COP 70 Operation of trackless mobile machinery

This printed copy is only valid for 17/04/2018

RICHARDS BAY MINERALS

CODE OF PRACTICE

Effective Date February 2017

Next Revision Date Jan 2019

APPLICABLE TO All Divisions

COP NO. 70 M

REVISION NO 13

PAGE 1 of 39

MANDATORY CODE OF PRACTICE FOR THE OPERATION OF “TRACKLESS MOBILE

MACHINES” This COP was drawn up in accordance with Guideline DMR Reference Number

DMR 16/3/2/2-B2 issued by the Chief Inspector of Mines

Compiled by : Engineer Reliability

1St Effective Date: 1 Aug 2000

2. TABLE OF CONTENTS ............................................................................................................................ 1

3. STATUS OF MANDATORY CODE OF PRACTICE ............................................................................. 4

4. MEMBERS OF THE DRAFTING COMMITTEE .................................................................................. 4

5. GENERAL INFORMATION ..................................................................................................................... 5

5.1 Description and Location of Mine ......................................................................................................................... 5

5.2 Commodities Produced ......................................................................................................................................... 5

5.3 Mining Method and Mineral Excavation Process .................................................................................................. 5

5.4 Description of Trackless Mobile Machinery .......................................................................................................... 5

5.5 Other Relevant Codes of Practice/Procedures ...................................................................................................... 6

6 TERMS AND DEFINITIONS ...................................................................................................................... 7

6.1 Terms ....................................................................................................................................................................... 7

6.2 Definitions ................................................................................................................................................................ 8

7. RISK MANAGEMENT ........................................................................................................................... 10

7.1 RBM RISK ASSESSMENT STRATEGY.............................................................................................. 10

8. ASPECTS TO BE ADDRESSED IN THE MANDATORY COP ....................................................... 11 8.1 Design and Specification Register………………………………………………………………………………………………………………………….11 8.2 Braking Systems…………………………………………………………………………………………………………………………………………………….11

8.2.1 Braking systems and combination of braking systems ....................................................................................... 11 8.2.1.1 Design and Provision of Service Brake System ................................................................................................... 11 8.2.1.2 Design and Provision of Park Brake System ........................................................................................................ 11

COP 70M REV NO: 13 PAGE 2 of 39


8.2.1.3 Design and Provision of Emergency Brake Systems ............................................................................................ 11 8.2.1.4 Combined Park and Emergency Brake Systems .................................................................................................. 11 8.2.1.5 Combined Service, Park and emergency Brake Systems .................................................................................... 11 8.2.2 Use and Testing of Brake Systems ...................................................................................................................... 12

8.3 Protection of Driver/Operator & Other Persons........................................................................................................ 12 8.3.1 Protection from Falling Objects ................................................................................................................................. 12 8.3.2 Roll Over Protection. .................................................................................................................................................. 12

8.4 Inadvertent Movement of TMM’s ............................................................................................................................. 12 8.4.1 Prevention of inadvertent moving ............................................................................................................................. 12 8.4.2 Inadvertently Running Out of Control ....................................................................................................................... 13 8.4.3 Prevention of TMM Being Set in Motion by Unauthorised Person ........................................................................... 13

8.5 Safe Boarding/Alighting and Access/Exit of TMM ..................................................................................................... 13

8.6 Design and Operation of Tow Bars and Coupling Devices.......................................................................................... 13 8.6.1 Design of Tow Bars and Coupling Devices .......................................................................................................... 13 8.6.2 Use of Tow-bars and Coupling Devices ............................................................................................................... 14

8.7 Illumination.............................................................................................................................................................. 14 8.7.1 Light Intensity and Range .................................................................................................................................... 14 8.7.2 The distinction between Front, Rear and Side Lighting ...................................................................................... 14 8.7.3 Positioning of Lights to Indicate the Width of the TMM ......................................................................................... 15 8.7.4 Installation and Adjustment of Lights ..................................................................................................................... 15 8.7.5 Reflectors ................................................................................................................................................................ 15 8.7.6 Procedure in Case of Luminaire or Lamp Failure .................................................................................................... 15 8.7.7 The Use of Adjustable Lights to Illuminate Places of Critical Safety ........................................................................ 15 8.7.8 Cleaning and Maintenance of Lights ....................................................................................................................... 15 8.7.9 Measurements and Inspection of Lighting Equipment ........................................................................................... 16

8.8 Physical Constraints to Operator/ Driver Vision ....................................................................................................... 16

8.9 Remote and remotely controller trackless mobile machines .................................................................................... 16

8.10 Maintenance and Inspection of Trackless Mobile Machines .................................................................................... 16 8.10.1 Scheduling of Planned Maintenance, Inspections and Over Inspections ........................................................... 16 8.10.2.1 Pre-Use Checklists ............................................................................................................................................... 16

8.10.2.2 Pre-inspection of Third Party TMM ………………………………………………………………………………………………………………..16 8.10.3 Conditions under Which TMM’s should Not Be Used......................................................................................... 17 8.10.4 Changing Wheels and Rims ................................................................................................................................. 17 8.10.6 Procedure for Repair That Could Endanger Persons ........................................................................................... 17 8.10.7 Support of TMM during Maintenance ................................................................................................................ 17 8.10.8 Battery Changing Procedures on Battery Powered TMM’s ................................................................................ 18 8.10.9 Battery Charging and Maintenance .................................................................................................................... 18

8.10.10 Diesel refuelling facility ………………………………………………………………………………………………………………………………….18 8.10.11 Hazards associated with Operation and Maintenance ……………………………………………………………………………………19 8.10.12 Isolation and Lock-out ……………………………………………………………………………………………………………………………………19

8.11 Health and Safety Provisions on trackless mobile machines ................................................................................... 19 8.11.1 Safety systems to negate unexpected incapacitation of the Driver ……………………………………………………………………….21 8.11.2 Vibration Control Divices ………………………………………………………………………………………………………………………………………21 8.11.3 Design, Control ans Maintenance of Noise Control Systems …………………………………………………………………………………21 8.11.4 Prevention of Injury ……………………………………………………………………………………………………………………………………………..21 8.11.5 Proximity Detection Systems ………………………………………………………………………………………………………………………………..22 8.11.6 A suitable ergonomic environment ………………………………………………………………………………………………………………………22 8.11.7 Signals and communications ………………………………………………………………………………………………………………………………..22



8.12 TMM’s to be operated by Competent Authorised Persons ...................................................................................... 22 8.12.1 Recruitment/Selection, Education and Training of Competent Persons to Drive a TMM .................................. 22 8.12.2 Record Keeping .............................................................................................................................................. 23 8.12.3 Procedures for Appointment and Licensing of Competent Persons to Drive TMM’s ......................................... 23

8.13 Design of Excavations and Roadways ..................................................................................................................... 23 8.14 Operating Procedure ……………………………………………………………………………………………………………………………………….24

8.14.1 Safe Start-up, Operation and Shut down Procedures ........................................................................................ 24 8.14.2 The procedure to be used on any roadway and underground incline and decline…………………………………………25 8.14.3 Traffic rules and road signs, incline speed, authority to move, right of way and restricted entry with regards to dangerous areas, obstructions or restricted clearances …………………………………………………………………………..25 8.14.4 Where more than one TMM travel in an underground incline or decline at any one time in either direction, procedure to ensre this is done safely ………………………………………………………………………………………………………….25 8.14.5 Procedure to ensure a TMM is towed or attended to for repairs under controlled conditions ……………………..25

8.14.6 General Safety Rules relating to the Interaction between Pedestrians, Cyclists and TMM’s. ............................ 25 8.14.7 Methods for the Safe Loading, Transport and Unloading of Persons, Equipment, Material, Minerals or

Explosives On or From TMM’s ............................................................................................................................ 26 8.14.8 Procedure to ensure TMM entering mine premises pose no significant risk …………………………………………………26

8.14.9 Safe Towing or Pulling of Trailers and Skid Mounted Machinery by TMM ......................................................... 27

8.15 Illumination of Environment .................................................................................................................................. 27 8.15.1 Positioning and Spacing of Lights ........................................................................................................................ 27 8.15.2 Intensity and Dispersion of Lights. ...................................................................................................................... 27 8.15.3 Reflectivity of the Surrounding area ................................................................................................................... 27 8.15.4 Steps to be taken in the Case of Illumination Failure ......................................................................................... 27

8.16 Visibility of TMM, trailers, skid mounted machinery and broken down TMM ………………………………………………….27

8.16.1 Placing of Signs to Warn in the Case of Parked, Stationary and Broken down TMM’s that are poorly visible ... 28 8.16.2 Measures to Ensure the Visibility and Safety of Pedestrians, Cyclists or Other Workers Close to TMM’s ......... 28 8.16.3 Timeous Warning Systems, Where Employees Work in Haulage’s where TMMs Operate ................................ 28

8.17 Inclines and Declines ............................................................................................................................................... 28

8.18 Raising/Lowering, suspension and transporting of persons ……………………………………………………………………………..28

8.19 Personal Protective Equipment ............................................................................................................................. 29

PART D: IMPLEMENTATION ........................................................................................................... 31

1 Implementation Plan ............................................................................................................................................... 31

2 Compliance with the COP ...................................................................................................................................... 31

3. Access to the COP and Related Documents ..................................................................................................... 31

ANNEXURE 1 – REFERENCES LIST OF RELEVANT SIMRAC PROJECT REPORTS, STANDARDS AND NOTIFICATIONS ............. 36 ANNEXURE 2 - Description of trackless Mobile Machinery in use at RBM

ANNEXURE 3 – Drawings of Areas of Restricted Vision for Operator/Driver .................................................................... 38

ANNEXURE 4 - TMM Design and Specification Register ……………………………………………………………………………………….……...39



3. STATUS OF MANDATORY CODE OF PRACTICE

This mandatory COP was drawn up in accordance with Guideline DMR 16/3/2/2-B2 issued by the Chief Inspector of Mines.

This is a mandatory COP in terms of Section 9(2) and 9(3) of the Mine Health and Safety Act (Act 29) of 1996. All employees and contractors employed by RBM are bound by this COP. Noncompliance with this COP will be considered as an offence in terms of Section 91 (I)(c) of the same Act.

The COP may be used during accident or incident investigations to measure compliance and also to establish whether the COP is effective and fit for purpose.

This COP supersedes all previous relevant COP’s and must be reviewed for validity following any significant incidents involving TMM or as part of change management relating to TMM.

All policy instructions, appointments, standard operating procedures and standard engineering procedures regarding maintenance and management of TMM’s must comply with this COP.

4. MEMBERS OF THE DRAFTING COMMITTEE

4.1 The RBM Central Safety Committee was consulted regarding the content of this COP. 4.2 A working group was appointed responsible for the drafting of this COP as agreed by the RBM Central Safety Committee.

4.3 The working and review group consisted of the following members: Refer to signatures on attendance register

Name Designation Qualification and Affiliation Experience

B Naicker Manager -Technical & Asset Management NHD Mech Engineering, GCC Mechanical 20 Years

J Behrmann Superintendent - Facilities Qualified Artisan, Diesel Fitter 31 Years

G Daley Maintenance Controller – Mobile Maintenance

Qualified Artisan, Diesel Fitter 28 Years

U Myasur Technician – Mobile Operations Qualified Earth Moving Equipment Artisan 8 Years

F Dunn Safety Representative – Mobile Maintenance


M Dlamini Union Representative – NUM – Mobile Maintenance


J Hunter Maintenance Controller – Mobile Maintenance

Qualified Artisan, Fitter Diesel 23 Years

R Devan Maintenance Controller – Mobile Maintenance (LMV)

Qualified Artisan, Mechanical 18 Years

A Smal Engineer – Mobile Equipment National Diploma Mechanical Engineering, GCC Mines & Works, GCC Factories,

ECSA

22 Years

M Sikhosana Planner – Mobile Maintenance Qualified Artisan, Diesel Fitter 19 Years

B Joubert Engineer – Reliability National Diploma In Electrical Engineering – GCC Mines & Works, Electrical - ECSA

21 Years

S Dladla Planner – Mobile Maintenance HME Qualified Artisan, Diesel Fitter 16 Years

J Kalapdeo Supervisor Technical Grade 12 12 Years

T Govender Superintendent - SHEQ BSC Chemistry 10 Years

The above are members of various RBM Safety Committees



5. GENERAL INFORMATION

5.1 Description and Location of Mine

Richards Bay Minerals (RBM) is a subsidiary of Rio Tinto, was established in 1976 to mine, process and market naturally occurring heavy minerals.

RBM is located in northern KwaZulu-Natal, adjacent to the Indian Ocean coastline approximately 20km north-east of Richards Bay. RBM has four mining plants currently in operation on the coastal dunes, and sophisticated processing and smelting plants adjacent to its Richards Bay Office complex approximately 7kms inland.

Fig 5.1 – Map of General Location

5.2 Commodities Produced

Commodities produced are Titania Slag, Pig Iron and various grades of Rutile and Zircon.

5.3 Mining Method and Mineral Excavation Process

The mining method involves dredge and dry mining the sand dunes and the on-board wet separation of concentrates.

The heavy mineral concentrate (HMC) extracted from the dunes contains Ilmenite, Zircon and Rutile. The HMC is transported to the Smelter site and following further gravity and magnetic separation, the Ilmenite is smelted to form Titania slag and high purity Iron. Rutile and Zircon are treated in a Mineral Separation Plant using a combination of wet gravity, magnetic and high tension separation to produce various grades of final mineral products.

5.4 Description of Trackless Mobile Machinery

The types of TMM used are listed in Annexure 2.



5.5 Other Relevant Codes of Practice/Procedures

C3 Rio Tinto Safety Standard on Vehicles and Driving COP 4 Training on Procedures and RBM Systems COP 9 Contractor Management COP 10 Hazard Identification & Risk Assessment COP 11 Non-conformances, Incident and Injury Reporting and Recording COP 12 Official Enquiries into Incidents COP 13M Mandatory Code of Practice on Emergency Preparedness and Response COP 17 Personal Protective Equipment COP 19 Engineering Designs and Controls COP 19.1 Management of Change COP 22M Mandatory Code of Practice for Minimum Standards of Fitness to Perform Work at RBM

COP 24 ISOLATION/LOCKOUT OF ANY HAZARDOUS SYSTEM COP 26 Hazardous Substance Control

COP 28 WORKING AT HEIGHTS

COP 29 LIFTING EQUIPMENT AND MACHINERY COP 49 Pressure Vessels

COP 52 MACHINE GUARDING

COP 53 Working on, Adjusting, or Setting, Moving or Energised Equipment and Machinery COP 59 Rail System and Rolling Stock

COP 61 LIGHTING, MONITORING & CONTROL COP 62M Mandatory Code of Practice for an Occupational Health Program on Personal Exposure to

Airborne Pollutants COP 64 Hydrocarbon Management COP 85M Mandatory Code of Practice to Combat Rock Fall and Slope Instability Related Accidents

5.5.1 Related Documents E24 GP002 Working near or beneath any live overhead power lines E28 GP006 Working at heights – Principles and minimum requirements E28 GP007 Safe use of Mobile Elevated Work Platforms E29 GP002 Lifting and hoisting planning and recording E50 GP001 Standards and specifications for oxy-fuel (gas) cutting, welding and heating work E70 GP001 Safe Operation of Service Vehicles around Heavy Mobile Equipment. E70 GP002 Roadwork’s – traffic control E70 GP003 Hiring of Mobile Equipment E70 GP004 Use of Wheel Chocks for mobile equipment and rolling stock E70 GP005 Approach & Depart from any Mobile Equipment. E70 GP006 Tow Hitch General Procedure E70 GP007 Transportation of abnormal loads E70 GP008 Standard for Seatbelts on all types of Vehicles and Mobile Equipment E70 GP010 General Procedure for Operating Brake Tester E70 GP011 Human Physical Dimension E70 GP012 Hiring of Light motor vehicles for use at RBM E70 GP015 Administration of issuing LDV HME fuel tags E70 GP016 Hot Fluids and Pressurized systems on Heavy Mobile Equipment E70 GP017 Changing a tyre or wheel on a light motor vehicle E70 GP018 Heavy Mobile Equipment(HME) Tyre and Rim Standard E70 GP021 RBM Traffic Management Plan



E70 GP022 Smelter Proximity Warning System (PWS) E70 GP023 TMM Pre Operational Inspection E70 GP024 Vehicle Pre-start inspection E70 GP025 Proximity Detection System (PDS) and Start Prevention (Sedna) installation on Trackless

Mobile Machinery (TMM) E70 GP026 TMM Brake Testing ESMESOP11 Isolation and Lock Out Of Mobile Equipment ESMOSWP 70.24 Delivering Diesel to Mining Plants FCOMS SOP054 Maintaining Man Up Turret Truck Batteries at RBM Stores MEQTC 002 Training and Licensing of Mobile Equipment and Vehicle Operators and Drivers MOA – 39 Mine Proximity Warning System (PWS) MPT 04-09-02 Operation of Rail Crossing Booms POL 132 Personal Protective Equipment (PPE) Policy SANS 1200 Road Construction SEC/PSO/001/2009 RBM Physical Security Operations SH 55 Motor Vehicle and Mobile Machine Safety SS – 09 Construction of pond access and servitude road SS – 11 Dozer at Tails Stacker in High Winds SS – 21 Safe Operating Procedure for a Dozer TAMTPJHA16 Chocking Vehicles TAMTPSOP02 Transport Vehicle Lock-out Procedure TAMMESOP47 Pre-operational inspections: Mobile crane and HME on hire to RBM TAMMOSWP 70.39 Recovery of Mobile Equipment TAMSWP 70.9 Operation of Mobile Crane TOTAL 001 Offloading of fuel tankers T10 GP 003 Job Hazard Analysis (JHA) T10 GP 004 Take 5 (Pre-Task Hazard Assessment) T60 GP 001 Noise and Vibration Monitoring at RBM

5.5.2 Other References Mine Health and Safety Act and Regulations (Act No. 29 of 1996) National Road Traffic Act (Act No. 93 of 1996) National Nuclear Regulatory Act and Regulations (47/1999). Rio Tinto Safety Standards ISO 3471:2008 Earth Moving Machinery – Roll over protection structures ISO 7096-2000 Earth Moving Machinery – Laboratory evaluation of operator seat vibration

6 TERMS AND DEFINITIONS

The following abbreviations, words, phrases or terms and their meanings are used in this document.

6.1 Terms

Act - Mine Health and Safety Act, Act 29 of 1996

COP - Code of Practice

CIOM - Chief Inspector of Mines

Competent - A person who is qualified and authorised to do a certain job

DMR - Department of Minerals Resources

ECSA - Engineering Council of South Africa

EHS - Environment Health and Safety

Employer - Means and owner as defined in section 102 of the Mine Health and Safety Act

Engineer - Is a person appointed in terms of section 2.13.1 as per Mine Health and Safety act or a person who is the holder of an appropriate mechanical or electrical engineer’s certificate of competence in terms of the regulation



EGP - Engineering General Practice

FOPS - Falling Object Protection Structure

GVM - Gross Vehicle Mass

HMC - Heavy Mineral Concentrate

HME - Heavy Mobile Equipment

HIRA - Hazard Identification and Risk Assessment

JHA - Job Hazard Analysis

KPH - Kilometre per Hour

LDV - Light Delivery Vehicle

LUX - Unit in which light intensity is measured

MBO - Management by Objectives system (NOSA)

MHSA - Mine Health and Safety Act

OEM - Original Equipment Manufacturer

RBM - Richards Bay Minerals (The Employer)

PDS - Proximity Detection System

PWD - Personal Warning Device

PWS - Personal Warning System

ROPS - Roll over Protection Structure

RT - Rio Tinto (Owner)

SHEQ - Safety, Health, Environment & Quality

SEP - Standard Engineering Practice

SOP - Standard Operating Procedure

TMM - Trackless Mobile Machine

6.2 Definitions

.

“Braking system” means a device or combination of devices capable of reducing the speed of a trackless mobile machine to a standstill; “Combined Braking System” means a braking system consisting of a service brake and at least one of the following: either a park brake or an emergency brake; Contractors: can be categorized in 3 categories as specified in the RBM Standards (COP 9): a) Cat.1 Individual engaged on temporary contracts to work within existing operations. b) Cat.2 Vendors or individuals engaged for a specific project in a designated area separate from existing operations. c) Cat.3 Vendors or individuals engaged under contracts to carry out specific tasks or services within existing operational areas. Note: The Cat.1, 2 & 3 contractors will fall within the scope of this COP “Delivery Vehicle” means a vehicle that is deemed to deliver or collect commodities at RBM on an irregular basis and may not have any contract with RBM and defined under regulation 8.10.28 of the MHSA. All other vehicles are deemed to be doing work and it is expected that they comply with this COP.

“Emergency Brake” means an easily accessible device, which when applied will bring the trackless mobile

machine to a standstill under all operating and emergency conditions; “Fail to Safe” means to design as to activate and effectively perform its intended function without harm to persons and without human intervention; “Ngwenya” means a Safety Observation and Coaching intervention



“Park Brake” means a break capable of holding fully loaded, parked trackless mobile machine stationary, at the maximum safe operating gradient, without the support of any other braking system; Personal Warning System (PWS) The Personal Warning System is the overall system including all hardware and software and is made up of

•Proximity Detection System – The Unit fitted to a TMM including its display, warning lights and antennas that warns the operator, both of people and vehicles. •Personal Warning Device - The blue 438 gram warning device a person carries with them (This consists of a battery and a transponder tag in a blue plastic housing) •Interactions System - a Central Database where all interactions that have been downloaded from the Vehicle Proximity Detection Systems are stored; analysed and reported on.

“RBM Site” means any operational area where RBM is active. “Service Brake” means the primary operating brake capable of retarding and stopping the fully loaded trackless mobile machine; “Static Test” means a test carried out to determine the compliance of the brake holding power of a trackless mobile machine measured against the design specification or an appropriate safety standard; “TMM” means any Trackless Mobile Machine, self-propelled or otherwise that is used for the purpose of performing mining, transport or associated operations on surface at a mine or surface at a mine and is mobile by virtue of its movement on wheels, skids, caterpillar tracks, mechanical shoes or any other device fitted to the machine but excludes rail bound equipment, scraper winches, mono rail installations, static winches, draglines, winding machine installations, track mounted conveyors and equipment attached thereto “Trailer” means any vehicle that is not self-propelled and needs to be towed by a trackless mobile machine by design.



7. RISK MANAGEMENT

7.1 RBM Risk Assessment Strategy

In terms of Section 11 of the MHSA, hazard identification and risk assessment (HIRA) must be carried out for all TMM’s operated on the RBM site, to identify the risk to health and safety of employees. The HIRA must consider as a minimum the following; Handling, driver vision, brake failure, tyre blowout and access and egress from the machine. The HIRA must involve operational and maintenance personnel and must consider maintenance, operation and task specific aspects of the TMM. The HIRA must be conducted in accordance with and on a frequency as per the guidelines provided in COP 10, Hazard Identification & Risk Assessment and procedure T10 GP 003, Job Hazard Analysis (JHA)

Where any of the identified risks cannot be eliminated then the following applies;- Controlling the risk at source – Technical and manufacturing specifications, operational requirements, ergonomic studies and accident statistics must all be considered to control and eliminate risks.

7.1.1 Baseline Risk Assessments

Qualitative Risk Assessment (including HAZOP, FMEA, etc.). Performed by a cross section of the department(s) including persons with supervisory, technical and operating (line) experience or exposure to the risk being analyzed. Inclusion of an “independent” person from another department (e.g. Health & Safety) should be considered to “challenge” perceptions. Recorded on Rio Tinto Business Solution (RTBS) and is known as the area based risk assessment or Level 2 Risk Assessment.

7.1.2 Issue Base Risk Assessments

Remaining risk – where the above steps have not removed the identified risks, suitable and effective personal protective equipment must be issued and worn and alarms and warning devices installed as necessary. When conducting HIRA’s on TMM the following information would be considered to assist the team in identifying the risks; SIMRAC reports, RBM accident statistics, ergonomic studies, OEM specifications and recommendations, design and performance criteria. Information regarding application, servicing instructions and technical specification of the various types of TMM’s used in RBM operations must be available. For TMM owned by RBM, this information will be maintained by the Mobile Maintenance or Transport workshops. The information should include the following as a minimum: vehicle type, make, mass, payload, dimensions, prime mover, power, speed, brakes, turning circle, safety devices and signaling arrangements, ROPS and FOPS standards/specifications. As required by Section 11(4) of the MHSA this COP will be reviewed and up-dated at least once every two years, or following any significant incident or significant change to mining procedures, plant equipment or materials. These risk assessment are conducted as per procedure T10 GP003, Job Hazard Analysis..

7.1.3 Continuous Risk Assessment

This is probably the most important and powerful form of risk assessment and should form part of the day-to-day management. Continuous risk assessment is a task conducted mainly by the front line supervisors to enable the process to be effective. Examples of continuous risk assessments employed at RBM operations are: -

Planned task observations

Take 5 prior to conducting work (pre-task risk assessment) or when the job or environmental conditions changes.

Pre-start checklist

Critical Control Checklist (CCC)

Audits and inspections

7.2 SIMRAC Project Reports, SANS and ISO standards and incident reports here-in attached were also used,

refer to Annexure 1.



7.3 Application and Technical Specification of TMMs The application and technical specifications of all types of TMMs used at the mine was available to enable proper hazard identification and risk assessment to be performed. This information include items such as type, make, mass, payload, dimensions, prime mover, power, speed, brakes, turning circles, safety devices, signaling arrangements. The information for those TMMs associated with significant risks are kept readily available at the mine

7.4 Review of the COP In addition to the 2 yearly review, the COP should be reviewed and updated after every emergency, altered circumstance’s, or if significant changes are introduced to procedures, mining layouts, mining methods, plant or equipment and material.

8. Aspects to be addressed in the mandatory COP

8.1 Design and specification register

a) Type and model of trackless mobile machines refer to annexure 4 b) Original equipment manufacturer refer to annexure 4 c) Maximum design capacity refer to annexure 4 d) Maximum design speed refer to annexure 4 e) Minimum turning circle refer to annexure 4 f) Maximum design operating gradient refer to annexure 4 g) Gross mass in kilograms refer to annexure 4 h) Minimum dimensions refer to annexure 4 i) Maximum operating dimensions Refer to annexure 4 j) Prime mover refer to annexure 4 k) Design rated power refer to annexure 4 l) Maximum towing capacity refer to annexure 4 m) Manual, remote or remotely controlled refer to annexure 4 n) Types of brakes refer to annexure 4

8.2 Braking Systems

8.2.1 Braking systems and combination of braking systems

8.2.1.1 Design and Provision of Service Brake System

Every TMM must be fitted with an effective service brake system designed and approved by the OEM.

8.2.1.2 Design and Provision of Park Brake System

Every TMM must be fitted with an effective park brake system designed and approved by the OEM.

8.2.1.3 Design and Provision of Emergency Brake Systems

Every TMM must be equipped with an effective emergency brake system designed and approved by the OEM to prevent the TMM from running out of control, if the manner of TMM operation requires this.

8.2.1.4 Combined Park and Emergency Brake Systems

Where the TMM’s park and emergency park system are combined into one braking system this combined system must comply with the requirements of both systems.

8.2.1.5 Combined Service, Park and emergency Brake Systems

Where the TMM brake systems consist of a combination of the service, park and emergency brake system in one braking system, the combined system must comply with the requirements of each separate system and a fail-safe principle must be used.



8.2.2 Use and Testing of Brake Systems

All new TMM’s must be delivered with an OEM test certificate proving the effectiveness of the brake systems and the compliance to the minimum requirements of the MHSA and other relevant legislative standards.

The OEM test certificate referred to above and the certificate of road-worthiness for all TMM being used on RBM Site must be made available to and approved by the Manager: Technical Asset Management or his delegate prior to the machine commencing work. The test results/certificates must be maintained departmentally or in the Contractors records for as long as the TMM is used.

Individual TMM drivers must test their TMM braking systems, in accordance with procedure E 70 GP 026, TMM Brake Testing, at the start of every shift and immediately prior to use as part of the pre-start checklist. Any machine failing this pre-shift brake test may not be operated until the fault(s) have been rectified.

TMM entering into the Mining plant operational area, will conduct a ramp brake test before entering into the operational area.

The TMM planned maintenance schedule incorporates braking system testing in accordance with manufacturers standards and specifications and maintenance SEP’s. Test results is maintained the planned maintenance record system.

After any repairs done on the brake system or part thereof, a brake test needs to be done.

8.3 Protection of Driver/Operator & Other Persons

8.3.1 Protection from Falling Objects

Where required by the task HIRA, TMM’s must be fitted with adequate falling object protection (FOPS) to protect the operator from material and objects falling from above. Where there is a risk of falling objects and ROPS cannot be fitted, a falling object protection (FOPS) must be provided to protect the operator from material and object falling. TMM without certified FOPS will not be allowed to work underneath unsupported areas

8.3.2 Roll Over Protection.

All TMM’s must be fitted with adequate roll over protection (ROPS) where there is a risk of TMM overturning and crushing the operator.

All ROPS shall comply with ISO 3471:2008, Earth Moving Machinery – Roll over protection structures or design approved by the Manager: Technical Asset Management or a suitably qualified Professional Engineer.

No person is allowed within the working area of any machine where there is a risk that the machine could overturn. Where persons are used to direct the activities of TMM’s they must position themselves such that they are always visible to the driver and cannot be injured should the TMM roll over or move suddenly.

All TMM’s must be fitted with individual seatbelts for every seat to ensure that persons are prevented from being injured as a result of operator sand/or passengers inadvertently falling out or being ejected from any trackless mobile machine in motion. Seatbelts must be worn whenever the TMM is being used, except where a HIRA indicates that in the event of an emergency the use of seatbelts may be hazardous to the operator. In these cases there must be an approved procedure or standard, which defines the special requirements for working under these conditions, approved by the Engineer.

8.4 Inadvertent Movement of TMM’s

8.4.1 Prevention of inadvertent moving

For TMM fitted with articulation joints, an articulation lock must be applied whenever work is being done on the TMM. No person may enter the area of an articulation joint unless the articulation joint has been locked out. Whenever work is being done on a TMM, which does not require the TMM to be operating, it must be isolated and locked out as per approved procedures TAMTSPSOP02, Transport Vehicle Lock out



Procedure and ESMESOP11, Isolation and Lock out Of Mobile Equipment. In cases where the TMM is required to operate while being worked on, for example testing lights or hydraulic systems, this work must be done in accordance with OEM and approved procedures governing the safe completion of

this work. The approved procedures should be on HIRA.

8.4.2 Inadvertently Running Out of Control

All TMM’s must be parked and the brakes applied, according to TAMTPJHA16, Chocking Vehicles and E 70 GP 004, Use of wheel chocks for mobile equipment and rolling stock, in such a manner to prevent inadvertent movement. TMM’s may not be parked on an incline/decline unless under emergency/breakdown conditions, in which case there must be procedures in place to determine methods to prevent the TMM running away. When Heavy Mobile Equipment exceeding a GVM of 3500kg is parked or left unattended it must be chocked to prevent uncontrolled movement of the TMM. Operators are trained as per operating training manual, which is based on the OEM standards to utilse all braking systems available to the operator or driver in an attempt to bring the machine to a controlled stop, including the hand brake device and in the event of brake failure. Drivers / operators shall not disembark whilst TMM is running or idling, or there is the risk of inadvertent movement.

8.4.3 Prevention of TMM Being Set in Motion by Unauthorised Person

Each TMM shall be provided with an effective device to isolate and lock out the main power supply necessary to activate the machine, or starting arrangement of the engine. Only persons trained in accordance with procedure MEQTC 002, Training and Licensing of Mobile Equipment and Vehicle Operators and Drivers, and authorized by the Engineer may operate a TMM. TMM may only be used for authorized company business. There must be practical and effective systems or controls in place for all TMM to prevent unauthorized persons from operating the TMM.

8.5 Safe Boarding/Alighting and Access/Exit of TMM

All TMM’s must be provided with safe access/exit as designed by the OEM and as determined by the generic TMM HIRA, RBM General Safety Induction and TMM Specific training. Access and egress routes or ladders should avoid the need for people to enter the articulation joint area. Boarding or alighting from any moving TMM is not permitted. Driver training and task SOP’s shall include instructions regarding safe access/exit procedures. Any person required to board/alight a TMM in operation must only do so after obtaining acknowledgement of his approach from the driver. The machine must be parked and the park brake applied before any person may approach the TMM. When working on TMM, safe access must be provided for persons working on the machine. Any work at heights must comply with the COP 28, Working at Heights and procedure E28 GP 006, Working at heights – Principles and minimum requirements

8.6 Design and Operation of Tow Bars and Coupling Devices

8.6.1 Design of Tow Bars and Coupling Devices

Towing of any machine by another will not be allowed unless both machines are fitted with towing facilities, which are approved by the responsible Engineer or provided in the integral design of the machine by the OEM Only coupling devices incorporated in the design of the equipment, or approved by the responsible Engineer, will be permitted on machines subject to the condition that no accidental disconnection of an attachment can take place Where there is no OEM design or specification, a competent person must approve designs and drawings for tow hooks, tow bars and coupling devices. Records of these designs and drawings must be retained for the life of the TMM and the preferred location shall be the Engineering Design Office. The design of any tow hook, tow bar or coupling device must incorporate all possible loading and operating conditions likely to be imposed on the TMM and Trailer. All designs must be as per the approved company standard or approved by the Engineer



All ball and claw towing systems must comply with SANS 1505: Ball type couplings and towing brackets for towing caravans and light trailers. All tow hitches must comply with procedure E 70 GP 006, General Procedure for Tow hitches

8.6.2 Use of Tow-bars and Coupling Devices

All tow hitches must comply with, be inspected and used in accordance with procedure E 70 GP 006, Tow Hitch General Procedure. Driver training and task specific SOP’s must include instructions regarding safe hitching, coupling and towing/pushing procedures as determined from task HIRA’s. These procedures must cover the requirements for efficient communication between the driver and any person moving between the

machines. 8.6.3 Prevention of Inadvertent Uncoupling

All tow hooks, tow bars and coupling devices shall be designed, constructed and used to prevent inadvertent decoupling of TMM’s. Driver training and task SOP’s must include instructions regarding the use of safety devices provided to prevent inadvertent uncoupling of trailers. All tow-bars shall be provided with a safety chain of suitable strength and dimensions to prevent uncoupling of the trailer in the event of failure of the tow-hook or coupler(except Jost coupling , does not require safety chain as the mechanism is a positive lock).

8.7 Illumination

8.7.1 Light Intensity and Range

All TMM’s required to operate on public roads must conform to the requirements of the National Road Traffic Act and OEM specifications. The average light intensity in the direction of travel on all TMM’s used during the hours of darkness must be a minimum of 10 lux at a distance of 20 meters. The light beam shall be of sufficient width, spread and intensity to enable the driver to safely operate at the maximum permissible speed for the area under normal conditions. At least two light beams shall be provided on the front of the TMM for forward travel, and at least one on the rear of the TMM for use during reversing. All TMM’s with a GVM>3500kg must be fitted with an amber flashing light prominently displayed at all times the TMM is operating. (Excluding vehicles designed and used for the exclusive carrying of passengers)

8.7.2 The distinction between Front, Rear and Side Lighting

All TMM’s must be fitted with white beam front lights, amber indicator lights, white rear reversing lights,

red rear brake and taillights and red rear reflectors.

Position Type Colour How to be fitted Minimum

Requirements Front Headlights White Factory fitted or bolted Lights: 10 Lux / 20 m

Rear

Reverse Lights Where

applicable, production area

White Factory fitted or bolted Lights: 10 Lux / 20 m

Rear Tail lights Red Factory fitted or bolted Visible

Front & Rear

Operator Safe View Side

Green Factory fitted or bolted One mounted on safe

view side

Operator Unsafe View Side

Red Factory fitted or bolted One mounted on the

unsafe view side



Position Type Colour How to be fitted Minimum

Requirements On the highest

practical possible point of the vehicle

Rotation lights (Explosives and

Emergency Vehicles only)

Red Bolted or magnetically

fitted One mounted

On the highest practical possible point of the vehicle

Rotation lights (Production / Construction

vehicles)

Amber Bolted or magnetically

fitted One mounted

On the highest practical possible point of the vehicle

Rotation lights (LDV)

Amber Bolted or magnetically

fitted One mounted

8.7.3 Positioning of Lights to Indicate the Width of the TMM

All TMM’s should be fitted with lights at the extremities of the equipment. Where this is not the case with certain OEM then additional lights, reflectors or reflective strips must be fitted to indicate the overall vehicle dimensions.

8.7.4 Installation and Adjustment of Lights

All lights must be installed accessible for maintenance and protected from damage as far as practically possible. Main front lights must be adjusted to comply with the requirements of section 8.7.1

8.7.5 Reflectors

Reflective strips or tags must be fitted to all TMM’s traveling on roads used by other TMM’s or vehicles to enhance safety and to increase visibility. The colour of the strip or tag shall indicate the side of the TMM as follows: White : Front Yellow or Amber : Side Red : Rear Reflectors fitted to TMM’s licensed for the public roads must comply with the relevant regulations of the National Road Traffic Act.

8.7.6 Procedure in Case of Luminaire or Lamp Failure

The TMM checklist, based on the TMM HIRA, must identify those lights that are essential to allow the vehicle to operate safely during the hours of darkness. No TMM may be driven if these essential lights are not operating properly. (At a minimum the standard specified in 8.7.1. needs to be adhered to). In such cases the TMM must be parked in a safe place until the lights have been repaired. On all RBM traveling ways and public roads the indicator lights needs to be working at all times

8.7.7 The Use of Adjustable Lights to Illuminate Places of Critical Safety

In all areas of TMM operation where lighting is critical to safety, regular lighting surveys should be conducted and suitable lighting installed where practical. Where it is not possible to provide general lighting and adjustable lighting is required to ensure safety, as defined by HIRA, this must be fitted to the TMM

8.7.8 Cleaning and Maintenance of Lights

All lights must be maintained and cleaned to ensure they provide the illumination or signals to the standard required by this COP. Lights must be inspected at the start of each shift and repaired or cleaned if required before the TMM is used.



The lights of all TMM’s licensed to operate on public roads must be maintained to conform to the

relevant regulations of the National Road Traffic Act. .

8.7.9 Measurements and Inspection of Lighting Equipment

TMMs licensed to operate on public roads must conform to the relevant regulation of the National Road Traffic Act. Pre-use inspections and checks must include inspection of lighting equipment. Should the HIRA indicate that it is not safe to use the TMM without lights it must not be used until the lights have been repaired.

8.8 Physical Constraints to Operator/ Driver Vision

1. TMM’s licensed to operate on public roads must conform to the relevant regulation of the National Road Traffic Act.

2. The HIRA for any TMM must consider any areas of restricted vision for the driver and the controls

or procedures required ensuring the safety of the operator and any other persons or equipment when moving off.

3. Suitable drawings of areas of restricted vision must be available for use during HIRA and should be included in training documents and task procedures. Copies of these drawings are available as detailed in Annexure 2.

4. Where deemed necessary by HIRA or task procedures a clearly audible alarm and/or clearly visible flashing light must be fitted so that it operates whenever the TMM moves in the direction of the restricted limited visibility.

5. Where TMM is reversing towards the edge of a stockpile or dump, a suitable barrier must be maintained to prevent inadvertent reversing over the edge of the stockpile or dump. Where required, a spotter must be in place and form part of the activity.

6. Condition of the windshield and wipers form part of the pre-start checklist and marked as a “no-go” item if found unserviceable

8.9 Remote and remotely controller trackless mobile machines

There are currently no remote or remotely controlled TMM in operation at RBM

8.10 Maintenance and Inspection of Trackless Mobile Machines

8.10.1 Scheduling of Planned Maintenance, Inspections and Over Inspections

Maintenance of TMM’s must be carried out according to the applicable OEM workshop/technical manuals and as determined by the Engineer – Mobile Reliability based on HIRA principles. Service intervals must be monitored to ensure compliance with the schedules and regular over inspections carried out to maintain service standards.

8.10.2.1 Pre-Use Checklists

No TMM may be used unless the operator of the machine has done a physical inspection of the machine and a pre-use checklist has been completed by all operators at the beginning of their shift to ensure that the lights, brakes and any other safety devices are functional prior to setting the TMM in motion, as procedure E70 GP 024, Vehicle Pre-start Inspection The checklist will clearly indicate the pre-established criteria under which the trackless mobile machine may or may not be put into motion The check list must be submitted to the shift supervision, for over-inspection and filing to be available for at least 3 months.



8.10.2.2 Pre-inspection of third party TMMs All third party TMMs, unless classified as per regulation 8.10.28 of the MHSA, must be subject to pre-inspection as per procedure TAMMESOP47, Pre-operational inspections: Mobile crane and HME on hire to RBM prior to entry to site and E70 GP023, TMM Pre Operational Inspection, by the

Engineer or his designated appointee.

8.10.3 Conditions under Which TMM’s should Not Be Used

Mandatory items on the pre-use checklist must be highlighted and the TMM may not be operated unless these mandatory items are in good working order. Other defects noted during the inspection must be corrected as soon as possible based on the

criticality of the defect.

8.10.4 Changing Wheels and Rims

The changing of all tyres and wheels must be carried out according to OEM/HIRA based procedures. The procedure must cover the safety aspects of removing, repairing, inflating and fitting of wheels taking consideration of the support of the machine during removal and fitting, the inflation of large wheels and the handling of heavy equipment as per E70 GP018, Heavy Mobile Equipment (HME) Tyre and Rim Standard

8.10.5 Changing, Inflating and Repairing of Tyres Tyre inflation procedures and pressures must comply with OEM or tyre specialist inflation specifications; refer to risk assessments TAMMEJHA 230, Mounting and Demounting of HME Wheel Assembly with Tyre Handler Forklift, TAMMEJHA 200, Inflating of Tyre at Nitrogen Station, and TAMMEJHA 208, Inflating of Tyre in the Field

8.10.6 Procedure for Repair That Could Endanger Persons

Maintenance must be carried out in according with the Safety Precautions in the OEM manuals and/or HIRA based procedures.

8.10.7 Support of TMM during Maintenance

The adequate supports of a TMM or any of its components, which may inadvertently fall on persons, are tabulated here below. NOTE: Before making use of any support, you must make sure that you match the correct support for the weight that is to be lifted

Prior to the use of any supports, the following rules are to be adhered to:

a) Perform a Hazard Identification & Risk Assessment in order to manage the possible hazards

and to ensure that the correct support is used for the correct job maximising safety

b) Perform a Pre-use Check on all tools and equipment in order to ensure maximum safety

c) Plan and organise the requested job in order to avoid unnecessary delays. This will include the:

Availability of equipment and a competent driver/operator for it Safe working area where the equipment shall not cause other traffic to be blocked. Availability of additional safety equipment over and above the prescribed PPE, where necessary Availability of the necessary tools and labour

d) If you must service the vehicle with the bin/bucket raised, perform the following safety measures:

Empty the bin/bucket and set the park brake Place a safety bar or stand under the bin/bucket Shut the engine down



Turn the start switch and master switch to the OFF position and lock it out. Chock the wheels Remove the ignition key and keep it on your person

e) NEVER work under a hydraulically raised component unless the component is secured with an approved prop, (bar) or some other safe means

f) The TMM to be supported must be parked in accordance and chocked as per procedure E 70 GP 004

Safety Stands and Trestles:-

The adequate support of a TMM or any of its components which may inadvertently fall on persons

All trestles or other devices used for the support of equipment above ground level will be of an approved design and the support equipment will be issued with a test certificate for the designed safe working load (SWL). A register will be kept of such devices with regular inspections carried out by competent Mobile Equipment Workshop personnel. Stands and trestles are tested and inspected annually by an approved service provider.

The Mobile Equipment (LDV) Workshop is fitted with a two post light vehicle lift. The safe working load of the vehicle lift shall not be exceeded. The lift will be load tested annually by an approved service provider.

Refer to procedure, COP29, Lifting Equipment and Lifting Tackle

8.10.8 Battery Changing Procedures on Battery Powered TMM’s

Refer to procedure, F Coms SOP 054, Maintaining Man up Turret Truck Batteries at RBM

8.10.9 Battery Charging and Maintenance

The following standards will apply where any battery charging for TMM’s is conducted.

Clean Impervious Floor: The flooring on which battery charging (and maintenance) is carried out must be impervious to acid spillage and maintained in a clean and good condition.

Lighting: Adequate lighting must be provided.

Minimize Acid spillage: Battery charging (and maintenance) procedures must be such that acid spillage is minimized.

Ventilation: The free flow ventilation of the area where battery charging (and maintenance) is carried out must be at least 0.5 m/s.

Ventilation Containment: The ventilation of the battery charging (and maintenance) area must be designed and located so that there is no contamination of adjacent working sections.

Provision of Water and Hosepipe: Adequate water supplies must be provided to service the battery charging area. For battery maintenance additional water and hose points to wash down spillage must be provided and procedures in place to neutralize and dispose of acid effluent.

Emergency Shower: If battery maintenance is carried out then an emergency shower must be installed conveniently located to the work area.

First Aid Equipment: Suitable and adequate first aid equipment must be available convenient to the battery charging (and maintenance) area.

Fire Precautions and Drills: A fire risk assessment must be carried out for the battery charging (and maintenance) area and fire equipment and control systems installed to meet the needs of the evaluation. Emergency evacuations, drills and firefighting procedures must be formally tested, reviewed and recorded at least twice annually.

Use of Non-Flammable Materials: The battery charging (and maintenance) building must be constructed of non-flammable material.

Other Aspects of Maintenance: Rigging, welding, exposure to toxic liquids or fumes, dust, firefighting, roadways, fuel handling, emergency preparedness, lock out procedures, hazardous substances, high pressure fluids and hot fluids are all covered in other COP’s, HIRA, SEP’s and /or SOP’s which are available departmentally.

8.10.10 Diesel refueling facilities

Permanent installed diesel refueling facilities will comply with the following requirements



i. Adequate through ventilation ii. Fire extinguishers and automated fire suppression systems to be maintained in operational

condition where provided iii. Effective provision to cater for oil and diesel spillage iv. Appropriate and adequate lighting v. Constructed in accordance with the following standards

a) SANS 10089-1: Petroleum industry Part 1: Storage and distribution of petroleum products in

above-ground bulk installations b) SANS 10089-2: Petroleum industry part 2: Electrical and other installations in the distribution

and marketing sector

Refer to procedure TOTAL 001, Offloading of fuel tankers

Refer to procedure FP GP 007, Emergency Procedure for Spillage at Tank Farms and Filling Stations

8.10.11 Hazards associated with Operation and Maintenance Other aspects such as rigging, welding, exposure to toxic liquids or fumes, dust, firefighting, roadways, emergency preparedness and the use of hazardous substances associated with operation and maintenance, must be addressed, unless covered in another Code of Practice Lifting and rigging:

REFER TO PROCEDURE COP 29, LIFTING EQUIPMENT AND MACHINERY Welding: Refer to procedure, E 50 GP001, Standards and specifications for oxy-fuel (gas) cutting, welding and heating work

Exposure to airborne pollutants: Refer to procedure, COP62M, Mandatory Code of Practice for an Occupational Health Program on Personal Exposure to Airborne Pollutants Emergency preparedness: Refer to procedure; COP 13M, Mandatory Code of Practice on Emergency Preparedness and Response Hazardous substance control Refer to procedure COP 26, Hazardous Substance Control

8.10.12 Isolation and Lock-out All trackless mobile machines shall be provided with an appropriate system or device to enable a positive isolation and lock out of the trackless mobile machines. All trackless mobile machines shall be isolated and locked out, and tested for zero potential as per procedure COP 24, Isolation/Lockout of any Hazardous System, before any maintenance or work on the TMM commences. Where “live” work must be done on TMM, it must be executed in accordance with procedure COP 53, Working on, Adjusting, or Setting, Moving or Energized Equipment and Machinery

8.11 Health and Safety Provisions on trackless mobile machines

The following will be provided with all TMM:

Roll Over Protection: Where applicable to a specific type of TMM, subject to a risk assessment, TMM shall be equipped with roll over protection to provide adequate protection to the operator in the event of a roll over.(excluding LMV and some passenger carrying vehicle which by design cannot be provided with ROPS)



Falling Object protection: Where required and based on a HIRA all TMM shall be equipped with adequate canopies, roofs or cages to protect the operator from objects falling from above.

Seat belts: All TMM will be equipped with seatbelts for all seats. Seatbelts shall be properly used whenever the TMM is running, unless a HIRA has identified that the use of seatbelts may increase the risk of injury. In this case HIRA based procedures must define the conditions and standards to be applied to protect the operator from injury. Mirrors: Rear view mirrors shall be provided to enable the operator to observe approaching vehicles and hazards. Where practical, mirrors or other suitable devices should be provided to improve operator vision of blind spots. Where this is not practical, operating procedures must define procedures to be used by the operator to ensure safety of all personnel and equipment before moving off. Articulation locks: Where the TMM is equipped with an articulation point, it must be fitted with an appropriate device to enable a mechanical lock-out of the articulation joint. Fire Extinguisher: All TMM’s will be equipped with suitable fire extinguishers or systems to protect the operator in the event of a fire. All operators must be trained on the operation of fire protection system. Trailers used for transporting flammable material or gasses (for example fuel and oxy-acetylene bottles) and/or trailers with mounted engines shall be equipped with suitable fire extinguishers or fire protection systems. Tyre fires: Training must be given to operators on trackless mobile machines tyre fires including exclusion zone Working under power line: A standard operating procedure must be put in place for activities under power line. (E24 GP 002) Isolation and Lockout point: All trackless mobile machines shall be provided with an appropriate system or device to enable a positive isolation and lock out of the trackless mobile machines. All trackless mobile machines shall be isolated and locked out as per standards defined before any maintenance or work on the TMM commences. Wheel chocks: All trackless mobile machines exceeding 3500kg in mass, excluding tracked machines, must be secured to prevent inadvertent movement parked or left unattended. Reverse alarms: All trackless mobile machines will be equipped with reverse alarms. The reverse alarm shall be automatically activated when engaging reverse gear. Seats: All trackless mobile machines shall be provided with suitable seats designed, installed and maintained to provide ergonomic protection to the operator. All glass fitted to trackless mobile machines shall be shatter proof or safety glass. Lights: All T trackless mobile machines except tracked machines shall be equipped with brake lights, indicator lights and tail lights. Tyre and Rim Safety : Operation must establish a tyre management system that is approved by Manager: Technical Asset Management Machine guarding: Adequate guards shall be fitted to protect operators and maintainers against accidental contact with rotating components (for example radiator fan and belt drives), hot surfaces (like exhausts and radiator cores or water lines) and high pressure hydraulic lines.

Protection Detection System: The PDS unit fitted to all trackless mobile machines including its display, warning lights and antennas that warns the operator, both of people and vehicles. The purpose of the PDS system is to take reasonable practicable measures to ensure persons are prevented from being injured as a result of collision between diesel powered trackless mobile machines, to detect the presence of any other trackless mobile machine within its vicinity and to warn the operators of the trackless mobile machines by means of an alarm system of each other’s presence. All trackless mobile machines shall be fitted in a phased period starting 2014 to 2017 with a PDS, operator warning and detection system of other personnel or trackless mobile machines operating closer than the prescribed safe zone, as determined for each type of



machine. The green zone will give a “pedestrian”, the orange zone will give a “slow” warning and the red zone will give a “stop” warning to the operator of the TMM as per procedures E70 GP022, Smelter Proximity Warning System (PWS) and MOA – 39, Mine Proximity Warning System (PWS).This excludes vehicles identified under regulation 8.10.28 of the MHSA. Ppersonal Warning Device - The blue 438 gram warning device, consisting of a battery and transponder, issued to all persons entering the operational area which will warn the bearer of trackless mobile machines in the vicinity as well as activating the PDS system installed in trackless mobile machines. Interactions System - A Central Database where all interactions that have been downloaded from the Vehicle Proximity Detection Systems are stored; analyzed and reported on Buggy Flag: Vehicles with a mass of less than 3500kg and exempted under regulation 8.10.28, will be fitted with a buggy flag. Lighting: All trackless mobile machines shall be fitted with adequate lighting.

8.11.1 Safety System to Negate Unexpected Incapacitation of the Driver

HIRA based procedures will define safety systems and procedures to be used in the event of unexpected incapacitation of the driver. The systems and procedures will depend on the level of risk should the driver be

incapacitated, the operating environment and conditions and the proximity to other personnel and equipment. Fatigue of operators is managed as per the guidelines provided in policy T 22 GP 001, Fatigue Management.

8.11.2 Vibration Control Devices

Adequate seating must be provided and maintained on all TMM’s to minimize vibration. All systems provided

to minimize vibration and shock loading must be maintained in a good working condition. Vibration control is managed in accordance with policy T 60 GP 001, Noise and Vibration Monitoring at RBM

8.11.3 Design, Control and Maintenance of Noise Control Systems

Where practical drivers must be isolated from the source of noise by a noise-insulated cabin. TMM to display maximum measured noise levels inside the cab as well as on the outside of the machine. Where such a cabin is not possible then appropriate PPE must be issued and used by the driver, maintenance personnel or other nearby employees to protect them from the noise. All TMM must be operated and maintained such that noise levels are minimized. Noise control is managed in accordance with policy T 60 GP 001, Noise and Vibration Monitoring at RBM

8.11.4 Prevention of Injury

a) Pedestrians required to interact with trackless mobile machines during repair work in a work place or in a travelling way or road way.

Proximity Detection System (PDS) installed between production trackless mobile machines and pedestrians to warn each other of possible collision. (Under implementation, to be fully operational end 2017)

b) Pedestrians required interacting with trackless mobile machines during maintenance work in a work

place or in a workshop.


c) The interaction of the trackless mobile machine with each other and with persons during the refuelling

processes.




d) The interaction of the trackless mobile machine with each other and with persons during traction battery replacement.

Not applicable, no battery operated traction TMM on site

e) Other trackless mobile machine being parked or operating in close vicinity of haul trucks at loading

and/ or discharge points


8.11.5 Proximity Detection System

All HME working permanently on site must be fitted, operated and maintained with a Proximity Detection System (PDS) in accordance with procedure E70GP 025, Proximity Detection System (PDS) and Start Prevention (Sedna) installation on Trackless Mobile Machinery (TMM), that will both warn the operator and pedestrians when in close vicinity to each other, installed over a phased in period, starting 2014 and ending 2017.

When installing a PDS on the HME, and determining the pedestrian warning zones for the operator the following must be taken into account:

the speed and the direction of travel of the HME;

the stopping distance and time to stop the HME;

the vehicle blind spots;

the location of pedestrians around the HME;

The stability and potential movement of the HME when interacting with pedestrians.

Testing of the PDS system forms part of the Pre-start check list, with a maintenance contract agreement with the OEM supplier.

8.11.6 A suitable ergonomic environment A technical standard is applied for the purchase of new equipment; refer to procedure E 19.1 GP 005,

Eliminating and Minimizing inherent health hazards when purchasing new equipment or replacing old equipment and tools.

Training is provided to operators on correct positioning of the TMM seats

Training on ergonomics is provided to form part of RBM’s occupational health program.

8.11.7 Signals and communications All TMM must be equipped with signal devices as prescribed in procedure E70 GP021, RBM Traffic Management Plan to warn personnel and other equipment working in close proximity to the TMM. Reverse alarms and hooters must be used to warn personnel in close proximity when driver vision is restricted in any direction. Positive contact must be made with the operator of HME before entering into the operational area of the machine

8.12 TMM’s to be operated by Competent Authorised Persons

8.12.1 Recruitment/Selection, Education and Training of Competent Persons to Drive a TMM

No person may operate TMM for which he/she has not been trained in accordance with the OEM operating procedures and found competent by the Engineer.



Recruitment, selection and training of operators and drivers of TMM will be made in accordance with policies E 70 GP 01, Human Physical Specifications of Mobile Equipment Operators and MEQTC 002 Training and Licensing of Mobile Equipment and Vehicle Operators and Drivers

The operators and drivers of all vehicles used for primary mining activities including contractors must be

authorized in writing by their supervisor and the responsible engineer, excluding vehicles as described under regulation 8.10.28 of the MHSA. This approval is valid for a period of 12 months, unless in accordance with regulation 18.1.7 of the MHSA, a person has to be re-authorized.

8.12.2 Record Keeping

Driver training records shall be maintained and kept available for at least 4 years. For drivers of RBM vehicles or hired vehicles driven by RBM employees and/or Cat.1 contractors this record shall be retained by the Mobile Training Section. The Cat.2&3 contractors’ records should be kept by the Contractor (7.4.) line manager or the

accountable 7.4 RBM line manager where there is no 7.4 contractor manager appointed.

8.12.3 Procedures for Appointment and Licensing of Competent Persons to Drive TMM’s

Driver appointment, licensing approval and issue will be done in accordance with procedure MEQTC 002, Training and Licensing of Mobile Equipment and Vehicle Operators and Drivers Drivers of TMM will carry the original license with them, except where exempted in terms of regulation 8.10.28 of the MHSA. A copy of the License Control Form is attached in Annexure 3

Where there is Category 2 or 3 contractors on site with 7.4 Contractor Managers appointed the following will apply.

No category 2 or 3 contractor employee may operate any mobile equipment on RBM site, unless:

Authorization in writing by the supervisor and the appointed Engineer or his subordinate Engineer.

For all other contractors, this authorization must be done by the Line Manager of the Company and the appointed Engineer or his subordinate Engineer of the area in which they will operate if the Contractor Company is a “Supervised” (ref. COP 09) Contractor Company.

The driver must be in possession of the following: (a) A valid medical certificate (b) Completion of the RBM “Drivers Awareness” training (c) A valid ID/Training/License card with photograph identifying the individual and the vehicles or machines for

which they are authorized to operate on RBM site (d) Either of the two below

A valid National License for the category of the vehicle or machine being operated, or

Both a valid certificate from an approved training institution for the vehicle or machine being operated and proof of a practical assessment of the competence of the operator to operate the vehicle or machine. This competence to be signed by the Manager or the appointed delegate

(e) Completion of the PDS training

Contractor Management Centre will update and issue ID/Training/License cards upon confirmation of all the requirements defined above. Only personnel with valid licenses may operate vehicles or mobile equipment on RBM site or lease.

8.13 Design of Excavations and Roadways

8.13.1 The design of all excavations and roadways must be based on a HIRA and the performance and operating

criteria of TMM likely to use the road. During the design, aspects such as TMM power, brakes, deceleration, holding, skidding, weight, load, surface friction, incline angle, height, width, clearances, turning circles must be considered.



All dangerous areas, obstructions or areas of restricted clearance must be clearly identified and marked. Working near overhead power lines must be done in accordance with procedure, E 24 GP 002, working in the vicinity of any live overhead power lines or near any other live equipment and cables. Excavations and Roadways must be inspected at frequencies as determined by Risk Assessment. The inspection must focus on the integrity of the excavation and roadways and defects should be reported and prioritized. Areas that are identified as unsafe for use should be barricaded with fix barricading. The design and layout of plant excavations and specifically roadways, considering pertinent aspects such as calculations relating to power, brakes, deceleration, holding, skidding, surface friction, incline angle and numbers of persons potentially exposed to the associated significant risks. Refer to Traffic management plan (Final Products and Mine) for general traffic rules, following distances, right of way, markings and signs. Construction of roads at the mining plants will be done in accordance with procedure, SS – 09, Construction of pond access and servitude road. Prior to entering plant areas, all TMM need to perform a brake test at the designated brake test area. Brake Test ramps are designed to replicate 20% excess of the steepest access routes to the mining plants, and are located at the entrance points to the individual plants. Included in the design is a run off arrestor bed. Dry Mining Areas: Brake Test Ramps for Front End Loaders (FEL’s) are constructed within the operational area, in such a manner that the FEL can perform a brake test before proceeding with loading operations. The operation; areas for FEL’s are kept as flat as possible, and runaways are not expected in this environment Haulage roads are constricted in accordance with SANS 1200, Road Construction, standards.

8.13.2 Based on the nature of the operation, there are no restrictions on roof height, width or turning circle

clearances 8.13.3 Identification and marking of dangerous areas, obstruction or restricted clearance A dangerous area is any place where Trackless Mobile Machines may travel or operate and considered to

be a source of danger to persons, and any place affecting the safe operation of such machines including areas containing obstructions or restricted clearances. Dangerous areas will be identified and suitably marked with conspicuous notices and symbolic signs. In the event of a broken down machine causing an obstruction, triangular markers shall be placed at a distance of 10m ahead and behind the machine. Dune license training applicable to the mining operation include identification of dangerous areas.

8.13.4 The design and location of run-off areas to slow down vehicles in case of a runaway, are at the end of the

decline, but angled away from the mining pond area (not perpendicular to a mining pond). The nature of the ore body (sand) allows for rapid arresting of any type of vehicle.

.

8.14 Operating Procedures

8.14.1 Safe Start-up, Operation and Shut down Procedures

No TMM may be used unless the operator of the machine has done a physical inspection of the machine and a pre-use checklist, as per examples SS-21, Safe Operating Procedure For A Dozer and TAMSWP 70.9, Operation of Mobile Crane, has been completed by all operators at the beginning of their shift to ensure that the lights, brakes and any other safety devices are functional prior to setting the TMM in motion. The checklist will clearly indicate the pre-established criteria under which the trackless mobile machine may or may not be put into motion.



All TMM’s must be operated as per the OEM procedures, which must be incorporated into all TMM training modules and procedures and which includes start up and shut down procedures. HIRA based procedures must be used for training of operators for each task conducted by the TMM. All TMM with a GVM > 3500kg must be chocked according to procedure E 70 GP 004, Use of chocks for mobile equipment and rolling stock, when parked or left unattended.

8.14.2 The procedures to be used on any roadway and underground incline or decline Operator training contained in RBM’s driver awareness and TMM specific training modules include training on the procedures and safety devices to be used when driving on any roadway or working on inclines or declines. Equipment and operational area training is based on a HIRA and written procedures for working or operating on inclines or declines, refer to procedure SH 55, Motor Vehicle and Mobile Machine Safety

8.14.3 Traffic rules and road signs, including speed, authority to move, right of way and restricted entry with regard to dangerous areas, obstructions or restricted clearances.

Traffic rules, appropriate to the operating parameters within the operation and plant areas, have been determined and are enforced as per procedure E70 GP021, RBM Traffic Management Plan. The appointed person shall ensure the safe usage of machines under his control. Supervisors must ensure that drivers and operators become familiar with traffic rules and procedures to be followed and that they are provided with the information and instructions necessary to perform their work safely. Clearly legible road signs are provided at appropriate places to indicate speed restrictions, road crossings, compulsory stopping, direction of travel, restricted clearances, persons working in roadways and any other activity considered necessary for the safe operation of machinery. Speed signs, indicating the maximum allowable speed for the road or area, are erected in different areas. Roadwork traffic control is done in accordance with procedure E 70 GP 002, Roadwork’s – traffic control, whilst traffic rules are enforced in terms of procedure SEC/PSO/001/2009, RBM Physical Security Operations

8.14.4 Where more than one trackless mobile machine travel in an underground incline or decline at any one time in either direction, procedure to ensure this is done safely Mining operation is limited to above ground operation where traveling of TMM is in accordance with RBM Traffic Management Plan (TMP), procedure E 70 GP 021

8.14.5 Procedure to ensure a trackless mobile machine is towed or attended to for repairs under controlled conditions Towing of any machine by another will not be allowed unless both machines are fitted with towing facilities, which are approved by the responsible Engineer or provided in the integral design of the machine by the OEM. Approved slings may be used only where tow-bars are not suitable as per procedure COP 29, Lifting

operation, equipment and machinery. Recovery of TMM will be done in accordance procedure TAMMOSWP 70.39, Recovery of Mobile Equipment and with a HIRA prepared and approved by the Engineer for the specific TMM and the conditions under which it must be recovered.

8.14.6 General Safety Rules relating to the Interaction between Pedestrians, Cyclists and TMM’s

Pedestrians have right of way in all areas, but should approach TMM with caution and only if the operator has indicated he has seen the pedestrian and indicated he can approach. Pedestrian walkways and crossings must be used where they are available. All employees (including drivers) operating in plant areas must complete both generic RBM safety, plant specific safety training programs that includes interactions with TMM’s and relates to persons working or traveling in close proximity to TMM’s and be fitted with a PWD.



Where TMM are required to interact with each other during normal operations, such activities will be done in accordance with a procedure E70 GP 005, Approach and depart from any mobile equipment. Where maintenance vehicles have to interact with TMM, it will be done in accordance with procedure E 70 GP 001, Safe operation of service vehicles around heavy mobile equipment. Warning devices must be fitted to all TMM’s to provide both audible and visual warning of their presence and intentions. In operational areas, no vehicle or TMM may approach another TMM within 50m unless the driver of the TMM has provided positive acknowledgment of the TMM and indicated that the vehicle or TMM may approach.

.

8.14.7 Methods for the Safe Loading, Transport and Unloading of Persons, Equipment, Material, Minerals or Explosives On or From TMM’s

Transport of hazardous goods and loads must be done in accordance with the provisions as stipulated in the National Road Transportation Act 93 of 1996, chapter VIII of the regulations, Transportation of dangerous goods and substances by road. Each driver must adhere to the applicable rules and procedures for the safe loading, transporting and unloading of equipment, material and minerals on or from TMM’s. The driver must ensure that nothing in the manner that equipment, materials or minerals is loaded, secured, transported or unloaded will pose a danger to any person. When loading, the driver must ensure that no persons are in a position where they may be injured. All equipment being transported in a TMM must be secured to prevent inadvertent movement. All TMM must be provided with safe means of access and egress such that the operator is able to maintain 3 point contact at all times. No persons will be transported in a goods vehicle unless the vehicle complies with regulation 247 of the National Road Transportation Act 93/1996. Equipment and materials may not be transported in the same compartment as people unless properly secured or stowed. As required by the National Road Traffic Act, permits for the transportation of people and equipment must be obtained. The application for this permit is the responsibility of the Line Manager (or designate) responsible for moving the people/equipment. For the conveyance of abnormal loads, the person responsible for the abnormal load must obtain permission from the relevant provincial authority as per procedure E 70 GP 007, Transportation of abnormal loads. The transportation of radioactive products must comply with the conditions of the Nuclear Certificate of Registration COR 26, issued in terms of the National Nuclear Regulatory Act and Regulations (47/1999). No TMM may be overloaded. The procedures and training for operation of the TMM must include methods for the operator to ensure the TMM is not overloaded. All TMM will be equipped with a clearly visible sign indicating the maximum safe working load of the TMM. No persons may be transported in a trailer unless it has been purpose built and approved for this purpose and provides the same protection to the passengers as defined in this COP. HIRA based procedures must be in place for the operation of the trailer. All trailers operating on public roads must comply with the relevant regulations of the National Road Traffic Act.

8.14.8 Procedure to ensure trackless mobile machines entering mine premises pose no

significant risk The following procedures are used to ensure TMM entering the mine pose no significant risk:

E70 GP021, RBM Traffic Management Plan

E70 GP022, Smelter Proximity Warning System (PWS)

E70 GP023, TMM Pre Operational Inspection

E70 GP024, Vehicle Pre-start inspection

E70 GP025, Proximity Detection System (PDS) and Start Prevention (Sedna) installation on Trackless Mobile Machinery (TMM)

E70 GP026, TMM Brake Testing

MOA – 39, Mine Proximity Warning System (PWS)



TAMMESOP47, Pre-operational inspections: Mobile crane and HME on hire to RBM

Any vehicle entering the production area that does not comply with the TMM COP must be escorted by a mine vehicle

8.14.9 Safe Towing or Pulling of Trailers and Skid Mounted Machinery by TMM

The towing and towed vehicle mass ratio may not exceed the OEM recommendations for the operating conditions and environment. Where this is not available the combined braking power of the towing and towed vehicles must be sufficient to ensure the two vehicles can be stopped without causing risk to

persons.

Trailers No trailer will be used for the conveyance of persons. All trailers supplied , will be designed in accordance with SANS specifications applicable to the manufacture of trailers, and comply to requirements as prescribed under the National Road Traffic Act (Act No. 93 of 1996)

Skid mounted machinery Skid mounted machinery must be towed in accordance with the procedure based on a risk assessment, approved by the Engineer for the specific equipment.

8.15 Illumination of Environment

8.15.1 Positioning and Spacing of Lights

Adequate lights must be provided at night at all places where work is being done in such a way that the work can be done safely and accurately.

They must be so spaced so that the external parts of the structures are also clearly visible.

Must adhere to Regulation 15.3.2 of the MHSA

The positioning and spacing of lights providing illumination for the general area where transport of persons, material, mineral or explosives takes place.

8.15.2 Intensity and Dispersion of Lights.

Lights are to be positioned with sufficient illumination intensity to all areas within the transport environment where significant risks are anticipated as per risk assessments that have been carried out previously

Lighting will be provided as per plant standards where loading and off-loading of persons, material, mineral or explosives take place.

A lighting surveys should be conducted after any changed circumstances and improvements as an on- going practice.

8.15.3 Reflectivity of the Surrounding area

Lighting must be installed such that no reflection of light occurs that may impair the vision of drivers of TMM’s or persons working in their vicinity.

8.15.4 Steps to be taken in the Case of Illumination Failure

Installed lighting must be maintained at the original illumination levels through regular monitoring and maintenance via planned maintenance system. Drivers are required to stop work if they consider that it is unsafe to continue, or as required by

procedures.

8.16 Visibility of trackless mobile machines, trailers, skid mounted machinery and persons



8.16.1 Placing of Signs to Warn in the Case of Parked, Stationary and Broken down TMM’s that are poorly visible

Under normal conditions TMM’s should only be parked in designated or safe parking areas. Under emergency/breakdown conditions the driver must place reflective warning triangles (supplied with all vehicles), ahead and behind the vehicle to provide sufficient warning to other road users, as covered in RBM Driver Awareness training.

8.16.2 Measures to Ensure the Visibility and Safety of Pedestrians, Cyclists or Other Workers Close to TMM’s

All persons working in and around TMM’s in operational areas must be issued with a PWD tag and wear high visibility PPE to improve their visibility and to alert TMM drivers to their presence as per procedure, E 70 GP 005, Approach and depart from mobile equipment.

8.16.3 Timeous Warning Systems, Where Employees Work in Haulage’s where TMMs Operate

All drivers of TMM’s working in operational areas must be informed of work that is taking place within their operating area that may impact on their safety or the safety of others due to the operation of TMMs. Where practical and according to the HIRA risk factor involved TMM operations may be either suspended or re-routed or physical barriers installed in order to remove hazards. Adequate signage, warnings or traffic control must be in place during work on haulage ways or roads. Where persons need to enter into the operational area of TMM, approach and departure to and from such TMM must be done in accordance with procedure, E70 GP005, Approach and depart from any mobile equipment.

8.17 Inclines and Declines

8.17.1 Devices and Procedures to be used for safe operation within any incline or decline where trackless mobile machines are used.

To ensure the safe operation of TMM on an incline or decline, the following measures are put into place

Speed limit to 40km/h on the Mining Plants sand roads, refer to procedure E 70 GP 021, RBM Traffic Management Plan

Adherence to traffic regulations as per procedure E 70 GP 021, RBM Traffic Management Plan

Pre-start vehicle inspection as per procedure as per procedure E 70 GP 024, Vehicle Pre-start Inspection

A static brake test as per procedure, E 70 GP 026, TMM Brake Testing

A ramp brake test as per procedure E 70 GP 026, TMM Brake Testing

Driver awareness training on going up an incline and down a decline, applicable to mining operation

8.17.2 Where installed, run-off areas to slow down vehicles in case of a runaway The design and location of run-off areas to slow down vehicles in case of a runaway, are at the end of the decline, but angled away from the mining pond area (not perpendicular to a mining pond). The nature of the ore body (sand) allows for rapid arresting of any type of vehicle.

8.17.3 Measure must be in place that shall allow only one trackless mobile machine travelling in an incline or decline at any one time in either direction except when being towed or attached to for repairs, and under controlled conditions Access roads into the mining operations are constructed to allow for dual direction travel without impacting on TMM going in the opposite direction, where real estate allows, barriers are placed to separate dual traffic flow, refer to Mine TMP

8.18 Raising/Lowering, suspension and transporting of persons



8.18.1 Rules for the Use of TMM’s for the Raising, Lowering, Transportation or Suspension of Persons Generally and in an Emergency No person may be raised, lowered or suspended by means of a lifting machine in a man basket (Bosans Chair) except with the written permission of the Engineering 2.13.3.1 appointee and subject to such conditions as he may specify in his permission. Drivers / operators must have a valid license and be certified competent and appointed to operate the mobile crane or Mobile Elevated Platforms (MEWPS) All devices used for lifting of persons must be properly designed, constructed and certified for that purpose. HIRA based procedures must define the procedures, systems and devices to be used when hoisting persons in accordance with procedure E29 GP 002, Lifting and hoisting planning and recovery. Site area inspection must be undertaken for the use of Mobile Elevated Platforms (MEWPS) to ensure ground stability, inclination and working clearances. Area working at heights officer (WAH) to approve the use of MEWPS after reviewing risk assessment in accordance with procedure E28 GP 006, Working at heights – principles and minimum requirements. MEWP’s must be used in accordance with procedure E 28 GP 007, Safe use of Mobile Elevated Work Platforms.

8.18.2 Rules for transporting persons No person may be transported in any TMM that is not fitted with passenger seats and seat belts and the vehicle complies with regulation 247 of the National Road Transportation Act 93/1996. No dangerous materials may be transported with persons in a TMM. No person shall embark or disembark of a vehicle whilst it is still in motion No person may be transported in any TMM where the machine is not designed for it. For goods vehicles which have been modified for the conveyance of passengers, the following shall apply:

All passengers shall be seated with individual seatbelts as per procedure E 70 GP 008, Standard for seatbelts on all vehicles and mobile equipment

Passengers are to remain in their seats and are not allowed to stand up whilst the vehicle is in motion.

No smoking is allowed in any company vehicle

All passengers shall be enclosed within a suitable enclosure, which protects them from the elements. The enclosure shall be of sufficient strength to prevent a person from falling from such vehicle when it is in motion (when canvas covers are used, additional steel or fiberglass side protection is required to a height of at least 350mm above the surface on which a person is seated).

The vehicle, seating and enclosure shall be designed and constructed to protect the occupants from serious injury in the event of an accident, including rollover.

Sufficient head clearance shall be provided for all seated passengers with consideration of the impact as a result from roll-over.

Any door to the compartment in which passengers are conveyed shall be capable of being opened from the inside and outside.

The maximum and minimum permissible axle loads shall not be exceeded. The axle mass load of a steering axle must not be less than 20% of the sum of all axle mass loads.

8.19 Personal Protective Equipment

Richards Bay Minerals is committed to providing a safe and healthy place of employment. Procedure POL 132, Personal Protective Equipment (PPE) Policy set forth the requirements in order to protect all employees, contractors and visitors from exposure to workplace hazards and the risk of injury through the use of personal protective equipment(PPE).



Appropriate PPE must be issued to all workers according to baseline HIRA. Typically for TMM drivers this can include hard hats, safety boots, overalls, hearing protection, and in certain cases gloves, dust masks, high visibility clothing and life jackets if working close to water. All issue of PPE will be recorded in registers which will be maintained and available departmentally. In order to manage TMM to person interactions all persons must be equipped with a PWD and have it on person at all times while in operational areas. The issue of PWD’s must be controlled from centralized points. All employees that are in the operational areas must wear a personal warning device (PWD) to ensure that they and any HME that they interact with are warned of each other’s presence as per procedures E70 GP 022, Smelter Proximity Warning System (PWS), MOA – 39, Mine Proximity Warning System (PWS) and E70 GP021, RBM Traffic Management Plan All employees must complete the RBM generic safety training program and plant specific training which includes the reasons for wearing, care and use of the PPE issued to them. PPE must be managed in accordance with procedure COP 17, Personal Protective Equipment.



Part D: Implementation

1. Implementation Plan Activity Task Responsible

Infrastructure

Maintenance of TMM / pedestrial segragation

Engineering

Dedicated Parking Areas Engineering

Mine Infrastructure Development Mine Development

Training

Driver awareness and TMM training Mobile Ops Training

Authorisation of drivers Engineer

Risk Management

RBM Risk Management Strategy SHEQ

Planned Task Observations Supervisor

TMM inspections Engineering

Fatigue Management SHEQ

Investigations Proximity detection Engineering

Ergonomic & Vibration Survey SHEQ

2. Compliance with the COP

The Engineer will be responsible for compliance with the COP Planned Task Observations, as described in this COP TMM will be carried out The Mobile Training Department will be responsible for driver awareness, practical evaluation, and assessment of TMM operators and maintaining of competency TMM operator records.

Access to the COP and Related Documents A signed copy of the COP and related documents will be readily available from the RBM Document office. Copies of the COP will be available to the employee representative unions. An electronic version will be available on RBM intranet. Training will be provided to ensure compliance with this COP.



REVISION HISTORY AND APPROVAL

REV NO.

DATE PAGE NRS DETAILS

1 August 2000

Added section 2.1.9 – 2.1.11 and reference to Rio Tinto safety standards

2 Sept 2000 Added section 5 purchasing standards

3 June 2001 Mandatory inclusions from the DME 16/3/2/2/A2

4 Oct 2004 All pages Total review and update following BOP and audit of COP by DME. Inclusion of discontinued COP 27 - Conveyance of People and Goods

5 March 2005 5, 7, 9, 13, 14, 17, 18, 19, 20

Review the contractor management portion. After the review meeting held with the contracting HME operators on the 29

th of

March 2005, the final changes were made to this draft copy

6 Feb 2008 General review and update to include new COP’s and SOP’s

7 May 2009 4,8,10,12,13,14,21,23,2 General review and update to include new COP’s and SOP’s.

Inclusion of “OTR” tyre and rim management.

Inclusion of RT C3 Standard.

Protection from falling object.

Prevention of inadvertent uncoupling.

Light fitted to TMM’s.

Pre-use checklist. ROPS. Tyre fire and training. Tyre and rim safety. Warning Equipment. Changes to Annexure 1 and Annexure 3

8 July 2009 23 and 24 Amend Annexure 3 to read responsible 7.4/2.6.1 appointee

9 November 2011

4, 7, 9, 13, 14, 17 and 18 Item 3.5 page 4 – updated references. Item 6.1 page 7 – change reference from ESVSOP07 to ESMESOP47.

Item 6.6.1 on page 9 – added reference to E70 GP006.

Item 6.12.1 on page 13 – 6th bullet – Fire Extinguishers

Added last sentence:

Trailers used for transporting flammable material or gasses (for

example fuel and oxy-acetylene bottles) and/or trailers with

mounted engines shall be equipped with suitable fire

extinguishers or fire protection systems.

Item 6.12.1 on page 14 - Added last bullet

Machine Guarding: : Adequate guards shall be fitted to protect operators and maintainers against accidental contact with rotating components (for example radiator fan and belt drives), hot surfaces (like exhausts and radiator cores or water lines) and high pressure hydraulic lines. Item 6.16.5 on page 17 – added reference to E70GP007 for abnormal loads.



Item 6.17.1 on page 18 – added the following:

No person may be raised, lowered or suspended by means of a lifting machine in a man basket (added section) except with the written permission of the Engineering 2.13.3.1 appointee and subject to such conditions as he may specify in his permission. Added reference to E29 GP002 at end of 1

st

paragraph.

Item 6.17.1 on page 18 – added the following:

Site area inspection must be undertaken for the use of Mobile Elevated Platforms (MEWPS) to ensure ground stability, inclination and working clearances. Area working at heights officer (WAH) to approve use of MEWPS after reviewing risk assessment (see E28 GP006).

Item 6.17.1 on page 18 – 2nd bullet last sentence added: The passengers enclosure shall be of sufficient strength to prevent a person from falling from such vehicle when it is in motion (when canvas covers are used, additional steel or fiberglass side protection is required to a height of at least 350mm above the surface on which a person is seated). Item 6.17.1 on page 18 – 3rd bullet changed to read:

Sufficient head clearance shall be provided for all seated passengers with consideration of the impact as a result from roll-over.

10

July 2013

Document numbering has been changed to align to DMR

guideline.

Change title of Manager: Support Services to Manager:

Engineering Operations

Item 8.2.6 on page 8 - Added the highlighted wording:

Individual TMM drivers must test their TMM braking systems, according to SOP’s or training modules, at the start of every shift as part of the pre-shift checklist. Any machine failing this pre-shift brake test may not be operated until the fault(s) have been rectified. A dedicated sloped park brake testing area should be provided for identified TMM’s requiring testing on an inclination.

Item 8.7.1 on page 10 – Deleted “equivalent to 1.5 times the safe stopping distance of the TMM at its maximum allowable speed. The stopping distance shall include a reaction time of one second for the operator.” Replace deleted sentence with “10 lux at a distance of 20 meters” to align with the minimum standard as set out in the Mines and Works Regulations (GNR. 992 of 26 June 1970)



Item 8.13 on page 8 - Added: Excavations and Roadways

must be inspected at frequencies as determined by the Risk

Assessment. The inspection must focus on the integrity of

the excavation and roadways and defects should be reported

and prioritized. Areas that are identified as unsafe for use,

should be barricaded with fix barricading

Item 8.15.3 on page 17 - Added: Where TMM are required to

interact with each other during normal operations, such

activities will be done in accordance with a SOP which will

include the safe interaction between the different units. Such

an area must also be marked as an exclusion zone for

TMM’s only

Safety Committee Members included in approval process.

Annexure 1: Corrected number of machines

11 August 2015

All pages Total review in terms of the amendment of Chapter 8 of the

regulations

12 Oct 2015 1,3,5,8,9,12,14,17,18, Include next revision date; page 1

Item 4, include affiliation; page 3

Item 5.5, include new procedures E 70 GP 023 and T 60 GP

001; page 5

Item 5.6 – include references ISO 3471:2008 Earth Moving

Machinery – roll over protection and ISO 7096 – 2000 Earth

Moving Equipment – Laboratory evaluation of operator seat

vibration; page 5

Item 6.1 – include definition of ECSA; page 5

Item 7 – include SIMRAC report, change update from 3 to 2

years; include continuous risk assessment process, page 8

Item 8.3.2 – include reference to ROPS design standard, ISO

3471:2008; page 9

Item 8.7.2 – change colour for LDV rotating light from green

to amber; page 12

Item 8.10.3 – Include reference to procedure E 70 GP 023,

TMM Pre Operational Inspection; page 14

Item 8.11.1 – include reference to procedure E 70 GP 022,

Smelter PWS and MOA 39, Mine PWS; page 17

Item 8.11.2.1 – include vibration control management and

reference policy T 60 PG 001, Noise and Vibration

Monitoring at RBM; page 17

Item 8.11.2.3 – include reference to display of measured

maximum noise levels; page 18

13 Jan 2017 All pages

Review in accordance with guideline DMR 16/3/2/2 – B2

issued by the CIOM dated 23 Sept 2015



APPROVALS

POSITION NAME DATE SIGN

Manager – Reliability and Asset Management

Chairperson – Health and Safety Committee

Full Time Health & Safety Representative – Final Products

Full Time Health & Safety Representative - Mine

Health & Safety Representative - UASA

Health & Safety Representative - NUM

General Manager – Technical and Asset Management



ANNEXURE 1

References List of Relevant SIMRAC Project Reports, Standards and Notifications

Reference documents used in compiling the TMM COP – SIMRAC Reports, SANS Standard and DMR Report

COL 203 Engineering and human factors in machinery and transport accidents.

COL 341 Guidelines for the development of safer use of mobile machines.

COL 416 The influence of ergonomics of trackless machines on safety and health.

GEN 420 Methods whereby noise levels of mining equipment may be reduced.

GEN 603 an ergonomics strategy for the South African mining industry

SIM 02 05 04 Ergonomics of mining machinery and transport in the South African mining industry

SIM 02 05 02 Factors affecting driver alertness during the operation of haul trucks in the South African mining industry

SIM 040502 Brake testing on Trackless Mobile Mining Machines

SANS 1589/1:2012 The braking performance of Trackless Mobile Mining Machines Part 1: General Requirements

ISO 3471:2008 Earth Moving Machinery – Roll over protection structures

ISO 7096-2000 Earth Moving Machinery – Laboratory evaluation of operator seat vibration

DMR Report, 20131106 Mines Fatality



ANNEXURE 2

Description of Trackless Mobile Machinery in Use at RBM

The TMM fleet at RBM consists of the following categories and numbers of machines. Contractor TMM numbers may vary from time to time depending on requirements.

Type of TMM RBM Contractor Cranes 3

Excavators 9 11

Challenger Crawler crane 2

Mobi-lifts 1

Dozer D6, D7, D8 and D65 20 8

Front End Loaders – FEL 12 36

Grader 2 1

Bomag Roller 1 2

Skid Steers 1 3

Skidder 5

Articulated Dump Truck - ADT 1 18

Bell Logger 5

Pot Carrier – Large 3

Pot Carrier – Small 2

Forklifts 18 1

Man-up Forklift – battery operated 4

Horses 5 4

Tipper Trucks 0 4

Tractors 4 1

Light Delivery Vehicles (LDV) 169 161

Mini / Midi Passenger Busses 47

Passenger carrying truck, 4x4 6 2

Trucks, 4x2 and 4x4 10 18

Ambulance 2

ADT Flat Bed Truck 1

Back Actor (TLB) 4 4

Bell Trailers 4

Unitrans Fleet 18

MEWPS 7

Drill rigs 1



ANNEXURE 3

Drawings of Areas of Restricted Vision for Operator/Driver

Due to electronic file limitations these drawings are not included in the COP. The drawings for areas of restricted vision of the operator for each category of TMM are available from the RBM drawing office and the Mobile Equipment Training Centre. These drawings must be incorporated into driver induction and training modules. If a Cat. 2 or 3 Contractor Company is operating a TMM where RBM does not have a copy of the restricted vision drawing in the RBM drawing office or the Mobile Equipment training center; the Contractor Company needs to ensure that they have a drawing in their own training facility and that the drivers are briefed on this hazard.

Refer to RBM drawing 0499-M-0029 Front End Loader, Bell 0499-M-00308 Front End Loader, Cat 0499-M-00301 Front End Loader, CAT 428 TLB 0499-M-00306 Cat 325 Pingon 0499-M-00307 Bell Tractor and Trailer 0499-M-00300 Krest Iron Pot Carrier 0499-M-00309 CAT Raised Cab, Magnetic Hoist 0499-M-00311 Bell Grader 0499-M-00302 Cat 329D Excavator 0499-M-00298 Bell Front End Loader 0499-M-00305 Drill Rig 0499-M-00304 CAT Dozer D8R 0499-M-00303 CAT Dozer D7R



ANNEXURE 4

TMM Design and Specification Register Refer to RBM Sharepoint documents – Engineering / Specifications / Technical Specifications / TMM Design and Specification Register

COP 70 Operation of trackless mobile machinery

Documents

Transcript of COP 70 Operation of trackless mobile machinery