AL FALAH READYMIX

Quality Assurance Procedure

Numbe : FADQP –02
r
Title : Plants, Vehicles and Machineries Maintenance
Plan

1.0 Purpose
1.1 This Plan details the steps to be executed to ensure the proper maintenance of batching plants, transit
vehicles, concrete pump vehicles and ice plants. It also details about the “Preventive Maintenance”
process.

This Plan has been developed to highlight the importance of proper maintenance as a vital part of Al
Falah Ready Mix HSE Policy and Procedures.

In addition to ensuring that workers use the tools and equipment properly, it is vital that tools and
equipment be properly inspected, maintained, and kept in good repair. Our maintenance program will
reduce the risk of injury, damage and lost production.

2.0 Scope
2.1 It applies to the Repair and Maintenance Workshop and Batching Plant Maintenance department, which
is liable to look after the batching plants, concrete pumps, Ice Plants and transit vehicles to ensure
that all the equipment are in proper working conditions and fit to work to do the work.

3.0 Definitions & Abbreviations

3.1 Preventive Maintenance : It is the routine and periodic maintenance work to be done on
predetermined intervals to avoid the breakdown of equipment or
vehicle.
3.2 Breakdown/Corrective : It is the repairing process to correct the problem.
Maintenance
3.3 PM : Plants Manager
3.4 WSM : Workshop Manager
3.5 MM : Maintenance Manager
3.6 PF : Plant Foreman
3.6 WF : Workshop Foreman
3.7 ME : Mechanical Engineer
3.8 DC : Document Controller

4.0 Responsibilities
PM in conjunction with WSM, MM, Maintenance Supervisor and PF are responsible for the
4.1 implementation of this procedure. So that Batching plants, Ice Plants and Transit vehicles are
maintained in proper working and safe condition.
4.2 WF shall be responsible for maintenance of truck mixers, concrete pumps and other vehicles.
4.3 PF shall be responsible for maintenance of batching plant and ice plants.

4.4 Maintenance Plan Outlines

4.4.1 All company vehicles must be on the master preventive maintenance inventory list.

4.4.2 The maintenance schedule that will be followed will be the manufacturer’s suggested preventive
maintenance program.

4.4.3 Preventive maintenance will be conducted as per manufacturers’ recommendations.

4.4.4 All repair and maintenance will be conducted at Al Falah Ready Mix Central Workshop or site-based
workshop as appropriate

4.4.5 It is the responsibility of the Plants Manager to review the company’s preventive maintenance
program on an annual basis. This allows for an opportunity for program improvements.

4.4.6 Recommendations that are discovered as a result of the annual review or throughout the year will be

Issue : A Rev. : 3 Date : 01/11/2011 Page 1 of 6

 AL FALAH READYMIX
Quality Assurance Procedure
Numbe : FADQP –02
r
Title : Plants, Vehicles and Machineries Maintenance
Plan

documented and incorporated in a revised Maintenance program.

4.4.7 The Plants Manager will follow-up on the corrective actions on a pre-determined time frame (to be
determined on a case by case basis) to insure that the corrective actions have been completed.

4.5 Personnel Qualifications

4.5.1 Maintenance Personnel

The qualifications of maintenance personnel are key to the success of a maintenance program. All
individuals who perform maintenance work will have the appropriate skills, Training and/or
certification. This Training/certification applies both to company employees and to contracted
maintenance services.

4.5.2 Operator Qualifications and Training

All individuals who operate our mobile concrete pumps, Placing Booms, vehicles etc. will have the
appropriate skills, accreditation and/or certification. This applies to both company employees and
contracted equipment services.

4.5.3 The approval process includes the following:

1. Possession of a valid driver’s license appropriate to the type of equipment.

2. Successful completion of a practical operating exam administered by competent and authorized

personnel.

3. No history of epilepsy or of a disabling heart condition or any other physical disability or

impairment.

4. The operator should be trained in the following:

 their responsibilities to operate the equipment in a safe manner;

 familiarity and comprehension of safety requirements for the piece of mobile equipment
which they intend to operate;

 how to communicate to maintenance personnel when there is a problem with a specific

piece of equipment;

 hand signals and/or other requirements set by the company or dictated by site conditions.

4.6 Records

The maintenance program must contain a recording system. Part of this system should be made up of
inventories and schedules. In addition, the recording system should document what maintenance work
was done, when, and by whom.

4.7 Filing System

The Plants Department will establish a filing system to maintain the repair and maintenance records.

4.8 Monitoring

Issue : A Rev. : 3 Date : 01/11/2011 Page 2 of 6

 AL FALAH READYMIX
Quality Assurance Procedure
Numbe : FADQP –02
r
Title : Plants, Vehicles and Machineries Maintenance
Plan

The monitoring functions in a maintenance program fall into two areas.

First, the people responsible for operating and/or maintaining equipment must monitor that equipment
to ensure that appropriate checks and maintenance are done.

Secondly, management should monitor the entire program to ensure that it is functioning in
accordance with company policy.

5.0 Procedure
5.1 Transit Vehicle and Concrete Pump Maintenance
All mobile equipment is to be inspected and maintained according to the following Equipment
Inspection Schedule as a minimum. Records of all inspections and maintenance are completed and
maintained for review and approval.

Maintenance of equipment, release of lubrication fluids, etc., is performed only in approved areas.
Spills and leaks from equipment are to be avoided as far as possible and when occur it must be
cleaned up promptly.

Equipment Inspection Schedule

Type of
Type of Inspection Schedule
Equipment
Complete inspection and Before put to work and
certification annually
Critical items, controls, overall Daily or before each
functioning use*
Mobile Concrete Safety device, load carrying
Pumps and sections, main frame, cables, Weekly*
Hydraulic Placing electrical
Booms
Complete inspection Monthly*
Repair When failure occurs
Manufacturer’s
Preventative maintenance
recommendation*

Heavy Equipment Complete inspection Before put to work

and machines
Repair When failure occurs
(Wheel Loaders,
Electric Manufacturer’s
generators..etc) Preventative maintenance
recommendation*
Repair When failure occurs
Transit Mixers and
Trailers Manufacturer’s
Preventative maintenance
recommendation*
Repair When failure occurs
Concrete Batch
Plants & Ice Plants Manufacturer’s
Preventative maintenance
recommendation*
Compressors, Complete inspection Every 3 months
Welding Machines,
Repair When failure occurs

Issue : A Rev. : 3 Date : 01/11/2011 Page 3 of 6

 AL FALAH READYMIX
Quality Assurance Procedure
Numbe : FADQP –02
r
Title : Plants, Vehicles and Machineries Maintenance
Plan

Manufacturer’s
Preventative maintenance
Generators recommendation*
Deformation, cracks, corrosion, Daily or before each
Slings, Shackles, etc. use
Chokers, Lifting
Devices Regular inspections of all
Every 3 months
devices
Miscellaneous Complete inspection Before put to work
*Attached preventive Maintenance Schedule for each type/category of Plant.

5.2 Pre-Operation Checks by the Equipment Operator

Walk around checks on all pieces of mobile equipment are necessary to ensure the unit is safe to
operate both from the personnel standpoint and for the equipment; that is, all fluids must be at the
correct level and all components must be intact.

A. Check for personnel in the cab area and around the equipment.
Before the operator commences the pre-start checks, the operator should check the cab area for
other operators and others who may be working around the equipment.
B. Visual check
The operator should walk completely around the equipment looking underneath the equipment, in the
engine compartment, and in the cab.
C. Brake Lines
Visually check the brake lines for leaks. Check for moisture on the brake line. Report any leaks to
maintenance for repair as soon as possible. DO NOT operate equipment with brake leaks.
D. Steering Assembly
 Check the tie rod ends, pins and keepers, bell cranks, drag links, ball joints, steering rams and
hydraulic hoses.
 Check that all the joints are tight.
 Report any faulty conditions to your supervisor.
Note: Never operate a truck with faulty steering.

E. Front Tires
Conduct the following checks on the front tires:
 Visually check the tires for deep cuts, separations and embedded rocks, nails, or any other
foreign material.
 Check for tire bulges at the road surfaces which indicate low air pressure.
 Check the rims for cracks and breaks.
Check the valve stems for wear and cuts
F. Front Wheel Bolts
 Check the front wheel bolts each day.
 Report any loose or broken wheel bolts.
 If there are broken or loose, do not operate equipment.
 Report the condition to your supervisor.
G. Front Suspension
Check the front suspension for bottoming out and also check that all fastening devices are in place.
H. Fluid Levels
Check all the fluid levels at the beginning of the shift with the equipment on level ground.
If the fluid level is low, notify your supervisor. Do not operate the equipment until the appropriate
fluid level is brought up to operational level.
I. Fluid Leaks
Look for fluid leaks while checking the fluid levels. There may be fluid lines or gaskets that are
leaking.Make a visual check to see if fluid is running down the side of the engine block or any other

Issue : A Rev. : 3 Date : 01/11/2011 Page 4 of 6

 AL FALAH READYMIX
Quality Assurance Procedure
Numbe : FADQP –02
r
Title : Plants, Vehicles and Machineries Maintenance
Plan

areas while the engine is running.

J. Fan Belts, Blower Belts, Alternator Belt etc.
Check that all belts are in place, tight, and in good condition.
K. Main Frame
Visually check the main frame for cracks and report any problems to the supervisor.
L. Lights & Alarms
Turn on all equipment lights to see they are working properly including; headlights, clearance lights
and reverse alarm.
All faulty lights will be replaced prior to using equipment.
M. Glass
Check that the windshield, windows and mirrors are clean and free of cracks.
N. Handrails and Ladder
Check the condition of the handrails and ladder and look for loose handrails or rungs. Report any
unsafe conditions.
O. Seat Belts
Check that the truck has seat belts. It is important that the operator should use them.
P. Fire Extinguishers
Every piece of equipment must be equipped with adequate fire extinguishers in good condition.
Faulty fire extinguishers must be replaced immediately.

Reminder: Always use hand and power tools safely:

1. Select the right tool for the job
2. Keep tools in good condition
3. Use tools the correct way
4. Keep tools in a safe place
5.3 Batching Plants Maintenance
5.3.1 General
5.3.1.1 Maintenance Supervisor shall monitor the suitability of batching plants to ensure that plants are in
befitting standing to manufacture the concrete. PM shall keep abreast about the status of the batching
plants and that it is safe to operate.
5.3.1.2 PF shall ensure that mechanics check the batching plants regularly and shall do the necessary
maintenance work, if required. PM in conjunction with foreman shall device certain control measures
to ensure that plants are in proper working status.
5.4.1.3 All maintenance activities including repairs shall be recorded and maintained.
5.4.1.4 For maintenance schedule of Batching Plants refer to the maintenance plan or the manufacturer’s
manual. It shall be presented in Management Review Meeting for review and discussion.

5.3.2 Daily Maintenance

5.3.2.1 As a preventive action batching plants shall be checked for following attributes prior to the start of
the work. Mechanic shall check the plant for the following:
A. Greasing the parts, if required.
B. Changing Oil.
C. Cleaning the surface of the plants.
D. Checking all other parts including bearings.
E. Refer to the daily checklist for Batching Plant for other details
F. Checking shall be recorded and records shall be maintained.

5.3.3 Preventive Maintenance

A. Cleaning build-ups of hardened concrete.
B. Welding of the parts, if required.
C. Checking the inner portion of the central mixer thoroughly.
D. Checking and cleaning all electrical parts and entire plant itself.
E. Refer to the maintenance checklist for Batching Plant for other details

Issue : A Rev. : 3 Date : 01/11/2011 Page 5 of 6

 AL FALAH READYMIX
Quality Assurance Procedure
Numbe : FADQP –02
r
Title : Plants, Vehicles and Machineries Maintenance
Plan

F. Checking shall be recorded and records shall be maintained.

5.4 Ice Plants Maintenance

5.4.1 PF in conjunction with the assigned mechanics shall check regularly the functionality/condition of Ice
Plant and perform maintenance/repair to ensure continuous operation with no or minimal downtime
during operation.
5.4.2 Result of monitoring and maintenance activities including repairs shall be recorded and maintained.

6.0 Reference Documents

6.1 Workshop Organizational Chart
6.1 Checklist of Vehicle Maintenance
6.2 Checklist of Batching Plant
6.3 Daily Monitoring of Ice Plant
6.4 Records of corrective maintenance

Issue : A Rev. : 3 Date : 01/11/2011 Page 6 of 6