Specification

Standard Engineering Specification

General Guarding Requirements

Engineering

14 June 2012
100-SP-ME-0003
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TABLE OF CONTENTS

1. SCOPE ........................................................................................................................... 6

2. DEFINITIONS ................................................................................................................. 6

3. REFERENCE DOCUMENTS .......................................................................................... 7

3.1 FMGL Documents .............................................................................................. 7
3.2 Australian Standards......................................................................................... 8
3.3 General Documents & Standards ..................................................................... 8

4. GENERAL ...................................................................................................................... 9

5. DESIGN ........................................................................................................................ 10
5.1 General Design Requirements ........................................................................ 10
5.1.1 Function ............................................................................................... 10
5.1.2 Structural Integrity ................................................................................ 10
5.1.3 Removal............................................................................................... 10
5.1.4 Weight ................................................................................................. 11
5.1.5 Inspection Doors .................................................................................. 11
5.1.6 Projectile Protection ............................................................................. 11
5.2 Signage and Labelling..................................................................................... 12
5.3 Existing Equipment ......................................................................................... 12
5.4 Temporary Guarding ....................................................................................... 12

6. ORE PROCESSING PLANT AND EQUIPMENT GUARDING ...................................... 13

6.1 General ............................................................................................................. 13
6.2 Conveyor Guarding ......................................................................................... 13
6.3 Control Standards ........................................................................................... 13
6.4 Conveyor Guarding Further Design Considerations .................................... 15
6.4.1 Identification and Signage .................................................................... 15
6.5 Unprotected Edge, Removable Platforms & Walkways ................................ 15
6.5.1 Access Gates ....................................................................................... 16
6.6 Belt Drives ........................................................................................................ 16
6.7 Couplings and Shafts ...................................................................................... 16
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6.8 Workshops and Laboratories ......................................................................... 17

7. DROPPED OBJECT PROTECTION............................................................................. 17

7.1 Exclusion by Fences or Barricades ............................................................... 17
7.2 Protective Guardrail or Mesh .......................................................................... 18
7.3 Solid Flooring .................................................................................................. 18
7.4 Surge Protection.............................................................................................. 18
7.5 Shedders .......................................................................................................... 18
7.6 Rock Catch Protection .................................................................................... 19

8. CONTROLLED ACCESS PROTECTION ..................................................................... 19

9. IMPORTED EQUIPMENT ............................................................................................. 20

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List of Tables

Table 1: Definitions and Roles ................................................................................... 6

Table 2: Specifications and Data Sheets ................................................................... 7
Table 3: Drawings........................................................................................................ 7
Table 4: Standards and Codes ................................................................................... 8
Table 5: Legislation ..................................................................................................... 8
Table 6: Exclusion Areas by Barricade or Fences .................................................. 17
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1. SCOPE

This specification describes the general guarding requirements for FMGL and defines the
requirements for guarding to limit personnel interaction with plant and explains where there may
be differences to relevant Australian Standards.

This Specification applies to all FMGL sites.

This specification does not cover:

(i) Guarding requirements for construction equipment and temporary plant, i.e.
mobile aggregate plants

(ii) Guarding specific to mobile equipment or temporary guarding or barricading for

construction, maintenance or operational activities.

This specification does not repeat requirements already included in FMGL Design Criteria or
Equipment Specifications or the applicable Australian Standards.

Guarding requirements which are specific to equipment are described, in more detail, in the
FMGL Design Criteria or Equipment Specifications relevant to that piece of equipment.

2. DEFINITIONS

For the purposes of this document, the abbreviations and definitions listed in Table 1 apply.

Refer to the FMGL Mechanical Equipment Design Criteria for standard definitions and the
FMGL Major Hazards Control Standard for further common HSES terms and definitions.

Table 1: Definitions and Roles

Term Meaning

ALARP As Low as Reasonably Practical.

Contract Formal commercial agreement under which the work is performed and includes
“Contract”, “Agreement” or “Order” as the case may be.

Contractor The provider of goods or services under the Contract.

Critical Control Controls that have a primary role in the management of Major Hazards.

FMGL Fortescue Metals Group Limited.

Guard A guard is a physical barrier that prevents or reduces access to a danger point or area.

HSES Health, Safety, Environment and Security

MHCS Major Hazards Control Standards.

PIMS Project Information Management System.

Principal Fortescue Metal Group Limited.

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Principal Signatory The person signing on behalf of FMGL.

Principal Representative FMGL Responsible Representative.

Principal Engineering FMGL design criteria, specifications, data sheets, procedures and drawings which
Standards prescribe the minimum FMGL requirements.

3. REFERENCE DOCUMENTS

3.1 FMGL Documents

Table 2: Specifications and Data Sheets

Do c u m e n t No . Title
100-SP-ME-0001 Standard Engineering Specification for Conveyor Design Criteria
100-SP-ME-0002 Standard Engineering Specification for Mechanical Equipment Design Criteria
100-ST-SA-1000 Major Hazards Control Standard
100-PR-PM-0013 Safety in Design Procedure

Table 3: Drawings
Do c u m e n t No . Title
CO-00000-DR-CI-0036 CONCRETE STANDARDS SECURITY FENCE AND GATES GENERAL DESIGN
CO-00000-DR-ME-0032 MECHANICAL STANDARDS SKIRT & LOADOUT GENERAL ARRANGEMENT
CO-00000-DR-ME-0033 MECHANICAL STANDARDS SKIRT & LOADOUT SECTIONS
CO-00000-DR-ME-0036 MECHANICAL STANDARDS PORT LOADOUT & SKIRT ARRANGEMENT
CO-00000-DR-ME-0116 MECHANICAL STANDARDS HEAD CHUTE DETAILS SHEET 2
CO-00000-DR-ME-0121 MECHANICAL STANDARDS - INSPECTION DOOR DETAILS - SHEET 1
CO-00000-DR-ME-0122 MECHANICAL STANDARDS - ACCESS DOOR DETAILS - SHEET 2
CO-00000-DR-ME-0146 MECHANICAL STANDARDS CARRIAGE TAKE-UP 25T GUARDS ARRANGEMENT
AND DETAILS
CO-00000-DR-ME-0147 MECHANICAL STANDARDS SAFETY GUARDS - PANEL ARRANGMENT
CO-00000-DR-ME-0148 MECHANICAL STANDARDS SAFETY GUARDS 18m TRUSS ARRANGEMENT
AND DETAILS
CO-00000-DR-ME-0151 MECHANICAL STANDARDS SAFETY GUARDS IN TRANSFER STATION
ARRANGEMENT AND DETAILS
CO-00000-DR-ME-0150 MECHANICAL STANDARDS DRIVE GUARDS ARRANGEMENT AND DETAILS
CO-00000-DR-ME-0149 MECHANICAL STANDARDS SAFETY GUARDS ARRANGEMENT AND DETAILS
CO-00000-DR-ME-0123 CLOUD BREAK ORE HANDLING MECHANICAL STANDARDS 1000x750 CHUTE
ACCESS DOOR
CO-00000-DR-ME-0124 CLOUD BREAK ORE HANDLING MINE STANDARDS INSPECTION DOOR -
DOUBLE OPENING
CO-00000-DR-ME-0125 CLOUD BREAK ORE HANDLING - MINE STANDARDS - 750X1800 ACCESS
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Do c u m e n t No . Title
DOOR/500 X 500 INSPECTION DOOR
CO-00000-DR-ME-0126 CLOUD BREAK ORE HANDLING MINE STANDARDS INSPECTION DOOR
DETAILS (REMOVEABLE MESH)
CO-00000-DR-ME-0144 MECHANICAL STANDARDS PORT & MINE TAIL END GUARD ARRANGEMENT
CO-00000-DR-ME-0152 MECHANICAL STANDARDS PORT LOADOUT CROSSOVER ARRANGEMENT
AND DETAILS
CO-00000-DR-ME-0153 MECHANICAL STANDARDS PORT AND MINE - DUST COVER/GUARD MODULE -
DETAILS
CO-00000-DR-ME-0145 MECHANICAL STANDARDS PORT AND MINE - WATER SPRAY MODULE -
ARRANGEMENT
CO-00000-DR-ST-0068 STRUCTURAL STANDARDS SAFETY GUARDS STRUCTURAL SUPPORT
DETAILS

3.2 Australian Standards

Table 4: Standards and Codes

Do c u m e n t No . Title
AS 1755 Conveyors – Safety Requirements
AS 4024.1 Safety of Machinery
AS 1319 Safety Signs for the Occupational Environment
AS 1318 SAA Industrial Safety Colour Code

3.3 General Documents & Standards

Table 5: Legislation
Title
Mines Safety and Inspection Act,1994
Mines Safety and Inspection Regulations, 1995
Occupational Safety and Health Act 1984
Occupational Safety and Health Regulations 1996
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4. GENERAL

Guards shall be designed in accordance with the FMGL Engineering Standards, Major Hazards
Control Standards, Australian Standards and relevant statutory obligations.

In the event that a suitable FMGL Engineering Standard Equipment Specification, Design
Criteria or Drawing does not adequately cover the risk for a piece of equipment, then a formal
risk assessment shall be undertaken which complies with the intent of both FMGL and
Australian Standards. This risk assessment shall be used to identify the location, type and level
of guarding, barricade or exclusions to ensure that all risks are minimised to As Low As
Reasonably Possible (ALARP) and that guarding is consistent with the plant area in which the
equipment is to be installed.

All equipment shall be guarded where the risk of harm exists through inadvertent exposure to
moving parts or projectiles or where specified in relevant legislation. Plant and equipment shall
be provided with adequate safety guards, signage and devices necessary to protect personnel.

Guarding installed on equipment on FMGL sites (Mine, Rail or Port), are not designed to
prevent personnel actively and intentionally defeating them by deliberate actions whilst the plant
and equipment is in operation. The guards are designed to prevent inadvertent contact with nip
points or other areas of danger. The guards are designed to be easily removed, if required,
once the plant or equipment is correctly isolated as per FMGL Procedures.

Should guards need to be removed for operational or maintenance purposes, the plant or
equipment concerned must be isolated as per FMGL’s Procedures. A risk-based process shall
be in place for the temporary removal of guards on operating plant and equipment, e.g. for the
purposes of fault finding, testing and commissioning.

Interlocked guards are not to be used unless approved by FMGL, except in workshop
environments for equipment such as CNC machinery etc and where the equipment is designed
and installed in accordance with AS 4024.1. Fail to safe switches / devices shall be installed on
all manually operated rotating plant and equipment including power hand tools.

Where equipment is being guarded to prevent access or injury to the public and to personnel,
who are potentially unfamiliar with the Principal operations, and who access such areas as
accommodation villages, guarding shall be designed to be removable, only with the use of tools.

Guarding shall be reviewed as part of the major hazards physical separation review process
ensuring the Major Hazards Control Standard (MHCS), minimum standards are adhered to.

Guarding shall be installed and maintained in accordance with this document.

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5. DESIGN

Large pinned guards shall not be used due to the difficulty in removing and reinstating them.

Guards shall be constructed from 'ARC' mesh, 50x50x4 mm, with rolled edges, unless noted
otherwise on the drawings. Finish paint colour Y14 Golden Yellow.

Guards on rotating equipment shall cover the complete rotating component with no gaps
between the guard and housings, i.e. Low speed coupling guards and bearing housings.

5.1 General Design Requirements

5.1.1 Function

Equipment guarding shall be designed to perform its intended function when subject to all
conditions. Normal operational and non-operational conditions shall be reviewed to determine
the type of guard required, the structural integrity required of the guard, commissioning
requirements and any special requirements of operations and maintenance personnel.

Wherever possible guard installation should take into consideration the potential for spillage of
process material and allow for easy clean up. Where guarding is installed on concrete slabs, for
example, support posts mounted on the floor should be minimised. As a general rule guarding
should be supported from existing structure to facilitate cleanup operations.

Guarding shall be provided to protect personnel from hand related injuries such as burns.

Guards shall be designed considering practical reach distances for the equipment being
guarded as defined by AS 4024.1 and AS 1755.

5.1.2 Structural Integrity

Guarding shall be designed such that it will not permanently or temporarily deform under
operational conditions. Guarding shall be designed such that any deformation will not be to an
extent where the guard becomes ineffective by reducing clearances, creating openings or
through collapse. Guarding by design shall not allow personnel to climb or gain access onto the
guards. Under normal handling conditions the guard should not permanently deform.

5.1.3 Removal

Plant, equipment and machinery must be isolated if guards and interlocks are to be removed or
deactivated.
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Removal of guards once the equipment is isolated shall not expose personnel to further hazards
for example; a guard should not serve a dual purpose of guarding from rotating equipment as
well as falling from heights. Where required additional protection or guarding may be required
to protect from a secondary hazard, i.e. hand railing behind guards. It is the designer’s
responsibility to ensure such hazards are identified and the necessary measures are included in
the design to provide a safe work area.

5.1.4 Weight

Guard or guard component weights should not exceed 20 kg where the removal of the entire
guard or part of the guard is required for maintenance access. Guarding and any sub
components should be designed to be removable by one person. Where this is not possible,
hinged guards should be considered or multiple lift points shall be provided to allow multiple
personnel to remove the guards or guard sections up to a maximum weight of 40 kg. Again, the
structural rigidity of the guard should be considered when using these lift points to ensure flex or
twisting of the guard does not create awkwardness in lifting the guard.

Guards heavier than 40 kg or located in confined areas shall have appropriate lifting points to
allow removal by crane, hoists or chain blocks. The surrounding structure shall also be
reviewed for sufficient crane access or appropriate lifting points provided.

5.1.5 Inspection Doors

Equipment shall be designed so that monitoring and inspection requirements are able to be
conducted outside the guards and barricades.

Where a maintenance access door or hatch in a solid plate guard is required to be opened for
inspection purposes, whilst the equipment is operating or energised, a mesh panel shall be
used to protect the opening.

When a mesh safety door is to be opened the equipment to be inspected must be isolated as
per FMGL’s Procedures. A sign shall be fitted above or adjacent to the opening stating “Danger
Isolate Equipment Before Opening Inner Guard Door”. The mesh shall be sized in accordance
with the reach dimensions defined in AS 4024.1 and AS 1755.

5.1.6 Projectile Protection

Guarding shall be of a sufficient standard to prevent projectiles or product from causing harm or
injury to personnel external to the source.

Where there is a risk of components or fluids being ejected from the area being guarded, the
guard shall be designed to prevent the ejected item becoming a hazard, i.e. fluid from fluid
coupling, tramp metal from jaw crusher, noise emission, gas emission, etc.
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5.2 Signage and Labelling

All guards shall be signed or labelled in accordance with AS 1318 and AS 1319 and/or as
defined by the FMGL Standard Engineering Documents and Drawings.

The weight of the guards shall be clearly shown on the guards.

A typical signage and labelling example is shown on FMGL Standard Engineering Drawing: CO-
00000-DR-ME-0147.

Labels and signage shall be positioned to ensure they are clearly visible and not prone to
obstruction by spillage or other equipment and shall not be attached to doors such that the
signage is not visible when the door is opened.

The labelling should be legible at all times and should take into account the environment in
which the label is installed. In some instances this may require engraved or silhouette type
labels.

5.3 Existing Equipment

Guards and interlocks shall be included in plant or equipment maintenance and inspection
programs. Maintenance and inspection programs will be appropriately prioritised and shall not
exceed the manufacturer’s instructions.

Where existing equipment is being modified or upgraded, the upgrade and/or modification shall
include an assessment of the existing guards. Where the equipment does not comply with the
current FMGL Engineering Standard, Australian Standards or Statutory Requirements, the
guarding shall be upgraded to the current requirements.

5.4 Temporary Guarding

Temporary guards or barricading shall be subject to a risk assessment. There shall be a

documented timeframe that requires any temporary guarding or barricading to remain in place
for a prolonged period, however, this time frame shall not be longer than six months. Where
temporary controls are installed in excess of this timeframe justification is to be approved by the
Department Manager.
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6. ORE PROCESSING PLANT AND EQUIPMENT GUARDING

6.1 General

The Principal promotes the use of lift in / lift out guards without the use of an interlocking device
as allowed under AS 4024.1 and AS 1755 for mining applications – for conveyor guarding only
provided control standards described below in section 6.3 are implemented and maintained.

These guards may be affixed using pins, clips, cups or other non bolted methods. This
requirement does not change the extent of guarding or the structural integrity of the guards
being installed as prescribed by the relevant Australian Standards.

This requirement takes into account the harsh environment that the equipment guards are often
subject to, and that bolted guards are not always easily removed and more importantly easily
replaced due to corrosion, dust etc. Conveyor guards are designed to prevent inadvertent
contact with the nip point through slips, trips, falls, etc.

Where guarding and interlock systems are insufficient to protect personnel, the site shall ensure
access to plant and equipment is controlled, maintained and monitored. Plant, equipment and
machinery shall comply with the emergency stop requirements as set out in Western Australia
Code of Practice and/or relevant Australian Standard.

6.2 Conveyor Guarding

Securing conveyor guards so that they can only be removed with the use of a tool, can be at
odds with the requirement for “Guards shall not introduce a Hazard”, which can be the case
where fasteners are prone to seizing up becoming a hazard to remove as they have to be cut or
forced off, coupled with the possibility of them not being able to be properly re-fitted after forced
removal.

It is desirable from a maintenance point of view for conveyors used for mining that the guards
be secured in place but not require a tool to remove them.

The key point is that the guards are secured, i.e., they are captured and can’t fall off or be
dislodged and that it requires a deliberate act to remove them.

6.3 Control Standards

Site has the option to secure guards such that they can be removed only with the use of a tool if
they desire to do so or because the site cannot, or do not, wish to maintain “Control Standards”
(as listed below).
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For a site to qualify for Conveyor guards that are “Guards that are secured but do not require
the use of a tool to be removed”, the following “Control Standards” need to be implemented and
maintained.

(i) All personnel by be subjected to training with a competency based assessment on

the intent, control, management and inspection of Conveyor Guards and Safeguards
this is usually covered in conveyor safety training and site inductions.

(ii) Each and every guard must be labelled and identified as per Section 3.23.2, in
Document 100-SP-ME-0001 Conveyor Design Criteria. The label shall say
‘DANGER ISOLATE EQUIPMENT BEFORE REMOVING GUARD – MASS “_”kg’

(iii) Emergency stop pull-wire systems conforming to AS1755 shall be fitted such that
they are accessible from the guard that is deemed “Secured but removable without
the use of a tool”.

(iv) Guards located around pulleys and other high risk hazards shall be secured such
that they shall require a tool to be removed. e.g. High speed shafts, meshing gears,
high voltage enclosures etc.

(v) Conveyor guarding requirements, essentially those covered by AS 1755 must not
migrate to non-conveyor plant and equipment – Typically those covered by AS 4024
– General Plant and Equipment.

(vi) The Site isolation policies and procedures and all personal are subjected to
competency based training.

(vii) The Site shall have and maintain discipline policies and procedures for those
transgressing the isolation resulting in isolation breeches.

(viii) The Site shall have a security fence or other controls that positively prevent access
by unauthorised personnel.

(ix) The visitors induction shall include a competency based assessment for access
around conveyors and shall as a minimum include; the purpose and use of the
various emergency stops, what action to take in the event of an accident,
identification of what constitutes a “Hazard Zone” on a conveyor, the site isolation
policy for not removing guards or accessing a hazard unless the conveyor is isolated
in accordance with site isolation policies and procedures.

(x) All of the above requirements are mandatory and all must be addressed to quality for
guards that are “Secured but removable without the use of a tool”.

(xi) There is a documented process to cover the above and this is subjected to a
scheduled audit and assessment to ensure effectiveness – Minimum every 12
months.
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6.4 Conveyor Guarding Further Design Considerations

Large pinned guards shall not be used due to the difficulty in removing and reinstating them.

Guards shall be constructed from 'ARC' mesh, 50x50x4 mm, with rolled edges, unless noted
otherwise on the drawings. Finish paint colour Y14 Golden Yellow.

The reach dimensions for all guarding shall comply with AS 1755.

6.4.1 Identification and Signage

Conveyor guards shall be signed or labelled as follows:

(xii) The label shall say ‘DANGER ISOLATE EQUIPMENT BEFORE REMOVING
GUARD – MASS “_”kg’ - an example is shown on FMGL Standard Engineering
Drawing CO-00000-DR-ME-0147.

(xiii) Guards should be labelled individually.

(xiv) The label size shall comply with AS 1319.

6.5 Unprotected Edge, Removable Platforms & Walkways

Wherever there is an unprotected edge with the potential for falls more than 2 metres, access
shall be restricted and controlled and where necessary risk assessments shall be completed.

Designs should be such that access hatches, openings and removable floor panels shall be
avoided for maintenance and operations activities.

If designing out these risks is deemed to be impractical, this shall be brought to the attention of
the Principal’s Representative to assist with developing an acceptable solution. Where the
removal of flooring cannot practically be avoided, the following engineering enhancements shall
be considered:

(i) The void in the flooring cannot be created without a gate or barricade first being
in place.

(ii) Provision of permanent handrails, gates and signage in the affected area to
restrict access whilst flooring is removed.

(iii) Removable flooring is permanently affixed to the structure so it cannot be lost or

left out of place.

(iv) Should personnel be required to access beyond the guarded / gated area
locations, attachment for personnel full restraint devices shall be provided and
the area designed for the use of such devices. FMGL working at heights
procedure shall be followed.
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6.5.1 Access Gates

As per Standard drawings CO-00000-DR-ST-0014 and 0015 FMG preferred standard for
access gates is Monowills self closing swing type gates fixed to a standard Monowills
stanchion, as shown in these two drawings.

Drop barrier gates similar to those at the top of access ladders are non preferred due to the
additional risks with operating these types of gates and the risk that the drop type gates could
be left open.

6.6 Belt Drives

Guards over belt drives shall have the following features:

(i) Allow visual inspection of belts without the removal of guarding (preferably) for
running inspections.

(ii) Allow belt tension to be checked without the removal of the entire guard, i.e.
preferably through a protected hatch that can be accessed after equipment
isolation.

(iii) Allow belt replacement without complete removal of the whole guard assembly,
i.e. removable face plate or similar after equipment isolation.

(iv) Ensure no part of the rotating components can be accessed in the interface
between the guard and other fixed components such as motors, reducers, etc.

(v) Have the structural integrity to withstand belt breakage during operation.

6.7 Couplings and Shafts

The design of coupling and shaft guards shall ensure no part of the rotating components can be
accessed in the interface between the guard and other fixed components such as motors,
reducers, etc.

Guards on rotating equipment shall cover the complete rotating component with no gaps
between the guard and housings, i.e. Low speed coupling guards and bearing housings.

Typical coupling and drive shaft guards are shown on FMGL standard drawing: CO-00000-DR-
ME-0150.
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6.8 Workshops and Laboratories

Guarding of workshop and laboratory equipment shall comply with AS 4024.1. Where this
equipment cannot be guarded in accordance with AS 4024.1 due to its functional requirements,
i.e. rolling stock maintenance equipment, they shall be reviewed and a formal risk assessment
undertaken to determine what safety control measures are required to minimise the risks
associated with the operation of that equipment.

Fail-to-safe switches / devices shall be installed on all manually operated rotating plant and
equipment and power hand tools.

7. DROPPED OBJECT PROTECTION

Where a hazard can be created by the material being conveyed falling into or being projected
into an accessible area, then guarding shall be provided. Guarding requirements should include
guarding or protection against objects (equipment, tools) falling from height during the operation
or maintenance of plant and equipment. Consideration should be given to the height, mass
and speed of the material that can fall from height.

Where such hazards exist to personnel or equipment, appropriate measures shall be put in
place to eliminate the hazard or for protection to be provided by one or a number of the
following means:

7.1 Exclusion by Fences or Barricades

Exclusion by fences or barricades of personnel by use of distance guards, fences, chained

bollards or hard barricading. The horizontal separation provided shall include consideration of
the deflection of dropped objects based on the vertical drop height and potential trajectory.

Where exclusion areas by barricade or fences are required under conveyors, they shall be
nominally as per the table below:

Table 6: Exclusion Areas by Barricade or Fences

He ig h t o f Co n ve yo r Wa lkwa y Ab o ve Min imu m Offs e t o f Ba rric a d e fro m Co n ve yo r

Ba rric a d e d Le ve l Ce n tre lin e
< 1.5m Not Required
1.5m ≤ height ≤ 5m 3m
>5m 5m

These minimum offsets shall be adjusted out to suit each particular conveyor application taking
into consideration surrounding constraints and design features such as trestle footing centres,
width of conveyor trusses above, etc. Where trestles are outside the minimum dimensions
shown above, the exclusion zone shall be the dimension of the trestle width.
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Exclusion by fences and barricades is required to the underside of all conveyors carrying
primary and secondary crushed ore.

For conveyors carrying finished product (<8mm) and fitted with SL81 mesh to the trusses the
likelihood of spillage is low. Therefore permanent exclusion to the area under these conveyors
is not required, unless a risk assessment deems it necessary.

7.2 Protective Guardrail or Mesh

Protective guard rail or mesh shall be provided at or beneath the level where the objects may
fall from i.e. Mesh between kick plates and intermediate rails around platforms or beneath
conveyors. Safety mesh (SL81) shall be provided under all conveyors elevated greater than
1.5m above ground level. Safety mesh shall be used in conveyor trusses and within transfer
stations to prevent return idler rollers and other large items falling from above.

7.3 Solid Flooring

Solid flooring may be used in lieu of grid mesh where work occurs on a regular basis and the
potential for dropped objects exists. All kick plate in transfer stations shall be continuous all
along the floor edges and at penetrations. There shall not be any gaps such that any
equipment can be accidentally dropped.

7.4 Surge Protection

Surge protection on equipment to avoid overload or bogged conditions may consist of physical
barriers (surge bars) or protective devices (chute blocked chute switches, weigh frames, limit
switches etc). For conveyor transfers where surge protection has not been fitted then for
conveyors carrying primary and secondary crushed ore whose incline is greater than 10° will
need to be fitted with covers and hungry boards on convex sections to prevent material roll back
and bounce causing material to be ejected off the conveyor. The difference between stopping
times between conveyors to minimise surges after crash stops should be investigated to
minimise surges.

Note: Covers over or around conveyors (prevent material rolling back and falling off the belt) on
steep conveyors and covers or water shedding devices shall be provided in areas where
accumulation of standing water (in the conveyor valleys) can cause ore spillage.

7.5 Shedders

Shedders (personnel or vehicle) may be fitted as per section 3.23.6 where access is required
beneath operating plant where the potential for dropped objects exists.
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7.6 Rock Catch Protection

Rock catch protection mesh for protection beneath the equipment may be considered as a last
resort where material cannot be prevented from falling off the belt by the controls above.
Consideration is to be given to varying aperture size and operation depending on what purpose
the mesh is fulfilling and how the mesh is to be emptied.

Areas to be considered for dropped object protection should include:

2. General maintenance or work areas in the vicinity of transfer stations, belt weighers, splice
station, metal detector picking stations or beneath elevated conveyors.

3. Personnel and vehicle access ways

4. Conveyors with steep inclines ≥ 10° with large material, usually primary or secondary
crushed ore.

5. Area beneath tail pulleys where chute wash debris may fall during chute cleaning.

8. CONTROLLED ACCESS PROTECTION

A barricading and delineation procedure shall be implemented to notify and segregate

personnel from hazardous areas, plant or equipment.

A risk assessment shall be used to identify hazardous or restricted areas; access shall be
controlled and managed through an authorisation process.

Fencing shall be used to exclude personnel from areas of danger or where specific exclusion is
required to separate the general public from the Principal’s areas of activity. Areas where
fencing shall be used include, but are not limited to the following:

(i) Principal lease boundaries where public access is to be excluded.

(ii) Substation and transformer compounds.

(iii) Rail signal repeater stations.

(iv) Warehouse or maintenance yards.

(v) Laboratory robotic cells.

(vi) Explosive storage and handling facilities.

Typical Principal Standard fencing details are shown on standard drawing CO-00000-DR-CI-
0036.

Fencing may also consist of bollards and chains or guard railing, i.e. handrails to exclude
personnel from a particular area. Where exclusion is used, the distance of the barrier to the
hazard shall comply with the Australian Standards and shall be sign posted to warn personnel
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of the access requirements, i.e. “Danger – Restricted Access - No Entry Unless Equipment Is
Isolated”. Areas where this type of guarding is employed include car dumpers, conveyor
shuttles, rail workshops, opening or penetrations in floors and platforms.

9. IMPORTED EQUIPMENT

The adequacy of the safety guarding systems shall be reviewed to ensure compliance with the
relevant Principal and Australian Standards and statutory requirements on ALL equipment
which is to be imported. Where non-compliance exists, the suppliers shall rectify the
deficiencies identified to ensure compliance.

HAZID, HAZOP and Risk Reviews and supporting documentation as required in the Principals
Supplier Document Requirement List shall be provided, as required to meet the requirements of
Part 6 of the Western Australian Mines Safety and Inspection Regulations and supply of all
related documentation in accordance with the Principals Vendor Data Requirements
Specification 100-SP-DC-0002.