulting
Procedure from a specific activity or event.

Documented process detailing the requirements for

Rockburst
conducting an activity or task.
A rapid propulsion of a significant volume of rock
Reactive Ground or rapid closure of a drive caused by a combination
Ground that undergoes a spontaneous exothermic of rock mass strain energy or seismic energy, likely
reaction after it comes into contact with nitrates. The associated with depth.
reaction of concern involves the chemical oxidation
of sulphides (usually of iron or copper) by nitrates and Scaffold (ISO 6707-1)
the liberation of potentially large amounts of heat. The A temporary structure that provides access for
process is unpredictable and can be so violent that it operatives to construction works and support
results in premature or unplanned initiation of explosives. for materials and equipment.

Residual Current Device (RCD) Self-Assessment

May also be called Ground Fault Detection, Earth Leakage Internal formal assessment of a process, system, activity
Circuit Breaker (ELCB) or other element of the business against set criteria such
A device intended to isolate supply to protected circuits, as legal requirements, site procedures or these Protocols.
socket-outlets or electrical equipment in the event of a
current flow to earth, which exceeds a pre-determined
Shotfirer (or Blaster in Charge)
value. The RCD may be fixed or portable. Person with Training, competency, security clearance and
formal qualification for charging and initiating explosives;
Rigger/Dogman and who has the control over a specific blast.
A Rigger is a person that specialises in the lifting
or moving of extremely large or heavy objects, and
Significant Change
a Dogman is a person who directs the operation (Change management)
of a crane. A decision, change or event is significant if it could
potentially have a material impact on the achievement
of objectives. Where a change is proposed, an initial
review should be conducted to determine if the full
change management process should apply.

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Significant Changes to a Mine Plan, Slope Stability

Design or Sequence Relates to the Stability of material on a stockpile
Items to be considered in this category include: and/or dump.
Any change to the design of systematic
ground support;
Surface Operations
Changes to the underground Excavation Includes all surface areas relating to all activities
(see above definition) span or dimension (Surface Mines, Process Plants, Warehouses or Ports).
that can impact on Excavation stability; Excludes underground locations
Changes to the dimensions of a production
Excavation (for example, longwall panel, stope Testing (in the context of electrical
or surface mining strip); safety, also see Live Testing)
Any over steepening of a slope that reduces the The application of test instruments to terminals whilst
2D limit of equilibrium Factor of Safety below 1.2; they are energised above Extra Low Voltage.
Changes to an overall slope angle or an inter-ramp
angle or slope geometry; and
Tonne Kilometre Per Hour (TKPH)
Changes to the designed mining and support The load speed rating of a tyre, which helps determine
sequences or processes. the tyre’s suitability for an operation, is measured as tonne
kilometre per hour (TKPH). As tyres flex during rotation,
Single Piece Wheel heat builds up within the tyre. The rate of heat build-up
A Wheel Assembly that does not have components depends on the load on the tyre, average haul speed,
that can be dismantled - used in motor cars and some ambient temperature and distances travelled. Based on
light trucks. the tyre’s ability to withstand the heat generated while it
is working, the manufacturer assigns a TKPH rating that
Slopes and Excavations (surface) sets a limit on how hard the tyre may work before there is
Includes but is not limited to low-walls, footwalls, likely to be a detrimental effect on the tyre’s life.
high-walls, batters, berms, benches, spoil dumps
(in and out of pit), stockpiles, heap leach piles and Training
reject emplacements created during surface Initial training to verify competence and subsequent
mining and minerals processing. refresher training to verify that the competencies have
been retained.
Permanent infrastructure such as railway cuttings
and reinforced embankments. Tyre Burst
Trenches or other excavations created during Instantaneous release of stored energy within a tyre’s
civil works. air chamber.

Natural slopes. Tyre Explosion

Auto-ignition of an explosive gas mixture within
a tyre’s air chamber resulting in a large over pressure
leading to catastrophic tyre failure and rapid release
of hazardous energy.

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Tyre Pyrolysis Wheel Assembly

Thermochemical decomposition of the tyre’s inner liner Comprises a Rim Base, flanges, bead seat band, lock ring
producing gases that may form an explosive mixture and wheel disc or nave plate welded to the Rim Base.
within the tyre’s air chamber.
Workbox (Safe Work Australia)
Verified (in the context of Protocol 1 – A personnel carrying device designed to be suspended
Energy Isolation) from a crane to provide a working area for persons
elevated by and working from the device.
Verifying, by use of a procedure, that the actions taken
for the relevant Energy Sources, including identification, Worker (ICMM 2014, Health and
isolation and/or dissipation and securing/locking have safety performance indicators)
produced the desired effect. Workers are people who are engaged in work-related
activities on behalf of an employer. Workers may be
Voltage
employees, contractors or third parties.
Potential difference between conductors and between
conductors and earth. Working at Height
Means conducting work in any place, including a place
Categories
at or below ground level, where, if precautions were
Not exceeding 50V AC not taken, a person could fall a distance liable to cause
Extra Low Voltage (ELV) personal injury.
or 120V ripple-free DC
Exceeding Extra You are working at height includes:
Low Voltage, but not Work above ground/floor level outside of engineered
Low Voltage (LV)
exceeding 1000V AC barricades;
or 1500V DC
Potential to fall from an edge, through an opening or
fragile surface; or
High Voltage (HV) Exceeding Low Voltage
Potential to fall from ground level into an opening in a
floor or a hole in the ground.
Note: It is recognised that voltages vary from country
to country and this table is a guide only with the Work at height does not include a slip or a trip on the
same level, as a fall from height has to involve a fall from
one level to a lower level, nor does it include walking up
Wheel
and down a permanent staircase.
An assembly made up of a Rim and a centre
plate. Components of some Wheel Assemblies can Zipper failure
be dismantled. There are three major categories: single
Zipper failure means a circumferential fracture of the
piece wheels, divided wheels (split Rims) and
tyre side wall usually caused by fatigue. Over loading or
multi-piece wheels.
excessive side wall flexing when the pressure drops below
80 per cent of recommended causes fatigue, zipper
failure can result in Tyre Bursts. Tyre Bursts have caused
workplace fatalities.

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Control and Revision History

Document information

Property Value

Approved by: Lucy Roberts

Document owner: David Mellows

Effective date: 31/03/2021

Revision

Version Date Reviewed Review Team Nature of Amendment(s)

1-0 30/10/2013 Corporate HSEC Leads. First publication

Abandonment of the three

Corporate and Departments HSEC
implementation phases.
Leads.
2-0 31/03/2021 All Protocols were reviewed and updated
Internal and external technical
to incorporate incident learnings and latest
experts.
industry best practices.

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