Maaden Safety - Ehs Contractor Requirements

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MA-EHS-S-009.1
REV-1.0
Document Approval:
Signature Date
Approved by Magdal Al-Khaldi – ISD Director
C E N TR AL E HS
Number MA-EHS-S-009.1 Revision #: 1.0
Date Published:
Title Contractor EHS Requirements May 10, 2013
Date Revised:
Ma‘aden Aluminium – EHS Program Apr 17, 2017
This is Ma’aden Aluminium Environment, Health and Safety Program. Before using this document, check the Ma‘aden Aluminium EHS Web site to ensure that it is the most
current version.
TABLE OF CONTENTS
S# Contents Page
1. Purpose 3
2. Scope 3
3. Definition 3
4. Responsibilities 5
5. Requirements 6
6. Reference 71
7. Revision History 72
8 Attachments 72
Date Published:
Date Revised:
current version.
1. Purpose
1.1. The purpose of this document is to:
1.1.1. Describe the mandatory EHS responsibilities of Contractors, Subcontractors, and
Contracted Services when performing work for Ma’aden Aluminium.
1.1.2. Describes the requirements for Contractors, Subcontractors and Contracted Services to
ensure the appropriate EHS Values, Policies and Principles are implemented during all
phases of work or other contracted service.
1.1.3. Provide information relating to the Environmental Health and Safety standards and the
EHS behaviors required from the Contractor, Subcontractors or Contract Service provider
(herein known as the Contractor) while performing work at Ma‘aden Aluminium sites. This
document also outlines the administrative requirements for contracts/contracted services.
Note: This document shall be included in all contracts and purchase orders for Contractors
and Vendors.
2. Scope
2.1. This program applies to Ma’aden Aluminum owned, managed and leased locations where
Contractors, Subcontractors and Contracted Services are used.
3. Definition
3.1. Acceptable – Signifies that the Contractor’s methods and/or materials shall be acceptable to
Ma’aden Aluminium.
3.2. Approved – Signifies that the Contractor’s methods and/or materials shall be approve by Ma’aden
Aluminium.
3.3. Certified Person – Is someone who is competent and hold relevant skill certification from
recognized organization.
3.4. Competent Person – Is someone who has the specific knowledge and skill in a particular area of
expertise. This person has obtained this knowledge through training and experience and has
demonstrated the ability to recognize the unique hazards involved and authority to provide
measures to address the potential hazards.
3.5. Construction – Is an activity performed by Contractors that is generally the construction of new
facilities or the maintenance, renovation, or relocation of existing facilities. Construction is work
that normally requires civil, mechanical, electrical, and/or other specialty work, such as demolition
or environmental remediation.
3.6. Contractor – Describes entities or employees of entities that perform work governed by a
contractual arrangement between Ma’aden Aluminium and the entity and who are not directly
controlled or supervised by Ma’aden Aluminium employees.
Date Published:
Date Revised:
current version.
3.7. Contractor Responsible Person(s) – Is someone who has been appointed by the Contractor,
Subcontractor or Contracted Service and who possesses the detailed knowledge to fulfill the
Contractor, Subcontractor or Contracted Services EHS obligations under the contract, which
applies to the work. The Contractor Responsible Person(s) could be appointed from the
Contractor, Subcontractor or Contracted Service management group, superintendents, foremen
or from a third party.
3.8. Contracted Services – Describes entities or employees of entities that generally perform on site
support activities, such as janitorial, cafeteria, uniform delivery, lawn care, garbage disposal, pest
control, vending, engineering, design, training, consulting, or other professional or non-
professional services not directly controlled or supervised by Ma’aden Aluminium employees.
3.9. EHS – Environment, Health and Safety.
3.10. EPC/M – Is an abbreviation for Engineering, Procurement and Construction/ Management firms
that provide services for engineering projects. An EPC/M is a Contracted Service.
3.11. FOPS – Falling Object Protection System is used to protect equipment operators when there is a
risk of falling debris or objects.
3.12. Supervised Contractor – Describe entities or employees of entities that generally perform on site
support activities such as manufacturing (temporary employees) millwrights, electricians,
plumbers, engineers, or other professional or non- professional services directly controlled or
supervised by Ma’aden Aluminium.
3.13. Hazard Assessment – The identification of all existing or potential risks, hazards and
environmental pollution control issues associated with the location and/or the work, which may
need to be abated or controlled through the Job Specific EHS Plan and or implementation of the
Permit to Work Program to ensure the safe completion of the scope of work. When site conditions
change, the Safety Hazard Assessment shall be reviewed and, the Job Specific EHS Plan
updated.
3.14. HCIS – High Commission for Industrial Security, ministry of interior Kingdom of Saudi Arabia.
3.15. Incident – Any event resulting in an injury, illness, major injury free event or environmental release.
(Refer MA-EHS-MS-13- EHS Incident Investigation, nonconformity, Corrective and Preventive
Action)
3.16. Job Specific EHS Plan – A plan that details the abatement or control procedures or method
statement for the hazards identified in the risk assessment throughout the duration of the job. The
plan shall be reviewed, updated, and altered to reflect changes in the project scope, and/or
operating conditions. Work shall not begin until the plan is reviewed and approved by the Ma’aden
Aluminium Central EHS or respective BU EHS Manager.
3.17. Ma’aden Aluminium Property – Any location or facility, or portion thereof, which is controlled by
Ma’aden Aluminium and on which Ma’aden Aluminium operates.
3.18. Ma’aden Aluminium Responsible Person(s) – Is someone who represents Ma’aden Aluminium
interests; has a working knowledge of Ma’aden Aluminium and regulatory standards normally
Date Published:
Date Revised:
current version.
applicable to the type of contracted work and has successfully completed an Ma’aden Aluminium
Contractor, Subcontractor and Contracted Services Responsible Person Training Course.
Another name for the Ma’aden Aluminium Responsible Person could be the Single Point of
Accountability (SPA). A Plant Manager, Procurement Manager, EHS Manager, Engineer or
Maintenance personnel could all be a Ma’aden Aluminium Responsible Person.
3.19. Permit to Work – A written document authorizing a person or a group to perform maintenance,
inspection or construction work (Refer MA-EHS-S-037- Permit to Work Program).
3.20. PPE – Personnel Protective Equipment is the lowest level hierarchy of control.
3.21. Pre-Job Briefing – Is a short discussion with those assigned to a task to review critical steps,
determine where errors are likely to occur, protect from adverse consequences, share common
safety experiences related to the task and establish stop work criteria in the event the task cannot
be completed as planned. Pre job briefings are normally held when beginning a different phase
of work where new or different hazards may be encountered and may occur once or several times
during a shift, depending work activities.
3.22. Pre-Job Site Visit – Meeting with the potential Contractors, Subcontractors or Contracted Services
to discuss the Scope of Work, Site Conditions, and other aspects of the project.
3.23. Project Environment, Health and Safety Review (PEHSR) – A process directed at integrating EHS
into project management, engineering and research & development. PEHSR’s are utilized during
all 4 phases of construction. (Conception, Design, Construction and Commissioning.)
3.24. ROPS – Roll-Over Protection Structure is a system or structure intended to protect equipment
operator and motorist from injuries caused by vehicles overturns or rollovers.
3.25. Scope of Work – Is a documented, legal description of the project. The scope of work should be
concise with adequate information to explain the sequential steps of the project in enough detail
to ensure that the contractor understands the work. The scope of work becomes part of the
contract specifications.
3.26. Shall – The term “shall” as used in this program are intended to describe mandatory requirements.
3.27. Site Conditions – Are the specific rules, regulations, procedures, and administrative requirements
for the location. This document shall be detailed and specific about what is required to meet EHS
expectations. Site conditions shall be provided to the contractor as a legal attachment to the
purchase order. Contractor employees should be expected to know and understand all aspects of
the site conditions.
3.28. Subcontractor – Describes entities or employees of entities that perform activities or services
governed by a contractual arrangement between a Contractor and the entity, who performs work
for the Contractor and who is not directly controlled or supervised by Ma’aden Aluminium
employees. Subcontractors shall comply with the same requirements as Contractors.
4. Responsibilities
4.1. Refer MA-EHS-S-009-Contractor Safety Process latest version section 4.0 Responsibilities.
Date Published:
Date Revised:
current version.
5. Requirements
5.1. EHS Policy, Leadership and Commitment
5.1.1. Ma’aden Aluminium EHS Policy articulates commitments with respect to EHS (Refer MA-
EHS-MS-01-EHS Policy Leadership and Commitment). All Contractors and Vendors are
expected to understand, promote and comply with EHS Policy.
5.1.2. The Contractor's Management is accountable for the safety and health of the Contractor's
employees. The Contractor is also accountable for the impact that the actions of their
employees and subcontractors may have on the safety and health of others.
5.1.3. The project contractors shall develop an EHS Policy in accordance with MA-EHS-MS-01-
EHS Policy Leadership and Commitment requirements.
5.2. Compliance with Regulations
5.2.1. The Contractor, Subcontractors, and Contractor Services shall comply with all applicable
governmental EHS laws, regulations, rules, which includes HCIS, RC, PME, SASO and
other documents referenced in the contract specifications. In addition, the Contractor
and its Subcontractors shall comply with Ma’aden Aluminium Policies, Management
Systems, Programs, and Standards, and other additional provisions as specified by
Ma’aden Aluminium representatives and in project scope of work.
5.2.2. All construction activity shall be performed in such a manner to minimize interference with
normal operations. Contractor’s employees shall remain in their assigned work areas.
5.2.3. Any violation or deviation from the above conditions by the Contractor may result in the
dismissal of the Contractor or Contractor employee from the property and cancellation of
contracts with Ma’aden Aluminium.
5.3. Conduct of Contractor Employees
5.3.1. All Contractor, Subcontractor, and Contracted Services shall comply with the Ma’aden
Code of Conduct Policy.
5.3.2. While on Ma’aden Aluminium premises, the Contractor's employees shall not engage in
any dangerous, illegal or outrageous conduct, including but not limited to the following:
5.3.2.1. Violating EHS rules or common EHS practices, or causing an EHS threat to
a co-worker.
5.3.2.2. Creating or contributing to any unsafe or unsanitary condition.
5.3.2.3. Unnecessarily distracting the attention of any employee who is working, or
participating in a non-work related activity that interferes with the job.
5.3.2.4. Using abusive words or phrase.
5.3.2.5. Horse playing and fighting or instigating a fight.
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Date Revised:
current version.
5.3.2.6. Theft, abuse, or deliberate destruction of property, tools, or equipment of

employees or the Company.
5.3.2.7. Gambling of any type.
5.3.2.8. Possessing or consuming any intoxicating beverage or illegal substance on
the premises.
5.3.2.9. Reporting for work in an unfit condition, including being under the influence
of intoxicants or controlled substances, or misuse of any prescription drug.
5.3.2.10. Refusing to submit to drug and/or alcohol testing when properly directed by
supervisor. Test results showing the presence of alcohol or illegal drugs in
any amount will be grounds for dismissal.
5.3.2.11. Possessing firearms or other weapons on Company premises.
5.3.2.12. Making false or malicious statements concerning an employee, the
Company, or its products.
5.3.2.13. Falsifying records, including time cards, or making untrue statements that
may result in the falsification of records.
5.3.2.14. Misusing or removing from premises, without permission, employee lists,
blueprints, records, or confidential information of any nature, in any form.
5.3.2.15. Soliciting, collecting contributions, or distributing written or printed matter
without permission of management.
5.3.2.16. Posting or removing notices, signs, or writing in any form on bulletin boards
or Company property without specific permission of Ma’aden Aluminium
management.
5.3.2.17. Possessing or using mobile phones in production areas, contractor radios, or
cameras for personal use on Company premises without permission.
5.3.2.18. Throwing materials on Company premises or not giving attention to job during
working hours.
5.3.2.19. Failure to obey supervisor or other forms of insubordination.
5.3.2.20. Frequent tardiness or absences from work.
5.3.2.21. Leaving job or work area during working hours without permission.
5.3.2.22. Performing personal work on Company time or excessive use of mobile
phones and electronic gadgets for personal use.
5.3.2.23. Any action or behavior illegal under local law.
5.3.2.24. Smoking in offices, lunchrooms, or other areas not designated for smoking.
Date Published:
Date Revised:
current version.
5.3.2.25. Prohibited items: No cardiac pacemakers, finger rings or loose jewelry is

allowed in maintenance or production areas.
5.4. Substance Abuse
5.4.1. Possessing or consuming any intoxicating beverage or illegal substance is forbidden. It
is the responsibility of the contractor to monitor its employees prior to their entry to
Ma’aden Aluminium premises and also in the course of their work, those found to be
under the influence of alcohol or drugs will be removed from the premises and will be
denied future admittance.
5.5. Pre Job Meeting and EHS Plan
5.5.1. Prior to initiating work covered by a contract, the Contractor's representatives shall meet
with Ma’aden Aluminum representatives, including Project Manager and or Project
Leader(s) and Ma’aden Aluminium Responsible Person(s), for a pre-job meeting in order
to ensure a correct understanding of the scope of work and EHS requirements.
5.5.2. The contractor Job Specific EHS Plan shall be aligned with Ma’aden Aluminium EHS
Management System and EHS Program requirements and shall govern how safety is
managed throughout the Project/Work activities.
5.5.3. The contractor Job Specific EHS Plan shall be based on the EHS policy formally
endorsed by the contractor company owner or senior manager, project manager and
safety manager.
5.6. Job Specific EHS Plan Submittal and Review Requirements
5.6.1. Within 15 working days of contract award, contractor shall submit the job specific EHS
plan to the Ma’aden Aluminium for review.
5.6.2. Any review comments will be forwarded to the contractor for its action. Contractor shall
address all comments and resubmit the Job Specific EHS Plan to Ma’aden Aluminium for
final review and concurrence. Contractor shall not begin work onsite until the Ma’aden
Aluminium has concurred with the Job Specific EHS Plan.
5.6.3. The contractor Job Specific EHS Plan shall state specifically how the contractor will meet
Ma'aden Aluminium EHS requirements for the work to be performed. The contractor Job
Specific EHS Plan shall include the following as minimum:
5.6.3.1. EHS policy and commitment management statement.
5.6.3.2. Job specific organization chart that clearly defines safety reporting
relationships.
5.6.3.3. Job-specific assignment of safety responsibilities by job classification.
5.6.3.4. Leading and Lagging EHS Key Performance Indicators (KPI's)
5.6.3.5. Job specific training needs analysis and matrix show the safety training and
competencies required for all jobs as per the scope of the job.
Date Published:
Date Revised:
current version.
5.6.3.6. Aspects impact and hazard assessment and Job Safety Analysis process.
5.6.3.7. Program for reward and recognition for EHS performance of employees and
sub-contractors.
5.6.3.8. Management EHS walkthroughs program at worksite/project.
5.6.3.9. EHS observation program at work site/project to record the unsafe conditions
and unsafe acts and keep observations statistics and the trends, which shall
be analyzed and used as a tool to improved EHS performance.
5.6.3.10. EHS Audit and evaluation program.
5.6.3.11. Written task specific EHS programs as per scope of work (working at height,
scaffolding, crane safety confined space, mobile equipment etc.).
5.6.3.12. Heat stress program.
5.6.3.13. Respiratory protection.
5.6.3.14. Inspection program (specific but not limited to) for all work equipment,
electrical equipment, power tools, hand tools, mobile equipment’s)
5.6.3.15. Procedure to establish the requirements for the isolation (Lock out, Tag out
and Verify (LTV) of the hazardous energy sources to ensure the safety and
health of employees where unexpected startup or release of stored or
residual energy could cause injury.
5.6.3.16. Employee’s emergency evacuation program.
5.6.3.17. Incident reporting and investigation program.
5.6.3.18. Temporary facility requirements.
5.6.3.19. Electrical hazards program.
5.7. Risk Assessment
5.7.1. For all Ma’aden Aluminium contracts, the contractor and/or subcontractor(s) shall
develop, implement and adhere to contract specific risk assessment (Refer MA-EHS-MS-
02- EHS Aspects, Risk and Impact Assessment). The risk assessment shall list all
task/activities associated with the scope of work, potential hazards of each task/activities
and control measures to mitigate these hazards. The risk assessment shall not be a list
of generic hazards.
5.7.2. Within 15 working days of contract award, the contractor shall submit Project EHS risk
assessment to the Ma’aden Aluminium for review.
5.7.3. Any comments will be forwarded to the contractor for its action. Contractor shall address
all comments and resubmit the Project EHS risk assessment to the Ma’aden Aluminum
for final review and concurrence.
Date Published:
Date Revised:
current version.
5.7.4. The contractor’s Project EHS risk assessment shall be revised and amended when
condition change, new hazards are introduced or the scope of work changes.
5.7.5. Contractor shall prepare Job Safety Analysis for any job done under a work permit
condition, any critical jobs and new jobs as per MA-EHS-SP-15- Job Safety Analysis
Program.
5.8. Site Security
5.8.1. Contractor and/or subcontractor(s) shall ensure that all employees, visitors, delivery
vehicles to register at security department and obtain Ma’aden Aluminium security gate
pass / ID badge.
5.8.2. Each person entering the gate shall show their security gate pass / ID badge to security
gates.
5.8.3. In case of an incident, security is able to strictly control entry and exit from the facility not
allowing unauthorized person into the incident area or not allowing person to leave until
cleared.
5.8.4. Ma’aden Aluminium reserves the right to prohibit equipment and materials on company
property that does not meet Ma’aden Aluminium standards.
5.8.5. Only vehicles / equipment’s bearing an authorized valid Ma’aden Aluminium vehicle
pass/sticker shall be allowed access to Ma’aden Aluminium premises.
5.9. EHS Orientation/Induction, Training and Competency
5.9.1. No one shall work on site without successfully completing an orientation.
5.9.2. The site orientation will be presented by the Ma’aden Aluminium authorized orientation
personnel. The orientation program will conclude with a skill check. Orientation
attendance will be documented and a badge will be presented to employees who have
successfully completed the orientation.
5.9.3. Contractor shall ensure that all its personnel are qualified, competent and have
demonstrated they have the necessary knowledge and skills to safely and properly
perform their assigned work.
5.9.4. Contractor shall establish job classifications (e.g., welder, rigger, crane operator, heavy
equipment operator, and driver) required to perform the work and the specific job
skills/craft competence and training requirements for each of these job classifications,
including Saudi Arabian Government certification and or license requirements.
5.9.5. Contractor shall ensure their personnel receive documented training, based on job
classification.
5.9.6. Where a specific job requires Ma’aden Aluminum and or Saudi Arabian Government
certification and or license, these job functions shall be assigned only to properly certified
and or licensed personnel.
Date Published:
Date Revised:
current version.
5.9.7. Contractor shall establish additional training programs for personnel who perform high-
risk activities, such as but not limited to: confined space entry, fire watch, lock-out/tag-
out verify, working on or near energized electrical equipment, working at height, lifting
and rigging, excavation, specialized power tools and equipment, handling of hazardous
chemicals, waste storage and handling, etc.
5.9.8. Safety training shall also address off-job hazards (e.g., seat belt use, Defensive driving).
5.9.9. Contractor’s in-house or third party training facility shall include as minimum:
5.9.9.1. Training facilities complete with multimedia (audio/visual) resources.
5.9.9.2. Adequate furniture seating writing desk.
5.9.9.3. Class (group) size shall be restricted to suitable trainee to trainer ratio.
5.9.9.4. Away from noisy construction areas and activities.
5.9.9.5. Qualified instructors to ensure personnel properly receive the required
training.
5.9.9.6. Verbal instruction and written materials in a language clearly understood by
the personnel receiving the training.
5.9.9.7. Documented post-training competency assessments.
5.9.9.8. Documentation of completed safety training (e.g., pocket card, “safety
passport” or file copies of training records).
5.9.10. Contractors shall maintain training records for review by the Ma’aden Aluminium upon
request.
5.9.11. Ma'aden Aluminium reserves the right to test/verify the job skills/craft competency and
qualifications of contractor’s employees and to remove any employee failing this
test/verification.
5.9.12. Refresher training shall be conducted at the frequency not less than that established by
Saudi Arab Government regulation and or Ma’aden Aluminium requirements as per MA-
EHS-MS-06- EHS Training Awareness and Competency.
5.10. Contractor Site Supervisor and Safety Staff
5.10.1. The Contractor shall be responsible for the safety of its own employees as well as the
safety of all its Subcontractor’s employees. To this end, the contractor is responsible for
ensuring that there is adequate supervision at all times.
5.10.2. The contractor and sub-contractor line management including supervisor and foreman
shall directly be involved in the contractor‘s responsibilities for the safety and health of all
personnel at the work site and for making safety and health compliance a part of all work
assignments.
Date Published:
Date Revised:
current version.
5.10.3. Contractor shall provide full-time qualified site safety staff in accordance with Table 1.,
with respect to the maximum number of contractor and subcontractor employees who are
present at the job site at a given time, or as otherwise requested by the Ma’aden
Aluminium (e.g., during a Pre Job Meeting).
5.10.4. Table 1 Contractor safety staff ratio.
Activities Ratio EHS Experience
1 safety supervisor for: 50

Normal activities Minimum 5 years
work force
1 safety supervisor for: 30
Night shift work Minimum 5 years
work force
Turnaround, maintenance and 1 safety supervisor for: 15
Minimum 5 years
high-risk activities. work force
Manager minimum
More than 50 contractor work Safety Manager and 1 10 years
force trainer Trainer minimum 5
years
Manager minimum
Safety Manager, trainer, 10 years
More than 100 contractor work
engineer and supervisors as Trainer, engineer
force
per ratio. and supervisor
minimum 5 years
5.10.5. Safety staffs shall be fluent in English (Speak, Read and Write) and shall have a relevant
experience in EHS field as per Table 1.
5.10.6. Prior to mobilizing contractor EHS staffs, the Ma'aden Aluminium Central EHS or
respective Business Unit EHS shall screen and approve the contractor EHS staffs. If
required the Ma'aden Aluminium may also take a written examination.
5.10.7. The Ma‘aden Aluminium EHS department reserve the right to require the contractor
replace the any EHS staffs whose work is deemed unacceptable by the Ma‘aden
Aluminium.
5.10.8. The Ma'aden Aluminium EHS reserve the right to require the contractor to provide
additional safety, health and environmental specialist where special technical expertise
is required.
5.10.9. Contractor EHS staff shall not be assigned in dual roles.
5.10.10. Contractor’s site safety staff shall be present at the job site at all times while contractor
and/or subcontractor personnel are working, including nights, weekends, holidays and
extended working hours.
5.10.11. Contractor shall provide a communication devices to all their EHS staff.
Date Published:
Date Revised:
current version.
5.11. EHS Meetings

5.11.1. Contractor’s site supervisor or in charge shall conduct pre job (toolbox) EHS meetings
with their working group to address task specific EHS issues and recommendations prior
to beginning of work activity.
5.11.2. Contractor site management shall conduct weekly EHS meeting with the site supervisor
along with site safety personnel. This safety meeting shall be no shorter than 30 minutes
and shall cover, but not limited to: one-week forecast work hazards, recommendations
and previous minute’s action items as well as EHS weekly site performance.
5.11.3. Contractor site management weekly EHS meetings shall be documented with records
maintained and shall be made available for review by the Ma’aden Aluminium upon
request.
5.11.4. Upon request by the Ma’aden Aluminium, contractor’s site management, site supervisor
and or site safety staff shall attend the Ma’aden Aluminium EHS meetings.
5.12. Health Monitoring
5.12.1. Health monitoring shall be conducted by the contractor, as applicable (as identified in the
Project EHS Risk Assessment or JSA), to protect their personnel against exposure to
health hazards (e.g. radiation, respiratory, noise) as per MA-EHS-HP-01- Industrial
Hygiene Standard.
5.12.2. Contractor shall verify that its personnel are fit for duty relative to medical, physical and
substance abuse considerations as per MA-EHS-HP-08- Pre-Placement Medical
Evaluation.
5.12.3. Upon request by the Ma’aden Aluminium, contractor’s site management shall provide
Health Monitoring documents.
5.13. Site EHS Inspection
5.13.1. The contractor shall implement EHS observation and site inspection programs to detect
and correct unsafe acts and conditions. Observations and inspections shall be frequently
(e.g., daily, weekly) conducted by contractor site management (e.g., project manager,
construction manager, site superintendent).
5.13.2. Unsafe acts and conditions shall be immediately reported to the relevant supervisor for
correction as soon as practical. Life threatening hazards shall be corrected immediately.
Corrective actions for unsafe acts and conditions shall be identified and tracked until
completion to verify proper implementation.
5.13.3. Contractor shall perform trending and analysis of behavioral observations and site safety
inspections to identify negative trends and mitigate safety problems.
5.13.4. Statistics of inspection findings and observations shall be used to establish the priority of
pre job talks and awareness topics.
Date Published:
Date Revised:
current version.
5.13.5. Contractor shall provide copies of any inspection and observation records as requested
by the Ma’aden Aluminum.
5.14. EHS Incident Reporting and Investigation
5.14.1. Contractor shall establish a policy and procedures to promote timely reporting of all EHS
incidents in accordance with MA-EHS-MS-13- Incident Investigation Non Conformance
Corrective and Preventive Action and Investigation. Proper corrective and preventive
actions shall be promptly taken.
5.14.2. The Contractor is responsible for ensuring that all environmental incidents involving their
employees are recorded and reported.
5.14.3. All medical emergencies shall be reported to Ma’aden Aluminium Clinic (013 350 9111).
In the event of injury, occupational illness, injury-free event or property damage and
Environmental incidents, the Contractor shall notify the Ma’aden Aluminium Responsible
Person or Project Manager and or Project Leader immediately. If injured, no matter how
slight, get medical treatment immediately. The Contractor shall investigate all recordable
injuries and high potential injury-free events within 24 hours of the incident and a written
report submitted to the Ma’aden Aluminium Responsible Person. The Ma’aden
Aluminium Responsible Person and EHS Department representative shall participate in
the investigation.
5.14.4. Contractor shall investigate all incidents involving their personnel and or their
subcontractors’ personnel and shall participate in any Ma'aden Aluminium incident
investigation as requested by the Ma'aden Aluminium.
5.14.5. All Contractor’s shall maintained weekly and monthly EHS statistics report and submit
the report to Ma’aden Aluminium Business Unit EHS Department on attached form
(Attachment-1). Weekly report every Thursday afternoon before 15:00hrs and Monthly
report 3rd day of each month.
5.15. Discipline
5.15.1. Contractor shall implement a disciplinary policy and procedure. Persons shall be
dismissed from the site on the third EHS violation.
5.15.2. Persons will immediately be dismissed from the site if any of the following serious safety
violations:
5.15.2.1. Not complying with the 100% fall protection and 100% tie-off in high elevation
area.
5.15.2.2. Disregarding barriers (unauthorized access into an area marked as being
unsafe or unauthorized access into a restricted area.)
5.15.2.3. Violating Ma’aden Aluminium permit conditions in operational area or
performing work without a permit where a permit is needed.
5.15.2.4. Energizing or de-energizing a power source without proper authorization.
Date Published:
Date Revised:
current version.
5.15.2.5. Operating or cause to operate equipment without a valid operator’s license.

5.16. Emergency Plan
5.16.1. All Contractors are expected to work/operate in a manner, which protects the
environment and the health of his employees and the citizens of the surrounding
community.
5.16.2. The Contractor shall develop a job specific emergency plan as per MA-EHS-MS-10-
Emergency Preparedness and Response, communicate to employees, and include any
necessary training to ensure compliance. This plan becomes part of the Contractor Job
Specific EHS Plan.
5.16.3. Report all emergencies immediately to the Ma’aden Aluminium Emergency Control
Center (013 350 9111).
5.16.4. When transmitting an emergency message by telephone ensure the following information
is provided:
5.16.4.1. Exact location (rally point, building number etc.).
5.16.4.2. Nature of emergency.
5.16.4.3. Type of service required (fire truck, ambulance etc.).
5.16.4.4. Number of injured personnel.
5.16.4.5. Caller name and badge number.
5.16.5. During an evacuation alarm, the Contractors shall proceed to the nearest exit point. The
Contractor Job Supervisor shall account for his employees and determine if anyone is
still present in the building(s). If the Contractor Job Supervisor determines he has a
missing individual, he shall alert the Ma’aden Aluminium Emergency Control Center and
report this information.
5.16.6. Releases to the environment, including spills, gas releases, and explosions, are
considered a serious matter. A release constitutes potential for ground water
contamination, storm water, surface water contamination or releases of hazardous
materials into the atmosphere, even if the material released is not generally considered
hazardous.
5.16.7. Contractors, Subcontractors, and Contracted Services shall follow emergency
procedures if a release of hazardous material occurs.
5.16.8. It is the Contractor, Subcontractor, and Contracted Service’s responsibility to ensure the
Ma’aden Aluminium is not exposed to any adverse effects to vegetation, property, and
animal life through air, water, and/or chemical releases. It is the Contractor,
Subcontractor, and Contracted Service responsibility to correct and restore any adverse
effect that is caused by their actions. All cleanup materials shall be the responsibility of
the Contractor, Subcontractor, and Contracted Services but shall follow Ma’aden
Aluminium Waste Management Program.
Date Published:
Date Revised:
current version.
5.16.9. Contractor, Subcontractor, and Contracted Services shall apply all standard practices for
spill prevention. Such practices shall include but not be limited to secondary containment
and Ma’aden Aluminium Loading and Unloading Procedures.
5.17. Traffic and Vehicle Safety
5.17.1. Only authorized and certified drivers shall operate motor vehicles. Operator credential
shall be verified prior to their being allowed to operate motor vehicle.
5.17.2. All drivers shall have in their possession a valid Saudi Arabian Government Driving
license.
5.17.3. The number of light vehicles permitted on operating sites shall be controlled by Ma’aden
Aluminium and restrictions may vary between locations.
5.17.4. Ma’aden Aluminium reserves the right to inspect the contents of any vehicle entering or
leaving a site.
5.17.5. Contractor and their subcontractors shall provide safe and adequate transportation to
and from the work site for their employees.
5.17.6. Motor vehicles used for transportation of contractor’s employees shall have a valid
Ma'aden Aluminium vehicle sticker and be kept in a clean and hygienic condition.
5.17.7. Contractor’s employees shall be transported in the passenger compartments of motor
vehicles equipped with seat belts for all occupants. All seats in cars and trucks shall face
forward.
5.17.8. Driver and all occupants of motor vehicles and buses in motion shall continuously wear
seat belts.
5.17.9. Buses shall not be overloaded (no more occupants than the manufacturer has stated
seating capacity of the bus) and emergency exits shall be accessible and operable (not
blocked or locked). Buses shall be equipped with fire extinguisher(s).
5.17.10. Personnel operating motor vehicles and buses on Ma’aden Aluminium premises or
project sites shall follow all Saudi Arabian Government Regulations and Ma'aden
Aluminium MA-EHS-S-026 Driving Safety requirements.
5.17.11. Drivers shall be held accountable for the safe operation of the vehicle.
5.17.12. Drivers shall abide by all Saudi Arabian Government traffic regulations and Ma'aden
Aluminium traffic requirements at all times in all locations.
5.17.13. Not exceed the posted speed limit at any time.
5.17.14. Not use a cell phone, eat or drink while driving.
5.17.15. Properly transport materials and ensure loads do not exceed the vehicle manufacturer’s
design load capacity. Loads shall be properly secured and tied down. Materials shall not
extend over the sides of the vehicle. Loads extending beyond the front or rear shall be
marked with a red flag and trailers shall be equipped with visible brake and taillights.
Date Published:
Date Revised:
current version.
5.17.16. Ensure unauthorized persons are not transported in vehicles.

5.17.17. Not transport passengers in the rear of pickups or on truck beds.
5.17.18. Only park in designated parking areas. Parked vehicles shall not obstruct other vehicles,
roadways, access ways or fixed firefighting installations.
5.17.19. Not leave the vehicle unattended while the engine is running.
5.17.20. Motor vehicle accidents that occur on Ma'aden Aluminium premises or Ma'aden
Aluminium project sites shall be reported to the nearest Industrial Security Supervisor.
5.17.21. Drivers shall not leave the scene of an incident or move the vehicle after a collision until
released by the Saudi Arabian Government police officer or a Ma'aden Aluminium
Industrial Security representative.
5.17.22. Any traffic violation within Ma’aden Aluminium premises shall be penalized as per MA-
ISD-S-013 Traffic Accident / Violations.
5.17.23. Only equipment having the correct logbook, manufacturers operation and maintenance
manual and current certification shall be permitted to operate on site.
5.17.24. Contractor shall develop road escort procedure to control of the interface between light
vehicles and other traffic whenever heavy equipment and large mobile cranes travel on
public roads, in process areas, and on plant access roads. The movement of oversize
loads is also governed by this procedure.
5.17.25. At all times the contractor shall be aware of vehicle / pedestrian interface issues and
implement systems or rearrange the work method to eliminate the potential for injury,
particularly where it is necessary for vehicles to reverse.
5.17.26. The Contractor shall obtain specific approval from Ma’aden Aluminium ISD, Fire, and
Emergency department prior to setting up any form of access restriction (barricade) that
shall restrict access or close a road.
5.17.27. Ma’aden Aluminum mining operations have a mandatory 50 meter exclusion zone
between light vehicle/pedestrians and operating heavy mobile equipment. Exclusion
zones shall be applied where there is potential interface between earthmoving
equipment, light vehicles and or pedestrians.
5.17.28. Restriction of access shall include such situations as:
5.17.28.1. Scaffolds
5.17.28.2. Temporary access platforms
5.17.28.3. Any road works or excavation
5.17.28.4. Cable pulling
5.17.28.5. Locating mobile welding equipment
Date Published:
Date Revised:
current version.
5.17.28.6. Mobile air compressors and other such equipment

5.17.28.7. Barricading for overhead work precaution
5.17.28.8. Locating mobile cranes and Elevated Work Platforms and other special
vehicles.
5.17.28.9. Locating delivery vehicles such as concrete trucks, steel and equipment
delivery vehicles.
5.17.28.10. Temporary buildings including toilets.
5.17.28.11. Spray painting locations.
5.17.28.12. High-pressure water usage areas.
5.17.29. Mobile equipment that is used at Ma’aden Aluminium sites shall have a risk assessment
undertaken to determine the need or otherwise for the use of ROPS and/or FOPS. The
contractor shall hold risk assessment documentation and a copy provided to Ma’aden
Aluminium.
5.17.30. The Contractor is responsible for ensuring that all equipment used on site is maintained
and used in a mechanically safe condition.
5.17.31. On all of Ma’aden Aluminum bauxite mining and large earthworks projects (such as mud
lake and road construction), a >50M exclusion zone between heavy mobile equipment
and light vehicles/pedestrians is required. Refer to the location Operating Procedures for
specific requirements. Should the 50m-exclusion zone prove impracticable, then a
specific approved exclusion zone procedure including hazard risk assessment and a JSA
shall be developed and deployed after approval by Ma’aden Aluminium.
5.17.32. Ma’aden Aluminium reserves the right to audit any procedures adopted by the Contractor
to certify equipment. Ma’aden Aluminium will conduct inspections from time to time, and
the Contractor shall make available, on request, the vehicles and related documents for
that purpose. However, this shall not absolve the Contractor of responsibilities for
ensuring acceptable vehicle maintenance, nor shall the failure of Ma’aden Aluminium to
detect defects in the Contractor’s vehicle be taken as acceptance of the vehicle.
5.17.33. Contractor shall ensure that flatbed trucks or crane decks exposed to different level fall >
1.2 meters is protected with a fall prevention or with a fall protection.
5.18. Site Office and Amenities Buildings
5.18.1. Any type of temporary site facilities sited in Ma’aden Aluminium shall be in accordance
with HCIS SAF 03 and contractor shall obtain MA Land Use Permit.
5.18.2. Where the scope of the job requires site facilities, the Contractor shall provide a site office
and temporary facilities to effectively manage the contracted work, unless otherwise
advised by Ma’aden Aluminium.
Date Published:
Date Revised:
current version.
5.18.3. The Contractor shall be notified at the site visit with full details of site facilities and services
that shall be provided by Ma’aden Aluminium. The Contractor shall provide all other site
facilities and services required to complete the contracted work.
5.18.4. Contractor’s site facilities shall be established only in locations approved by Ma’aden
Aluminium and Amenities buildings shall in accordance with following guidelines.
5.18.4.1. A weatherproof shelter with fly-screened windows capable of being opened.
5.18.4.2. Each unit shall be of a size with not less than one square meter of flooring
area for each person.
5.18.4.3. Each unit shall be lined, adequately lit and ventilated (including an extractor
fan) and shall have washable floors and fly strips to the doorway.
5.18.4.4. Each unit shall be equipped with a non-absorbent washable table or tables
with seating accommodation providing a bench of not less than 400mm wide
and 450mm long for each person.
5.18.4.5. Hooks at least 450mm apart for hanging clothes.
5.18.4.6. Covered garbage bins.
5.18.5. On completion of the contracted work, all Contractor site facilities, including tie lines into
power and water services, shall be removed and the plant area restored, by the
Contractor, to the satisfaction of Ma’aden Aluminium.
5.19. Workshops and Storage Area
5.19.1. The Contractor may establish site workshops and/or storage areas if approved by
Ma’aden Aluminium. The Contractor’s request for approval to establish workshop and/or
storage areas shall include details of building type and size of the proposed facilities.
5.20. Portable Cabins
5.20.1. All portable cabins shall be constructed, protected, arranged, equipped, maintained, and
operated to avoid danger to the lives and safety of its occupants.
5.20.2. Ma’aden Aluminium Emergency and Fire department shall review all portable cabin
layout plans.
5.20.3. Contractor shall established periodic inspection of all temporary offices and portable
cabins.
5.20.4. In portable cabins under construction, adequate escape routes shall be maintained.
5.20.5. Location of the portable cabins shall allow access from two directions for firefighting.
5.20.6. Split-type air conditioning devices shall be preferred.
5.20.7. Two means of egress, as a minimum shall be provided in every portable cabins section.
Date Published:
Date Revised:
current version.
5.20.8. The exit routes shall be sufficient to accommodate the maximum permitted number of
occupants.
5.20.9. Exit shall be clearly visible marked by sign reading “Exit”. Exit sign shall be illuminated to
a surface value of at least five foot-candles (54 lux) by a reliable light source.
5.20.10. Class A: B: C portable multi-purpose fire extinguishers shall be provided within less than
9.7 meters (32 feet) travel distance.
5.20.11. Portable cabins in hazardous areas (Natural Gas area), a sprinkler system shall be
installed and designed in accordance with NFPA 13 and shall provide complete coverage
throughout the portable cabin, except for computer server rooms and kitchens, where
proper dedicated extinguishing means shall be used.
5.20.12. Adequate fire protections shall be established inside the server rooms.
5.20.13. Room temperature shall be maintained within the limits as recommended by server
manufacturer. Daily inspections shall be carried out to ensure adequate cooling and
temperature readings shall be recorded.
5.20.14. Expiry date of any batteries (UPS) shall be checked periodically and recorded
5.20.15. Smoke detectors shall install and a functional test shall be performed on all smoke
detectors upon initial installation.
5.20.16. All power cables shall be insulated properly and protected in conduit or buried.
5.20.17. In portable cabins, the wiring for lighting, receptacle power and other systems shall be
installed in electrical metallic tubing (EMT) including a ground wire.
5.20.18. Feeder shall be provided with over current protection. Where a feeder supplies
continuous loads or any combination of continuous and non-continuous loads, the rating
of the over current device shall be less than non-continuous load plus 125 percent of the
continuous load.
5.20.19. A main disconnecting means shall be provided to disconnect all conductors in portable
cabins.
5.20.20. A non-combustible shield shall be provided between the switchboards and portable cabin
walls.
5.20.21. All cabins shall be grounded at least two points, on opposite corners, with copper ground
rod (grounding cable size equal to or greater than No.2AWG copper or equivalent),
having a buried length of minimum 8 feet (2.44 meters). Grounding system cable shall be
standard copper, with green or green with yellow striped PVC insulation.
5.20.22. Lighting fixtures shall be listed and labeled by “UL” (Underwriters Laboratory) or
equivalent certification agency of the equipment’s country of origin.
5.20.23. All lamps for general illumination shall be protected from accidental contact or breakage
by a suitable fixtures or lamp holders with a guard.
Date Published:
Date Revised:
current version.
5.20.24. Emergency illumination shall be provided for not less than one and half-hour in the event
of failure of normal lighting.
5.20.25. Emergency lighting facilities shall be arranged to provide initial illumination that is not less
than an average of 11 lux.
5.21. Medical/ First Aid Facility
5.21.1. Contractor shall provide for medical care of its employees according to requirements
established by the Saudi Arabian Government Ministry of Health (MOH) and Saudi
Arabian labor law. As a minimum medical care shall include but not be limited to, first aid,
urgent and emergency care, stabilization and immediate transfer of patients to hospital
(ambulance), inpatient/outpatient hospitalization and emergency and disaster response.
5.21.2. The Contractor’s site personnel who provide medical treatment/first aid shall be properly
trained and qualified, with a copy of their current valid certification maintained on site.
5.21.3. Contractors shall ensure all their employees, including subcontractor employees, are
continuously provided with valid medical health insurance coverage, before they enter
the work site, for outpatient, first aid, emergency, specialist and inpatient care at a nearby
hospital that is operated 24-hours a day, seven days a week.
5.22. Site Planning and Layout
5.22.1. Site planning shall include, but not be limited to building spacing, fire protection, welfare
facilities, rest areas, assembly areas, offices, medical facilities, dining facilities, prayer
areas, laydown yards, fabrication shops, etc.
5.22.2. The site layout shall be planned before mobilization to the work site to identify issues
such as, but not limited to emergency access routes, normal traffic flow, parking areas,
siting for cranes, staging areas, material storage, sanitation/welfare facilities, first aid
stations/medical facilities, fixed/portable fire protection, utilities, etc.
5.22.3. Access road planning shall include, but not be limited to traffic flow, loadbearing
capacities, traffic signs and controls, road striping, parking areas, road intersections and
multiple-use roads. Emergency response vehicle access shall be provided at all times to
all locations.
5.22.4. Contractor shall provide adequate shelters/rest facilities and drinking water supply at
construction sites and work locations, including as needed for prevention of heat stress.
5.23. Parking Area
5.23.1. Risk assessment shall be performed to identify the needs/ risk from the vehicles and
transportation.
5.23.2. Sufficient designated parking areas shall be provided for the authorized vehicles within
the work site/project.
Date Published:
Date Revised:
current version.
5.23.3. Pedestrian sidewalks (properly barricaded and posted with identifying signs) shall be
provided. A proper control shall be provided at road crossings for safe personnel
passage.
5.24. Work Permits
5.24.1. A work permit is a written document requiring authorized sign-off by Ma’aden Aluminium
and Contractor shall obtain appropriate work permit prior to any task perform within
Ma’aden Aluminium premises as per MA-EHS-S-037- permit to Work Program.
5.24.2. Work permit receivers shall have a valid Ma'aden Aluminium receiver certificate. Receiver
shall attend and pass the work permit receiver course conducted by Ma'aden Aluminium.
5.24.3. The issuer and receiver shall conduct a joint site inspection before signing the permit.
Work shall not begin before the permit has been properly signed.
5.24.4. Prior to the start of work, the work permit receiver shall communicate the hazards and
precautions for the job, as well as other requirements on the permit, to all workers working
under the permit.
5.24.5. Periodic reviews of the job site, including gas testing, shall be conducted as required.
5.25. Personnel Protective Equipment (PPE)
5.25.1. Appropriate engineering or administrative controls and or personnel protective equipment
control shall mitigate hazards not eliminated through design.
5.25.2. Contractor and their subcontractor(s) shall provide the proper PPE that meets Ma’aden
Aluminium specification to its employees. (Refer MA Personnel Protective Equipment
Program). As a minimum, the following PPE shall provide, maintained and worn by all
employees working on site:
5.25.2.1. Head protection;
5.25.2.2. Hearing protection;
5.25.2.3. Eye protection;
5.25.2.4. Body and extremity protection;
5.25.2.5. Foot protection; and
5.25.2.6. Respiratory protection.
5.25.3. Contractor and subcontractor personnel who work in Ma’aden Aluminium plant areas
where use of special clothing (molten metal, flame, arc, caustic resistance) is required or
who may be exposed to molten metal, flame, arc or caustic hazards shall be provided by
contractor with the proper type, size and quantity of special clothing in accordance with
Ma’aden Aluminium requirements.
5.25.4. Contractor Supervisor/Responsible person shall ensure their personnel is trained in
inspection, use, maintenance and storage of PPE according to manufacturer instructions.
Date Published:
Date Revised:
current version.
5.25.5. PPE shall meet applicable ANSI requirements or equivalent as specified in MA Personnel
Protective Equipment Program.
5.25.6. Proper PPE (e.g., correct for type of exposure, sized to fit the worker, meets applicable
standards, no defects) shall be provided to personnel when/where required.
5.25.7. PPE shall be visually inspected by the user before each use. Defective or damaged PPE
shall not be used and shall be immediately replaced.
5.25.8. PPE that has exceeded its useable service life shall be immediately replaced.
5.25.9. Clothing shall be free of holes, excessive wear and other defects. Only proper work
clothing (e.g., coveralls, long pants and sleeved shirt) shall be worn by personnel
performing construction, maintenance and operations work (e.g., traditional loose flowing
“Eastern” style clothing shall not be worn, since it presents tripping and entanglement
hazards).
5.26. Barricades
5.26.1. Contractor shall establish barricade program to restrict access to location roads, work
areas and access ways, to control any situation where hazardous conditions are evident
or potentially foreseeable, which may present danger to persons, or damage to
equipment or property.
5.26.2. Consideration shall be given to the type of barricade material used, i.e. a hard physical
barricade constructed from material such as scaffold tubing shall be used around
excavations and holes in floors.
5.26.3. Red/white barricade means do not enter. Yellow/black barricade means enter with
caution.
5.26.4. Barricades shall be provided where required as per Ma'aden Aluminium Barricades
Program. Barricades shall be clearly marked with flagging. Barricades shall have
protective lighting, when necessary. As a minimum barricades shall be erected in such
situations as:
5.26.4.1. Overhead work
5.26.4.2. Enclosed space entry
5.26.4.3. Scaffold erection and dismantling
5.26.4.4. Chemical and product spill
5.26.4.5. Traffic and pedestrian control
5.26.4.6. Blasting and charging situations
5.26.4.7. Excavation
5.26.4.8. Road works
Date Published:
Date Revised:
current version.
5.26.4.9. Descaling
5.26.4.10. High pressure water use
5.26.4.11. Compressed air use
5.26.4.12. Pressure or hydro testing
5.27. Fire Prevention
5.27.1. Contractor shall include detailed fire prevention plan as part of Job Specific EHS plan.
5.27.2. Open fires are prohibited on Ma’aden Aluminium premises.
5.27.3. Do not store flammable liquids inside buildings unless approved by the Ma’aden
Aluminium Fire and Emergency Department.
5.27.4. Containers of flammable liquid with flash points below 140 degrees F (vapor pressure not
exceeding 40 psi absolute at 100 degrees F) shall be provided with atmospheric and
emergency relief vents equipped with flame arrestors. Containers from which such
flammable liquids are dispensed shall be electrically grounded and shall be equipped with
bonding wires to complete the grounding with the vessel into which the liquid is
dispensed. Provide spill containment at least equivalent to the capacity of the storage
container(s).
5.27.5. All containers shall be label per HCIS, Royal Commission and Ma’aden Aluminium
requirements.
5.27.6. Open fires and/or open burnings are strictly prohibited. Authorization shall be obtained
from the Ma’aden Aluminium Fire Department.
5.27.7. Smoking shall be permitted only in designated areas. “No Smoking” signs shall be
prominently displayed, particularly where flammable or combustible materials are stored
5.27.8. Provide portable dry-chemical fire extinguishers for fuel storage tanks, the size of which
is consistent with HCIS-SAF-04 Fire Protection Systems.
5.27.9. Install portable fire extinguishers on all lubrication trucks and all other mobile equipment
such as trucks, mobile cranes, service vehicles, forklift, trailers etc.
5.27.10. Fire extinguishers, hydrants, hoses and other firefighting equipment shall be regularly
inspected.
5.27.11. Designated site personnel (Fire Watchers, Fire Fighters) shall be trained in the use of the
various types of firefighting equipment on-site.
5.27.12. Refuel vehicles only in pre-designated outdoor areas. As a minimum, observe the
following procedures for refueling:
5.27.12.1. Shut off the vehicle engine.
5.27.12.2. Do not smoke.
Date Published:
Date Revised:
current version.
5.27.12.3. Do not overfill fuel tank.

5.27.12.4. When the fuel is liquid propane gas, ground the nozzle of the fuel hose to the
vehicle filler pipe with a ground wire.
5.27.13. Flammable materials (e.g., paints, fuels, chemicals) shall be separated and stored in a
designated flammable liquid storage area away from heat sources, electrical equipment
and other ignition sources.
5.27.14. Storage of flammable and combustible materials shall be restricted to the minimum
quantities necessary for an interruption cycle of operations or construction activities.
5.27.15. Use containers approved by Underwriters' Laboratories for transporting flammable liquids
and clearly label them to identify the contents. Plastic containers are prohibited for the
storage of flammable and combustible liquids.
5.27.16. Cellular/mobile phones or other electronic devices shall not be used when transferring
flammable liquids or when refueling vehicles.
5.27.17. Cutting, welding, and other hot work activities can only be performed when a Hot Works
permit is issued by Ma’aden Aluminium.
5.27.18. Observe the following precautions when using or storing oxygen, acetylene and other
flammable gas cylinders:
5.27.18.1. Oxygen storage areas shall be separated by at least 25 feet from combustible
liquids, flammable materials or heat sources such as fire, molten metal or
electric lines. If impossible to comply with this 25-foot distance, then isolate
the oxygen storage area by a non-combustible fire barrier with a 1/2-hour fire-
resistant rating.
5.27.18.2. Do not transport gas cylinders by overhead building cranes or truck cranes
except in approved holder or carrier designed for this purpose.
5.27.18.3. Properly vent oxygen storage areas.
5.27.18.4. Gas cylinders shall be stored, used and transported vertically and adequately
secured; keep valve caps in place when cylinders are not in use.
5.27.18.5. Maintain regulators and gauges for oxygen and fuel in proper working order
while in use. Keep oil and grease away from oxygen cylinders, fittings and
hoses.
5.27.19. Welding equipment, asphalt kettles, heating appliances and other open flames or hot
surfaces shall be segregated from flammable and combustible materials.
5.27.20. Proper bonding and grounding techniques shall be used for any operation where static
electricity could become an ignition source.
Date Published:
Date Revised:
current version.
5.27.21. Noncombustible or flameproof welding screens shall be provided around/under cutting,

welding operations that are adjacent to or above Natural Gas operations or
flammable/combustible materials.
5.27.22. Any cutting, welding or burning operation requires an assigned qualified fire watch who
shall remain in the work area during these activities and for no less than ½ hour after the
work has finished.
5.27.23. Temporary enclosures constructed for the protection of operational components and
equipment shall be of fire retardant materials.
5.27.24. Where possible or feasible, avoid performing Hot Work but rather substitute another work
method. Examples of some options may include moving the work to a Designated Hot
Work Area or using a pipe cutter or other non-sparking, open flame or heat producing
equipment.
5.27.25. Contractor shall identify a designated hot work area and obtain approval form Ma’aden
Aluminium Fire and Emergency Department. Designated hot work areas shall protect
personnel from hazards generated by hot work with welding screens/curtains, walls, etc.
5.27.26. Contractor shall develop a standard work instruction for all hot work activities executed
inside designated hot work area.
5.27.27. Wherever Hot Work is performed outside of designated hot work areas, a Hot Work
Permit shall be obtained.
5.27.28. All persons carrying out welding shall be suitably qualified to do so. Welder's
qualifications shall be held on contractor file at the work site and shall be audited by
Ma’aden Aluminium.
5.27.29. Contractors shall instruct employees in the safe use of welding and gas cutting
equipment.
5.27.30. Fuel gas hose and oxygen hose shall be of an approved type, being easily distinguishable
and shall not be interchangeable. Hoses shall be inspected at the beginning of each
workday and shall be repaired or replaced if defective.
5.27.31. Harmful gases can be given off when carrying out certain types of cutting and welding
work and the Contractor shall provide a proper atmosphere or appropriate respiratory
protection when welding, cutting or heating.
5.27.32. An approved operable fire extinguisher with current inspection tag shall be available for
standby use at the hot work job site.
5.27.33. Incombustible or flameproof shields in high hot work activity areas (welding workshop,
fabrication shop etc.) to protect persons from direct rays shall shield cutting or welding
operations. This can be achieved by the erection of temporary welding bays and /or
welding blankets being hung around the welding area.
Date Published:
Date Revised:
current version.
5.27.34. No person shall use matches, rope, wicks or other shouldering materials for the lighting
of gas torches. An approved type flint gun shall be used for this purpose.
5.27.35. No welding or burning shall be undertaken where hot metal can fall into an uncovered
cable ladder or onto electrical cables. Before cutting or burning work is started, all cables
shall be covered in an approved manner, using sheet metal or fire protection blankets.
Contractors shall request inspection by Ma’aden Aluminium before starting work.
5.27.36. Gas cutting on drums is not permitted on Ma’aden Aluminium work sites.
5.27.37. The use of flammable solvents, oil or grease is strictly forbidden for the cleaning or
lubrication of gas or oxygen hoses, fittings or other apparatus because of the risk of
explosion in the oxygen atmosphere.
5.27.38.
5.28. Housekeeping
5.28.1. Housekeeping is the responsibility of each Contractor or Subcontractor who shall:
5.28.1.1. Have a daily clean-up plan.
5.28.1.2. Cleaning of the entire site, including identifying areas where each
subcontractor is responsible for the cleaning.
5.28.1.3. Stack materials to maintain safe clearances and prevent toppling.
5.28.1.4. Collection, storage and disposal of nonhazardous and hazardous waste in
accordance with Royal Commission Regulations.
5.28.1.5. Remove loose overhead materials.
5.28.1.6. Immediately remove or bend over any nails protruding from lumber.
5.28.1.7. Not allow refuse to accumulate.
5.28.1.8. Locate containers throughout the Contractor's work area for collection of
employee's trash and empty on a regular basis.
5.28.1.9. Maintain unobstructed passageways for pedestrian and vehicle traffic.
5.28.1.10. Store materials only in areas designated and approved by project Manager/
Leader.
5.28.1.11. Maintain roofs free of combustibles, trash and debris.
5.28.1.12. Secure all loose materials on roofs so they cannot become airborne.
5.28.1.13. Maintain hoses and cords such that they will not become tripping hazards.
5.28.1.14. Not store material or equipment within a horizontal distance of 10 feet of a
high voltage line or equipment in accordance with Ma’aden Aluminium
Electrical Safety Program.
Date Published:
Date Revised:
current version.
5.28.2. The specific locations for the disposal of various wastes (clean excavated material,
common construction trash, etc.) shall be in accordance with Ma’aden Aluminium
instructions.
5.29. Ma’aden Aluminium Plant Machinery and Equipment
5.29.1. Contractors may not operate any equipment and tools belonging to Ma’aden Aluminium
unless authorized in writing by the Ma’aden Aluminium Responsible Person(s). The Area
Manager shall approve all use of Ma’aden Aluminium equipment and tools. Contractors
who use equipment belonging to Ma’aden Aluminium shall sign a “Hold Harmless
Agreement” prior to use.
5.29.2. In removing redundant or out of service equipment or piping, the risks are different from
those of installing new equipment or piping. Initially a risk assessment shall be conducted
and a method statement shall be developed for any removal of out of service equipment.
5.29.3. Demolition of structure and equipment is an inherently hazardous process. Formal
processes shall be adopted to ensure that the task is undertaken in a safe manner. As a
minimum the following shall be in place before work begins:
5.29.3.1. EHS risk assessment.
5.29.3.2. Step by step method statement.
5.29.3.3. Marking of structure and equipment
5.29.3.4. Job Safety Analysis for the task to perform.
5.29.4. Stackers, reclaimers, conveyors, pumps and ship loaders are vital to plant operation and
that can start up automatically or by remote control. No person shall access or climb onto
or over any part of this equipment at any time without due consideration of the following:
5.29.4.1. Work on machines and equipment shall not be commenced until the relevant
system has been appropriately isolated, tagged and verified in accordance
with LTV Procedures.
5.29.4.2. Safety guards, handrails or safety interlock devices shall not be removed or
overridden unless specifically approved by Ma’aden Aluminium for testing
purposes.
5.29.4.3. An on-line conveyor system shall not be stopped by any person unless
specifically authorized to do so, outside an emergency.
5.29.4.4. Material shall not be thrown or shoveled onto a moving conveyor, unless a
suitably designed installation has been provided specifically for that purpose.
5.29.4.5. Hot work (cutting, welding or heating) shall not take place over a rubber
conveyor belt.
5.29.4.6. Access ways beside all conveyor belts shall be kept clear of all material.
Conveyors shall not be used to convey tools, equipment or personnel.
Date Published:
Date Revised:
current version.
5.29.4.7. Portable conveyors shall have skirt boards to keep heavy material from falling
over the sides and light or loose material from blowing off.
5.29.4.8. All conveyors including bucket elevators shall be fitted with a locking or anti-
rollback device to hold the conveying unit at various fixed locations.
5.29.4.9. Any construction, testing, inspection, operating and maintenance work
associated with fuel gas pipelines shall not commence until Ma’aden
Aluminium Engineering department approved step-by-step method
statement.
5.30. Heavy Mobile Equipment
5.30.1. Contractor shall develop and implement a detailed program for mobile equipment and
crane as per Ma’aden Aluminium Mobile Equipment Program.
5.30.2. The Contractor shall ensure that employees assigned to operate mobile equipment have
had the required training and licensing and have demonstrated the necessary skills to
operate the equipment.
5.30.3. Contractor shall submit a list of mobile equipment including electrical, lifting etc. to
respective Maintenance & Engineering department for verification prior to start any job
activities.
5.30.4. Contractor shall establish a program to verify the mobile equipment operator competency
minimum as follows:
5.30.4.1. Valid Saudi Arabian mobile equipment operating license.
5.30.4.2. Medically, physically and mentally fit.
5.30.4.3. Satisfactory completion of a written and practical test/examination.
5.30.4.4. Crane and telescopic forklift operators shall demonstrated ability to read,
write, comprehend and use arithmetic and a load/capacity chart.
5.30.5. Contractor shall establish a program to verify the rigger competency minimum as follows:
5.30.5.1. Trained by approved third party.
5.30.5.2. Internal periodic refresh training by Contractor.
5.30.6. Documentation of the required training and licensing shall be maintained at the work site.
5.30.7. All heavy mobile equipment used for on-site shall be inspected in accordance with the
manufacturer specification.
5.30.8. Periodic inspection of equipment on site shall be at intervals no greater than six months.
5.30.9. Contractors shall ensure and attest that the equipment has been successfully tested and
checked for compliance with applicable requirements.
Date Published:
Date Revised:
current version.
5.30.10. Prior to operating the equipment, each operator shall complete a written pre-operational
inspection for industrial mobile equipment. Immediate action shall be taken on items
noted that pose safety concerns.
5.30.11. All motor vehicles and mobile equipment shall be maintained in a safe operating
condition, free of oil, hydraulics, and other fluids leaks, and with the necessary guarding
of moving parts in compliance with Ma’aden Aluminum requirements.
5.30.12. When using mobile equipment on Ma’aden Aluminium premises, due consideration shall
be given to the ENVIRONMENTAL impact.
5.30.13. All Contractor employees shall be required to wear occupant restraints when operating
vehicles equipped with these devices.
5.30.14. When mobile equipment is not in use, it shall be positioned where it will not obstruct
railroad tracks, roadways, walkways, electrical lines or temporary passageways.
5.30.15. When mobile equipment is not in use, it shall be positioned where it will not obstruct
railroad tracks, roadways, walkways, electrical lines or temporary passageways.
5.30.16. All equipment not in use shall be secured to prevent movement or operation. Mobile
cranes shall not be parked with the boom suspended over walkways, employee
passageways, roadways, railroad tracks, electrical or mechanical equipment, or
buildings. Mobile cranes shall not be parked in location that may obstruct building crane
or bridge crane travel.
5.30.17. When mobile equipment is in use, clearances shall be maintained to prevent anyone from
being caught between the equipment and structures.
5.30.18. The Contractor shall barricade the work area or provide an escort for the protection of
persons near the area.
5.30.19. Proper distance from electrical lines shall be observed per the Ma’aden Aluminium
requirements.
5.30.20. Mobile equipment operators shall be trained on operation of mobile equipment when
working near high voltage power lines.
5.30.21. Rotating warning lights shall be provided with all mobile cranes and equipment’s.
5.30.22. A durable rating chart(s) with legible letters and figures shall be provided with each crane.
5.30.23. All crane documentation and certificate shall be kept within the crane all times.
5.30.24. Cranes extending more than 60 meters (197 feet) above ground level shall have a
permanently mounted aircraft warning light operating 24 hours a day.
5.30.25. All mobile equipment’s shall have a backup alarm while reversing. It should be higher
than the surrounding sound level.
5.30.26. Contractor shall develop procedure for lifting plans and method statement under the
following conditions:
Date Published:
Date Revised:
current version.
5.30.26.1. Any load that exceeds 85% of the crane’s rated load capacity.
5.30.26.2. Any load lifted by more than one crane.
5.30.26.3. Any parts of a crane are working close to any process plants.
5.30.26.4. Any load weighing 40 tons or greater.
5.30.26.5. Any piling operation.
5.30.27. Lifting method statement formats shall contains at least the following information:
5.30.27.1. A brief description of operation to be performed, including the details of
Project, location, date and time.
5.30.27.2. List of people involved and the definition of their roles and responsibilities
within the activities.
5.30.27.3. Sequential step by step written description of activities.
5.30.27.4. Installation Drawings (Layouts, Foundation, Underground services, etc.)
Relevant for the lifting activities, as needed.
5.30.27.5. Information related to crane(s).
5.30.27.6. Information related to load.
5.30.27.7. The type, size, and capacity of rigging hardware.
5.30.27.8. Sketches showing the sling angles.
5.30.27.9. The ground-bearing capabilities and requirements for matting and/or pads.
5.30.27.10. Rigging drawings and sketches (Plan and Side View(s)), showing crane and
load locations on the area of lifting operation
5.30.28. Riggers shall wear a reflective vest for identification purpose.
5.31. Excavation
5.31.1. Contractor shall develop and implement a detailed program for Excavation.
5.31.2. Contractors, Subcontractors and Contracted Services doing excavation shall be
knowledgeable of local regulations on excavation.
5.31.3. Prior to starting any excavation work, Contractors, Subcontractors and Contracted
Services shall designate a competent person responsible for excavation work.
5.31.4. Prior to starting any excavation, Contractors, Subcontractors and Contracted Services
shall prepare a location specific excavation plan which includes the following site
conditions:
5.31.4.1. Type of soil expected to be encountered.
Date Published:
Date Revised:
current version.
5.31.4.2. Expected surface moisture and groundwater conditions.

5.31.4.3. Any previous disturbances of the soil.
5.31.4.4. Size and depth of the excavation.
5.31.4.5. Amount of time all or part of the excavation will be open.
5.31.4.6. Range of expected weather conditions during the excavation.
5.31.4.7. Location and type of equipment to be used.
5.31.4.8. Nearness and physical condition of adjacent structures and improvements.
5.31.4.9. Location and nearness of overhead and underground utilities.
5.31.4.10. Determination of responsibility to locate underground utilities.
5.31.4.11. Type and proximity of vehicular traffic to the excavation.
5.31.4.12. Shock or vibration created from blasting or pile driving.
5.31.4.13. Other nearby sources of shock and vibration.
5.31.4.14. If shoring is needed, the type and size.
5.31.4.15. Means of entry and exit.
5.31.4.16. Emergency rescue equipment required.
5.31.5. Ma’aden Aluminium excavation permit shall be obtained before excavation work is
started.
5.31.6. Wells, shafts, pits or other excavations shall be protected with appropriate physical
barricades when unattended and lighting shall be provided when needed. Upon
completion of work, immediately backfill excavations.
5.31.7. A competent person or engineer with experience in structural design shall design
structural ramps for personnel access to an excavation. Structural members with uniform
thickness for multi-piece ramps shall be used and connected together in such a way as
to prevent tripping. Cleats or special surface treatments shall be used on ramps to
prevent slipping. Access and egress to excavations and trenches of 4 feet (1.2 meters)
or more in depth shall be provided which require no more than 25 feet (8 meters) of lateral
travel.
5.31.8. Shield systems shall be deployed in a manner that prevents hazardous movements in
the event of sudden lateral loads on the shield. Personnel shall be prohibited from riding
in shields at any time. When a shield is designed to resist the calculated forces for the
full depth of the trench, excavations shall be permitted to a maximum of 2 feet (.6 meters)
below the bottom of the shield provided there are no indications of loss of soil behind the
shield.
5.31.9. Personnel shall be prohibited from working in excavations with accumulated water.
Date Published:
Date Revised:
current version.
5.31.10. Shoring, bracing, and underpinning shall be used to ensure the stability of adjacent
structures. The appropriate professional shall approve excavations below the level of a
base, footing, or retaining wall.
5.31.11. Personnel shall wear high visibility vests or clothing when excavating near mobile
equipment. Barricades with warning lights shall be used to warn traffic when excavating
near roadways. Personnel shall be prohibited from working under any overhead loads.
Use of mobile equipment near an excavation or approaching an excavation shall be done
with a clear, unobstructed view from the vehicle operator. Barricades, hand signals, stop
logs or berms shall be used to protect personnel working in excavations from mobile
equipment.
5.31.12. Loose rock or soil shall be removed from the face of an excavation by scaling, use of
protective barricades or other means. Personnel shall be prohibited from working on the
face of excavations while other people are working at lower levels unless adequate
protection from falling materials is provided. Personnel shall be protected by positioning
materials at least 2 feet (.6 meters) from the edge of the excavation, grading materials
away from the edge of the excavation, using restraining devices to keep material from
falling into the excavation, or a combination. Personnel involved in the loading or
unloading of excavation or trenching materials shall be in protective operator cabs or at
a safe distance.
5.31.13. Excavation deeper than 4 feet shall consider as confined space entry. Confined space
entry requirements shall be applied.
5.31.14. The competent person shall complete a daily inspection checklist of excavations and
surrounding areas if personnel will enter the excavation. This inspection shall be
conducted at the beginning of the shift and as needed throughout the shift. Inspections
shall be made after every rainstorm or hazard-increasing occurrence.
5.31.15. Backfilling and removal of shoring shall be accomplished first by backfilling up to a level
allowing for the removal of the lower braces. Another layer of backfill shall be positioned
in the excavation up to the next layer of braces to be removed. Removal of shoring shall
progress together with the backfill from the bottom to the top of the excavation. In unstable
soil, ropes shall be used to pull out the jacks or braces from above after all employees
have exited the excavation. All excavations shall be backfilled and the surface left in good
condition.
5.32. Lock Out, Tag Out and Verify (LTV)
5.32.1. Contractors are responsible for understanding the Ma’aden Aluminium Lock Out, Tag Out
and Verify procedure and transferring this understanding to their employees through
training. Specific equipment lock, tag and verify procedures shall be reviewed prior to
the application of locks and tags and shall be included in the Contractor Job Specific EHS
Plan. For additional information, consult the Ma’aden Aluminium LTV program and the
Ma’aden Aluminium Project Manager/Leader.
5.32.2. There are five fundamental rules.
Date Published:
Date Revised:
current version.
5.32.2.1. No person shall isolate any primary isolation device unless they are
competent and authorized to do so.
5.32.2.2. No person shall place a red equipment isolation tag and lock unless they are
competent and authorized to do so by Ma’aden Aluminium.
5.32.2.3. Competent and authorized persons may place White Personal Danger Tag
and lock on a single isolation point or at a common isolation point.
5.32.2.4. Where white personal danger tags and locks are required, individuals shall
place tag and lock at the start of a job and shall remove the lock and tag at
the finish of the job or at the end of the work period/shift.
5.32.2.5. Removal of a danger lock and tag, without prior Ma’aden Aluminium approval,
is regarded as a serious breach of safety regulations and may result in
dismissal from site.
5.32.3. An Identification Tag or Green Flag is used to positively identify equipment where there
is potential to incorrectly identify the equipment that is to be worked on or removed for all
work completed on an isolation. Contractors shall not commence work on any system or
equipment without identification tags.
5.33. Electrical
5.33.1. All Contractor employees shall be aware of the electrical hazards that within the scope of
their contract. Energy Control shall always be a consideration in all work being
performed. Contractors shall follow lock out/Tag out/Verify procedures. Contractors shall
follow the safe work procedures described below to eliminate electrical hazards. These
hazards are broken down into several categories.
5.33.2. High Voltage (over 1000 volts)
5.33.2.1. Unless specially trained and authorized, DO NOT work on or around any high
voltage power lines or electrical equipment. Special training shall be required
and certified by the Ma’aden Aluminium Responsible Person(s). If applicable,
the High Voltage Clearance Order procedure or permit for creating a safe
work zone shall be completed and followed.
5.33.2.2. DO assume all power lines and electrical equipment is energized.
5.33.2.3. DO NOT work within 10 feet of un-insulated power lines or equipment.
5.33.2.4. DO NOT have materials, tools, or other objects within 10 feet of un-insulated
power lines or equipment.
5.33.2.5. DO NOT operate mobile equipment in a manner that would allow any part of
the equipment to be within 10 feet of un-insulated power lines or equipment.
5.33.2.6. DO NOT place buildings, store materials, park vehicles, etc. under power
lines or within a horizontal distance of 10 feet of power lines.
Date Published:
Date Revised:
current version.
5.33.2.7. DO NOT block access to substations or other electrical equipment.

5.33.2.8. DO NOT work outside during thunderstorms or when lightning is present.
5.33.2.9. DO NOT exit a vehicle or other mobile equipment if it becomes energized due
to contact with a high voltage power line.
5.33.2.10. DO notify the Ma’aden Aluminium Responsible Person(s) in the event of an
electrical malfunction.
5.33.3. Low Voltage (under 1000 volts).
5.33.3.1. DO NOT work on or around any electrical equipment unless you have been
specially trained and certified.
5.33.3.2. DO NOT store materials, park vehicles, or leave equipment within 4 feet of
breaker panels, transformers, or other electrical equipment.
5.33.3.3. DO NOT touch cables, breaker panels, transformers, or other electrical
equipment unless authorized.
5.33.3.4. DO NOT operate disconnect switches unless authorized.
5.33.3.5. DO NOT use faulty electrical tools, cords, or other equipment.
5.33.3.6. DO use battery powered, grounded or “Double Insulated” tools, cords, and
other electrical equipment.
5.33.3.7. DO use “Ground Fault” outlets and/or cords for all construction activities.
5.33.3.8. DO NOT use metal or other conductive ladders.
5.33.3.9. DO NOT remove “Ground” wires from poles, towers, fences, transformers,
motors, panels, or other electrical equipment.
5.33.4. Temporary Power and Lighting
5.33.4.1. Contractor shall provide, install, operate and maintain power generation and
distribution facilities at project support facilities and worksites, as needed.
5.33.4.2. The power system shall provide electrical power supply at 220/110
volts/60Hz.
5.33.4.3. Power distribution panel boards shall be labeled to identify the service of
individual breakers.
5.33.4.4. All temporary lighting shall be fixed to the structure by the use of safety
chains. Lamps shall be protected by the use of a fine wire mesh guard.
Lighting installation shall be located such that clear access is given for
persons and accidental physical contact is avoided.
5.33.4.5. Hand held/portable lighting shall not exceed a potential of thirty-two (32) volts
AC or 12 Volt DC.
Date Published:
Date Revised:
current version.
5.33.4.6. Hand held/portable lights shall be equipped with insulated handles, have
substantial guards attached to the handle or holder, and not have paper-lined
metal shell/guard if AC. powers the light.
5.33.4.7. Hand held/portable lights shall not be used in Natural Gas areas.
5.33.4.8. All hand held/portable lights shall be inspected prior to issuing and using.
Frequent random on-site check shall be performed.
5.33.4.9. All power circuits above 32 volts for lighting shall be protected by a Residual
Current Device located external to the tank or work area.
5.33.4.10. The lighting circuit shall not be energized until the installation is complete,
tested and the current inspection tag affixed.
5.33.4.11. If the work area be, or become, a Class A (explosive atmosphere) area, then
all equipment and fittings shall conform to Class A classification intrinsic
safety fitting and no cable joints in the area.
5.33.4.12. As far as practicable, power leads shall not enter a vessel through the
personnel entry point. If this is not possible, then additional mechanical
protection shall be provided.
5.33.4.13. No person shall remove or interfere with any permanent light or power
installation without permission from Ma’aden Aluminium. Use of Ma’aden
Aluminium single-phase power outlets or 3-phase welding outlets is not
permitted unless written permission is given by Ma’aden Aluminium.
5.33.4.14. Any permanent lighting installation or fitting removed or temporarily
disconnected for construction tie-in or relocation, shall be replaced with a
temporary installation (by a licensed electrical worker), to satisfy 24-hour
operation requirements.
5.33.5. Portable / Plug in Appliances and Leads
5.33.5.1. All users of electrical tools, appliances and extension leads are responsible
for visually inspecting their electrical equipment for signs of damage and
unusual wear prior to using the equipment. This is in addition to the quarterly
appliance checks carried out by qualified electrical workers.
5.33.5.2. Flexible cords, cord extension sets, flexible cables and accessories used to
connect appliances and equipment to a power supply shall have a minimum
cross sectional area of 1.5 mm2. This shall not include the cord that is
permanently attached to the appliance or light fitting.
5.33.5.3. Maximum length of a flexible cord shall be 32 meters. The cord shall not be
joined in lengths in which the total length exceeds 32 meters.
Date Published:
Date Revised:
current version.
5.33.5.4. Extension cords shall not extend from a work level to more than one level
above or below it, except where the cords are used for work in lift shafts or
stairwells.
5.33.5.5. Cords shall be elevated at 2.4m on stands, or attached to structure by the
use of cable hangers. Welding rods, wire and rope are not approved for tying
cords to structure.
5.33.5.6. Extension leads shall not be left plugged in, turned on and with no appliance
plugged into the socket end. An open-ended live extension lead, exposed to
the environment is a possible fatality waiting to happen.
5.33.5.7. Extension cords shall not be used as a substitute for permanent wiring in
portable office facilities. If re-locatable power cords using in temporary office
facility shall be of the polarized or grounded type with over current protection
and should be “UL, FM or SASO” listed.
5.33.5.8. All extension cords shall have appropriate grounding pins and blades to fit
the socket outlet.
5.33.5.9. All extension cords plugs and sockets that meet SASO 2203 power cord plug
and NFPA 70 grounding and polarity requirements.
5.33.5.10. All electrical equipment used on a construction site such as leads, appliances
and tools including office and crib appliances shall undergo inspection and
testing prior to initial connection and use on site.
5.33.5.11. Portable electrical equipment, portable tools, extension leads, generators,
welders, etc. used on construction work, other than offices and crib rooms,
shall be tested and inspected monthly and appropriately tagged.
5.33.5.12. Portable electrical equipment and appliances used in offices and crib rooms
shall be tested and inspected every quarterly and appropriately tagged.
5.33.5.13. All electrical testing shall be carried out by a licensed electrical
worker/contractor approved by Ma’aden Aluminium Responsible Person(s).
The tests shall include:
5.33.5.13.1. Earth continuity where applicable.
5.33.5.13.2. Insulation megger test of active and neutral leads.
5.33.5.13.3. Testing of Residual Current Devices (Earth Leakage units).
5.33.5.13.4. Check visually for obvious external damage or component
defects in accessories, connectors, plugs or sockets.
5.33.5.13.5. Check that inner cores of flexible supply cords are not exposed
and that external sheaths are not cut, abraded or damaged in
any way. Also, check that unprotected conductors or insulation
tape are not in evidence.
Date Published:
Date Revised:
current version.
5.33.5.13.6. Fixed equipment and installations such as huts, workshops,

urns, etc. shall be inspected and tested by the electrical
worker/contractor.
5.33.6. Residual Current Devices / Safety Switches
5.33.6.1. Function tests on residual current devices by use of the ‘test button’ shall be
performed by anyone about to plug a lead or electrical tool into the protected
outlet.
5.33.6.2. In addition, a performance test of verifying the trip current and trip time shall
be carried out and recorded for each device by a licensed electrical worker
every month.
5.33.7. Overhead Power Lines
5.33.7.1. Any work required to be performed on or adjacent to overhead power lines
shall be controlled by a High Voltage Access Permit.
5.33.7.2. The term ‘adjacent to overhead power lines’ shall be interpreted as equipment
or personnel entering within the distance of a 3-metre horizontal and vertical
exclusion zone. Particular note shall be taken with crane booms or hooks,
which may drift into the area of exclusion.
5.33.7.3. All non-electrical work (welding, cutting, lifting, digging, fitting etc.) required
to be performed within 10 meters of an overhead power line or other exposed
high voltage conductor, shall be controlled by a High Voltage Vicinity Permit.
5.33.7.4. 10 Meter Rule
5.33.7.4.1. A “power line corridor” that extends 10 meters, horizontally,
either side of the nearest power line conductor (wire). With
power lines being about 2 meters from wire to wire, most power
line corridors shall be at least 22 meters wide. The regulation
requires that you shall have written authority to carry out any
work within the power line corridor. Ma’aden Aluminium uses the
HV Vicinity Permit to record the conditions by which that
authority is granted. Material shall not be stored within the
power line corridor.
5.33.7.5. 3 Meter Rule
5.33.7.5.1. Under no circumstances shall any person, material or
equipment (mobile or fixed) approach closer than 3 meters to an
overhead power line of a working voltage up to 50,000 volts.
This rule applies to approach from any direction below, side or
top. There is no circumstance under which work or lifting may
take place above live overhead power lines.
Date Published:
Date Revised:
current version.
5.33.7.5.2. If, during the course of work, it is physically possible for material
or equipment to inadvertently extend into the 3-metre exclusion
zone, grounding provisions shall be required, and these shall be
noted on the High Voltage Vicinity Permit.
5.33.7.5.3. Plant Manager Approval is required for specialized high voltage
electrical work, which may breach the 3-metre exclusion zone.
5.33.8. Working in Proximity to Live Cables in Cable Trays
5.33.8.1. Contractor shall develop a detailed procedure for working near or lifting loads
over cable ladders (trays) containing live electric cables. The procedure aims
at preventing contact or disturbance of high voltage cables, but the principles
apply equally to all cabling.
5.33.8.2. Contractor shall conduct a Risk Assessment if task needs to perform within 3
meters of insulated cables. If it is determined that contact may be possible,
then defensive techniques such as placing planking over the cable ladder
should be used. When working or lifting loads within 1 meter of cables,
barriers and barricades shall be used to protect the cables unless it can be
demonstrated that the work method guarantees no contact shall be made.
5.34. Portable Tools
5.34.1. Contractor shall develop a detailed portable tools program as part of Job Specific EHS
Plan.
5.34.2. Contractor shall ensure that homemade portable hand tools are not used within Ma’aden
Aluminium Premises.
5.34.3. It is the Contractor’s responsibility to ensure that all of their tools and equipment, which
are taken onto Ma’aden Aluminium sites, are clearly identified as belonging to that
Contractor. The onus of proof shall be the Contractor’s responsibility. Any tools and/or
equipment that do not have such an identifying mark may be retained at the Ma’aden
Aluminium location until such time that the Contractor can prove ownership.
5.34.4. A portable tool is defined as any hand tool or power tool (electric, pneumatic, hydraulic,
explosive or fuel driven) that can be manually transported and used by one person.
5.34.5. Excessively worn tools and tools requiring maintenance shall be removed from the job
site.
5.34.6. Electrical power tools shall have a three-wire cord with a ground and be plugged into a
grounded receptacle.
5.34.7. Electric power operated tools shall be of an approved double insulated design and be
connected with a Ground Fault Circuit Interrupter.
Date Published:
Date Revised:
current version.
5.34.8. Portable power tools shall be equipped with properly functioning constant pressure
switches or controls that will shut off the power when the pressure is released (i.e., a
“dead man” switch).
5.34.9. Power tools shall not be equipped with trigger locks.
5.34.10. Power tools shall be disconnected from the power source before changing bits, blades,
cutters or wheels.
5.34.11. Use of the electrical cord for hoisting or lowering power tools is prohibited.
5.34.12. Pneumatic power tools compressed air hoses shall be the correct size and rating for the
tool being used.
5.34.13. Compressed air hose joints (twist lock fittings) shall be secured with proper couplers and
safety wires or pins to prevent the tool and/or hoses from being inadvertently
disconnected.
5.34.14. The abrasive blast cleaning nozzles shall be equipped with an operating valve, which
shall be held open manually. A support shall be provided on which the nozzle may be
mounted when it is not in use.
5.34.15. All portable tools shall be in good state of repair and intrinsically safe for the user and
other people in the same area. They shall be used only for the job they were designed,
and in accordance with the manufacturer’s instructions.
5.34.16. Belts, gears, shafts, pulleys, sprockets, spindles, drums, flywheels, chains, or other
reciprocating, rotating or moving parts of tools and equipment shall be guarded if such
parts are exposed to contact by employees or otherwise create a hazard.
5.34.17. Wrenches, including adjustable, pipe, end, and socket wrenches shall not be used when
jaws are sprung to the point that slippage occurs.
5.34.18. Only employees who have been trained in the operation of the particular tool in use shall
be allowed to operate a powder-actuated tool.
5.34.19. Impact tools, such as drift pins, wedges, and chisels, shall be kept free of mushroomed
heads.
5.34.20. The wooden handles of tools shall be kept free of splinters or cracks and shall be kept
tight in the tool.
5.34.21. Files, wood chisels, and other tools with tangs shall be fitted and used with suitable
handles covering the end of the tang. Ends of the handles shall not be used for pounding
or tapping.
5.34.22. The following general practices shall be followed when using electrical tools:
5.34.22.1. Operate electric tools within their design limitation.
5.34.22.2. Use appropriate PPE when using electric tools.
Date Published:
Date Revised:
current version.
5.34.22.3. Store electric tools in a dry place when not in use.

5.34.22.4. Do not use electric tools in damp or wet locations unless they are approved
for that purpose.
5.34.22.5. Ensure that cords from electric tools do not present a tripping hazard.
5.34.23. Screwdrivers
5.34.23.1. Tips shall be correct size to fit the slot of the screw.
5.34.23.2. Pliers or other tools shall not be used to obtain additional leverage on the
screwdriver’s shank.
5.34.23.3. Screwdrivers shall not to be used as a prying tool, punch, wedge, chisel,
pinch bar, nail puller, or be struck with a hammer.
5.34.23.4. Handles shall not be subjected to blow from hammer or similar instrument.
5.34.23.5. Handles shall be insulated when used for electrical work.
5.34.23.6. If the tips of any screwdriver or special fastener are worn or misshaped, they
shall be turned in for a replacement issue.
5.34.23.7. Small objects shall not be held by hand, under the arm, or on the lap when
being worked on with a screwdriver.
5.34.23.8. Workers shall ensure they are well braced before applying force to a
screwdriver
5.34.24. Pliers
5.34.24.1. Pliers shall not be used as wrenches.
5.34.24.2. Pliers shall have insulated handles.
5.34.24.3. Pliers shall be kept free from dirt and grit.
5.34.25. Hammers
5.34.25.1. A hammer of suitable size and weight for the task shall be used.
5.34.25.2. Handles shall be made from smooth timber, bonded fiberglass or be made of
an integral head and shaft of steel.
5.34.25.3. Proper wedges shall be used to secure heads to wooden handles.
5.34.25.4. Hammers with loose or damaged handles shall not be used.
5.34.25.5. Hammers with highly tempered steel heads shall not be used on hard steel
objects.
5.34.25.6. Do not use one hammer to strike another hammer.
Date Published:
Date Revised:
current version.
5.34.25.7. A hammer shall be discarded if it shows dents, cracks, chips, mushrooming,

or excessive wear. Redressing is not recommended.
5.34.25.8. The sides of hammer heads are not case hardened and shall never be used
for pounding.
5.34.25.9. Do not grind, weld or reheat-treat a hammerhead.
5.34.26. Chisels
5.34.26.1. Cutting edges shall be kept sharp at all times, and the original shape and
angle shall be maintained.
5.34.26.2. Mushroomed heads shall be ground with a slight taper around the edge to
prevent chipping and reduce the tendency to mushroom again.
5.34.26.3. The angle of cut shall be away from the body.
5.34.26.4. Face shield shall be worn when using a chisel, punch, a tapered or straight
file, or an alignment drift.
5.34.27. Wrenches
5.34.27.1. Damaged, bent or broken wrenches, or wrenches with sprung jaws shall not
be used.
5.34.27.2. Wrenches shall not be struck with a hammer unless the wrench is designed
for this purpose.
5.34.27.3. When possible, use a box-end or open-end wrench rather than an adjustable
wrench.
5.34.27.4. Worn box wrenches or sockets will be exchanged for new tools.
5.34.27.5. When excessive pressure is required to free a nut or cap-screw, the pressure
shall be applied away from the face and body.
5.34.27.6. Ensure the wrench fits the nut or bolt head.
5.34.27.7. Where possible, use box wrenches for torque and less chance of slipping off
the nut or bolt.
5.34.28. Hand Saw
5.34.28.1. Handsaws shall be selected for the specific job.
5.34.28.2. Saws with broken teeth or broken or cracked handles shall not be used.
5.34.28.3. Saw teeth should be kept sharp and well set to prevent binding.
5.34.28.4. If a saw binds while cutting, the worker shall not attempt to force it through
the stock.
Date Published:
Date Revised:
current version.
5.34.28.5. Nails shall not be sawed. Saws shall not be dropped. Saws with dull teeth
can usually be sharpened and returned to use, but if the saw cannot be
restored, replace it.
5.34.28.6. When not in use, saws shall be wiped off with an oil-moistened rag and kept
in racks or hung by the handle to prevent damage to the teeth.
5.34.29. Hack Saw
5.34.29.1. A hacksaw shall be adjusted in the frame to prevent buckling and breaking,
but shall never be tight enough to break of the pin that support the blade.
5.34.29.2. Proper blades shall be selected for the material to be cut.
5.34.29.3. Pressure shall be applied on the forward stroke only, away from the user
body.
5.34.29.4. Blade shall not be twisted while using.
5.34.30. Crowbars and Wrecking Bars
5.34.30.1. Crowbars and wreaking bars of sufficient size and weight shall be selected.
5.34.30.2. Makeshifts bars, such as pipes or other metal objects, shall not be used in
place of crowbars and wrecking bars.
5.34.30.3. Crowbars shall have a point or toe to grip the object to be moved and a heel
to act as a pivot or fulcrum.
5.34.30.4. Damaged crowbars shall not be used.
5.34.30.5. Case-hardened steel tools shall not be used to strike crow bars or wrecking
bars
5.34.31. Files
5.34.31.1. The right kind of file the job shall be selected.
5.34.31.2. Files shall never be cleaned by being struck against a vise or other metal
object.
5.34.31.3. Files shall not be used as pry bar.
5.34.31.4. Broken files shall be discarded.
5.34.31.5. Always use a wooden or plastic handle with a file.
5.34.32. Shovels
5.34.32.1. Shovels shall be maintained in good condition at all times.
5.34.32.2. Blades shall not be blunt, turned, split or jagged.
Date Published:
Date Revised:
current version.
5.34.32.3. If the handle has been cracked or broken, the tool shall be discarded and
replaced.
5.34.32.4. Shovels are not in use at the job site, they shall be positioned where the
working surface cannot be stepped on.
5.34.33. Portable Drills
5.34.33.1. Align the bit with the desired hole location before turning the drill on.
5.34.33.2. Hold the drill firmly with both hands while drilling.
5.34.33.3. Disconnect the drill from the electrical supply when installing bits.
5.34.33.4. Select the correct bit for the finish and material being drilled. Make sure the
bit is securely tightened in the drill chuck.
5.34.33.5. Tighten the drill bit by rotating the chuck key to all holes in the chuck.
5.34.33.6. Do not allow the cord to become wrapped around the drill when working.
5.34.33.7. Maintain good balance at all times when drilling.
5.34.33.8. The portable electric drill shall stopped rotating before the drill is laid down.
5.34.33.9. Drills shall not be equipped with a trigger lock.
5.34.34. Abrasive Wheels Machinery
5.34.34.1. All grinding machines shall be supplied with sufficient power to maintain the
spindle speed at safe levels under all conditions of normal operation.
5.34.34.2. All abrasive wheels shall be closely inspected and ring-tested before
mounting to ensure that they are free from cracks or defects.
5.34.34.3. Grinding wheels shall fit freely on the spindle and shall not be forced on. The
spindle nut shall be tightened only enough to hold the wheel in place.
5.34.34.4. Abrasive wheels shall be used only on machines provided with safety guards.
5.34.34.5. The safety guard shall cover the spindle end, nut, and flange projections. The
safety guard shall be mounted to maintain proper alignment with the wheel,
and the strength of the fastenings shall exceed the strength of the guard.
5.34.34.6. On offhand grinding machines, work rests shall be used to support the work.
The work rest shall be securely clamped after each adjustment. The
adjustment shall not be made with the wheel in motion.
5.34.34.7. The spindle speed of the machine shall be checked before mounting of the
wheel to be certain that it does not exceed the maximum operating speed
marked on the wheel.
Date Published:
Date Revised:
current version.
5.34.34.8. All contact surfaces of wheels, blotters and flanges shall be flat and free of
foreign matter.
5.34.34.9. All employees using abrasive wheels shall be protected by appropriate
personnel protective equipment, hearing protection and face protection.
5.34.35. Jig Saws
5.34.35.1. Use the proper size of blade for the work being done.
5.34.35.2. Make turns slowly. Do not make sharp turns with a wide blade; use a narrow
blade for sharp turns.
5.34.35.3. Always wear appropriate personnel protective equipment and face protection.
5.34.35.4. Wear guard (for example, mesh gloves, metal guards) on the free hand to
protect it from flying particles.
5.34.35.5. If device is provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used.
5.34.35.6. Be sure to switch power OFF and disconnect the plug from the receptacle
when changing blade.
5.34.35.7. Use the splinter guard when cutting wood materials will reduce splintering of
cut surface.
5.34.36. Jackhammers
5.34.36.1. Use the proper weight of the jackhammer for the job. Use a lighter
jackhammer for the job as much as possible.
5.34.36.2. All electric models with a three-wire system are properly grounded.
5.34.36.3. Check that the compressed air hose and the connections are not damaged.
5.34.36.4. Check that all compressed air connections are properly attached.
5.34.36.5. Use the proper point for the material to be broken. Remember to use rock
point for rock, spade point for asphalt, and chisel point for concrete. Never
use a broken or cracked point.
5.34.36.6. Rotate workers, whenever possible, when jackhammering for extended
periods of time.
5.34.36.7. Inspect the jackhammer and associated equipment regularly for defect or
damage.
5.34.36.8. All employees using jackhammer shall be protected by appropriate personnel
protective equipment, hearing protection eye face protection and face
protection.
Date Published:
Date Revised:
current version.
5.34.37. Nail gun

5.34.37.1. Only full sequential trigger type nails guns are allowed.
5.34.37.2. All the users shall be trained in a manner that employee can understand the
following:
5.34.37.2.1. How nail guns work and how triggers differ.
5.34.37.2.2. How to load the nail gun.
5.34.37.2.3. How to position.
5.34.37.2.4. How to hold the nail gun
5.34.37.2.5. How to fire the nail gun.
5.34.37.3. Check tools and power sources before operating to make sure that they are
in proper working order. Take broken or malfunctioning nail guns out of
service immediately.
5.34.37.4. Always shoot nail guns away from body and away from co-workers.
5.34.37.5. Never bypass or disable nail gun safety features. This is strictly prohibited.
Tampering includes removing the spring from the safety-contact tip and/or
tying down, taping or otherwise securing the trigger so it does not need to be
pressed.
5.35. Fixed Power Equipment
5.35.1. Use of high-pressure hydraulic equipment in the form of ‘Porta Power’ type units
(electrically, air, petrol or manually powered) shall be operated in strict accordance with
the manufacturer’s instructions.
5.35.2. Fixed or permanently mounted electrical tools shall be hardwired to the power supply.
5.35.3. Manufacturer maintenance instructions shall be adhered to.
5.35.4. Only manufacturer recommended hydraulic oil shall be used in ‘Porta Power’ hydraulic
equipment.
5.35.5. All fixed power equipment’s feeder switch shall have a provision for Lockout Tag out
Verification lock.
5.35.6. Shear and Metal Presses
5.35.6.1. Ma’aden Aluminium workshop metal presses are not available for use by the
contractor unless otherwise a written permission form Ma’aden Aluminium.
5.35.6.2. Shear and metal press used on site shall be equipped with guards and
emergency shut off switch as per manufacturer recommendation.
5.35.7. Pedestal Drill, Grinders, and Buffers
Date Published:
Date Revised:
current version.
5.35.7.1. No person shall operate a bench or pedestal drill, grinder or buffer in a

temporary work situation until the equipment has been leveled and securely
anchored.
5.35.7.2. Floor or bench mounted abrasive wheels shall be provided with safety
guards. Safety guards shall be capable of withstanding the effects of a
bursting wheel.
5.35.7.3. No person shall remove any safety guard device from a grinding or drilling
machine unless the equipment is LTV applied.
5.35.7.4. Abrasive wheels for fixed grinders shall be inspected and ring tested before
mounting.
5.35.7.5. Abrasive wheels shall be balanced and centered as per wheel manufacturer
recommendation.
5.35.7.6. No grinder or buffer shall be fitted with any other cutting wheel, e.g. saw
blade, polishing disc or pad, etc. than those recommended by the
manufacturer.
5.35.7.7. 9” electric grinders shall never be fitted with cutting disks. (Maximum size
electric grinder for cutting is 7”).
5.35.8. Portable Fans and Blowers
5.35.8.1. All electric powered fans and blowers shall be protected by an Earth Leakage
Circuit Breaker. (ELCB.)
5.35.8.2. All fans shall be equipped with guards to prevent accidental personal contact
with the fan blade therein.
5.35.8.3. When used as a forced ventilator for a vessel or confined space, the intake
or exhaust to the fan/blower shall not be obstructed by any material.
5.35.8.4. Devices which may produce noxious fumes (e.g. mobile welder, fuel storage
tank or an air compressor) shall be kept clear of the fan intake area.
5.35.8.5. Dust producing activities (e.g. grinding) shall be kept clear of the fan intake
area.
5.35.9. Fixed Table Saw
5.35.9.1. Fixed table saw shall be permanently wired to an emergency electrical
disconnect switch that has the capable of being locked in the off position.
5.35.9.2. A mechanical or electrical power control shall be provided on machine to
make it possible for the operator to cut off the power from machine without
leaving his position at the point of operation.
Date Published:
Date Revised:
current version.
5.35.9.3. On applications where injury to the operator might result if motors were to
restart after power failures, provision shall be made to prevent machines from
automatically restarting upon restoration of power.
5.35.9.4. Table saw shall have blade guard that cover the saw at all times.
5.35.9.5. Exposed part of the saw located underneath the table shall be guarded.
5.35.9.6. Sufficient working place shall be provided around the saw.
5.35.9.7. Push stick or push block shall be provided at the workplace in the several
size and types suitable for the work to be done.
5.35.9.8. Operate the saw at the speed specified by the manufacturer.
5.35.9.9. Stand to the side of the saw blade to avoid injury do to kickback.
5.35.9.10. Always wear face and respiratory protection in addition to standard PPE.
5.35.10. Portable Pumps
5.35.10.1. Portable pumps, including their delivery hoses, shall not be positioned in such
a way to restrict access.
5.35.10.2. Pump delivery hoses shall have safety couplings at each set of hose joiners.
5.35.10.3. Barricading shall be installed where normal roadway, access way or path is
restricted by portable pump hoses installation.
5.35.11. Concrete and Brick Cutting Equipment
5.35.11.1. Any concrete cutting device brought on site shall comply in accordance with
manufacturer’s instructions. Operators shall be trained and competent in the
use, care and maintenance of cutting machinery before operating such
machinery on site.
5.35.11.2. When operating a concrete/brick-cutting device on site the Contractor shall
take effective measures to suppress and/or control dust generated by the
cutting operation. This suppression and/or control may be in the form of:
5.35.11.2.1. Ventilation system
5.35.11.2.2. Wet cutting procedure
5.35.11.2.3. Respiratory protection
5.35.12. High Pressure Water Equipment
5.35.12.1. The term “High Pressure Water Jetting” covers all water jetting systems
including the use of additives or abrasives with an output capability greater
than 800 bar liters per minute. Jetting systems with an output capability
greater than 800 bar liters per minute and less than 5600 bar liters per minute
Date Published:
Date Revised:
current version.
are identified as Class A systems. Jetting systems with a capability in excess

of 5600 bar liters per minute are identified as Class B systems.
5.35.12.2. High-pressure water jetting operations shall be carried out by competent
personnel experienced in the handling of the equipment being used.
5.35.12.3. High pressure blasting areas shall be barricaded (red & white physical
barricade) and danger signs with wording “Danger Do Not Enter - High
Pressure Water in Use” shall be erected.
5.35.12.4. Personal protection equipment suitable to the work shall be worn and shall
include:
5.35.12.4.1. Eye protection – Combination of visor and chemical goggles.
5.35.12.4.2. Foot protection – Safety boots/Rubber boot with steel toecap
5.35.12.4.3. Head protection – Safety helmet
5.35.12.4.4. Body protection – Gloves and waterproof clothing having
regard to the nature of work being done.
5.35.12.4.5. Hearing Protection – Ear plugs and ear muffs
5.35.12.5. Prior to performing any high pressure water jetting work, the contractor shall
carry out a risk assessment.
5.35.13. Hoses (Air, Water, Hydraulic and Gas)
5.35.13.1. Ensure all hoses and components are appropriate rated to handle the
maximum operating pressure.
5.35.13.2. All hose connections shall be installed in such a manner to eliminate any risk
of a hose parting from the coupling or connections.
5.35.13.3. Safety clips, whip check and retainers shall be securely installed and
maintained on pneumatic impact tools to prevent them from being
accidentally expelled.
5.35.13.4. Where two or more air hoses are joined, they shall not be used unless
couplings/connections are fitted with approved safety pins/clips and hose
clamps.
5.35.13.5. Aluminium hose couplings, clamps and other fittings shall not be used where
there is any risk whatsoever of these coming into contact with caustic soda
or its derivatives (i.e. hose water, liquor and slurry).
5.35.13.6. Contractor shall establish an inspection regime for all hoses.
5.36. Confined Space
Date Published:
Date Revised:
current version.
5.36.1. Contractor shall develop a detailed Confined Space Entry Program as per Ma’aden
Aluminium Confined Entry Program to ensure the health and safety of any persons
required to enter or work in a confined space.
5.36.2. The Confined Space Entry Procedure and Permit is required for each confined space
entry.
5.36.3. Contractors, subcontractors, and contracted services shall follow all facility confined
spaces entry procedure when entering any confined space.
5.36.4. Before entry into a confined space, the minimum requirements are:
5.36.4.1. When working in or near confined spaces all employees shall know the
location specific procedures for confined spaces, including rescue methods,
confined space classification, and specific confined space entry permit
requirements.
5.36.4.2. Each individual shall be trained and assessed as competent in Confined
Space Entry via the Ma’aden Aluminium confined space entry training
program.
5.36.4.3. Each work group to ensure that the control measures in place on the confined
space entry procedure and the confined space permit are complied with and
a Job Safety Analysis is complete for each individual work group.
5.36.4.4. Contractor shall ensure that a location based rescue plan is available and a
trained rescue teams and rescue equipment is available.
5.36.4.5. An atmospheric gas testing shall be conducted in accordance with Ma’aden
Aluminium Confined Space Entry Program and Permit to Work Program.
5.36.4.6. Personnel entering/exiting a confined space shall sign a log in/out sheet.
5.36.4.7. Maintained an effective means of communication with entrant, attendant and
rescue services.
5.36.4.8. Ground Fault Circuit Interrupter (GFCI) protected electrical tools, low current
low voltage shall be used in confined space.
5.36.4.9. Lighting shall be provided as needed to safely enter, exit and work inside a
confined space.
5.36.4.10. If the confined space entry activity is suspended, the entry point shall be
barricaded and a NO ENTRY sign shall be posted.
5.36.4.11. Fall hazards shall be eliminated or controlled in accordance with the Ma’aden
Aluminium Fall Control Program in Confined Space.
5.36.4.12. Before personnel are permitted to enter a confined space, all equipment’s
and sources of kinetic and potential store energy shall be physically de-
Date Published:
Date Revised:
current version.
energized, immobilized, disabled, relived, disconnect restrained in

accordance with Ma’aden Aluminium Lockout Tag out Verification Program.
5.36.4.13. Hazardous Atmosphere is any atmosphere that may expose personnel to the
risk of death, incapacitation, injury, acute illness or may prevent the unaided
escape from a hazardous confined space. The following are hazardous
atmospheres.
5.36.4.13.1. Atmospheric oxygen concentration below 19.5% or above
23.5%
5.36.4.13.2. Flammable gas, vapor or mist in excess of 5% of its lower
explosive limit.
5.36.4.13.3. Airborne combustible dust at a concentration that meets or
exceeds its lower explosive limit.
5.36.4.13.4. Atmospheric concentration of any substance where entrant
exposure exceeds the dose or occupational exposure limit
established by local regulations.
5.36.4.13.5. Any other atmospheric condition that is immediately dangerous
to life or health.
5.36.5. Atmospheric gas tests shall be performed and immediately recorded.
5.36.5.1. Prior to entry.
5.36.5.2. After break or other interruptions in the work.
5.36.5.3. If there is any reason to believe that conditions inside the confined space
have changed.
5.36.5.4. At defined periodic intervals as necessary to determine whether acceptable
atmospheric conditions are being maintained during the course of the
confined space entry.
5.36.6. A Ma’aden Aluminium approved gas tester shall only conduct atmospheric gas test.
5.36.7. Hot work shall not be permitted if the atmosphere is above 0% of LEL without a valid
justification and control measures in place.
5.36.8. Compressed gas cylinders shall not be placed in a confined space.
5.36.9. Internal combustion engines shall not be positioned inside a confined space or at a
location that could allow exhaust to enter the space. This type of equipment shall be
positioned downwind from confined space entry/exit points and air mover intakes.
5.36.10. Flammable/combustible materials shall not be stored inside a confined space.
Date Published:
Date Revised:
current version.
5.36.11. When work is complete and the confined space is ready to be returned to normal service,
the confined space shall be inspected to ensure all equipment and tools have been
removed.
5.36.12. Mechanical ventilation shall be used in all confined space entry.
5.36.13. Blowers or other means of introducing air into a confined space shall be placed
5.37. Fall Prevention
5.37.1. Contractor shall develop a detailed Fall Prevention and Working at Height Program as
per Ma’aden Aluminium Fall Prevention Program.
5.37.2. The ‘Fall Prevention and Control Policy’ shall be applied in establishing work procedures
for each and every task where a potential exists to fall.
5.37.3. In every situation where a fall arrest device is required to be used, the preferred method
is a retractable lanyard with an approved safety harness. Lanyard with shock absorber
shall be used if a retractable lanyard not available.
5.37.4. In each and every fall potential situation, a safe method of work shall be identified and
documented. The normal hierarchy of controls applies placing PPE equipment (Harness
and Lanyard) at the lowest level of protection. All other means of performing the task
should be reviewed before consenting to PPE being the only control to prevent a person
from falling.
5.37.5. A Qualified Person with a recognized degree or professional certificate is required to
determine anchorage points when permanently installed pre-approved anchorage points
do not exist.
5.37.6. Safety nets shall not be used as a means of personal fall protection.
5.37.7. Install barricades and safety signs below elevated work.
5.37.8. Ensure access ladders are secured and inclined at 1 in 4 (or where not practicable
develop a Risk Assessment which shall be approved by Ma‘aden Aluminium specifically
to ensure safe access).
5.37.9. Vertical access ladders shall have landings at least every 6 meters.
5.37.10. Access ladders that allow for a potential fall of greater than 4 meters, or access ladders
that are external to the scaffold shall be provided with a shoulder rail.
5.37.11. Use modular assembly methods at ground level to reduce working at height exposure.
5.37.12. Use workboxes or elevating work platforms to eliminate climbing of columns by
riggers/steel fixers.
5.37.13. Ensure that fall arrest equipment is inspected by a competent person and is serviced or
discarded in accordance with manufacturer’s specifications.
5.37.14. Documentation of fall protection equipment inspections is also required.
Date Published:
Date Revised:
current version.
5.38. Elevated Working Platform (EWP)

5.38.1. EWP shall only be operated by competent, certified persons.
5.38.2. EWP’s shall always have a competent person as a watch person on the ground. The role
of the watch person is in the case of emergency to lower the basket.
5.38.3. When working from EWP’s, a “tool tidy” shall be used to keep tools components and
equipment off the floor of the basket.
5.38.4. EWP’s working adjacent or on a roadway shall operate within a barricaded area to
prevent direct interface with normal traffic, where this restricts traffic flow a flag person
shall ensure that traffic flow is maintained.
5.38.5. Egress/Access to EWP’s while the basket is elevated shall only be done after Ma’aden
Aluminium has granted permission. A specific Risk Assessment (EHS Aspects, Impact
and Hazard Assessment) shall be developed and submitted to Ma’aden Aluminium
together with a permit for approval.
5.38.6. All personnel in the bucket of the EWP shall continuously wear the correct full-body
harness with the lanyard securely attached to an approved anchorage point.
5.38.7. Personnel shall not be on any EWP’s during storms or high winds (i.e., sustained winds
more than 65 kph or as per manufacturer recommendation) unless the EWP work area
is indoors or otherwise unaffected by the weather conditions. EWP’s shall not be used
during thunderstorms or when there is likelihood of lightning.
5.39. Portable Ladders
5.39.1. Aluminium ladders whether of whole or part construction shall not be brought on to, or
used at any Ma’aden Aluminium site without prior approval.
5.39.2. Ladders shall only be located in Plant and Mine Site areas for such time as is reasonable
to affect work.
5.39.3. Each overhead work situation wherein a ladder is used shall be assessed for Overhead
Work Precautions.
5.39.4. All portable ladders shall be inspected for damage and integrity prior to use on any
specific job.
5.39.5. A competent person or scaffolding inspector shall secure portable ladders when in use,
with rope or ladder clamps to prevent slipping or overbalancing.
5.39.6. Ladders shall always have a firm footing to prevent the ladder feet from moving
unexpectedly. Wooden blocks, off cuts, bricks, etc shall not be used to level the feet of
any ladder.
5.39.7. Portable ladders shall be placed on a substantial base at a 4:1 pitch, have a clear access
top and bottom and extend a minimum of one (1) meter above the egress landing.
Date Published:
Date Revised:
current version.
5.39.8. Portable metal ladders and wire-reinforced ladders shall not be used for any electrical
work, for any work using portable power tools or where contact with electrical conductors
is foreseeable.
5.39.9. Always inspect the ladder prior to using it. If the ladder is damaged, it shall be removed
from service and tagged until discarded.
5.39.10. Always maintain a 3-point (two hands and a foot, or two feet and a hand) contact on the
ladder when climbing. Keep your body near the middle of the step and always face the
ladder while climbing.
5.39.11. Ladders shall be free of any slippery material on the rungs, steps or feet.
5.39.12. Do not use the top step/rung of a ladder as a step/rung unless it was designed for that
purpose.
5.39.13. Do not move or shift a ladder while a person or equipment is on the ladder.
5.39.14. An extension or straight ladder used to access an elevated surface shall extend at least
3 feet above the point of support.
5.39.15. A ladder placed in any location where it can be displaced by other work activities shall be
secured to prevent displacement or a barricade shall be erected to keep traffic away from
the ladder.
5.40. Scaffolding
5.40.1. All scaffolds and scaffolding shall only be erected, modified or dismantled in conjunction
with the Ma’aden Aluminium Fall Control Program.
5.40.2. All types of scaffolds shall be erected by competent and experienced personnel.
5.40.3. Scaffolds shall not be erected in such a situation that it shall impede the access of
emergency vehicles unless a written permission has been obtained from Ma’aden
5.40.4. Scaffolds shall not be erected on roadways and access ways unless a written permission
has been obtained from Ma’aden Aluminium Central EHS and Fire Emergency
Department and considering application of collision protection from vehicles and mobile
equipment.
5.40.5. Scaffolds shall not be erected without consideration and application of the relevant
Barricade Procedure, and Overhead Work Procedure.
5.40.6. Scaffold materials shall not be thrown or dropped from heights.
5.40.7. Tube and coupler scaffolds over 125 feet in height shall be designed by a qualified
competent engineer, and shall be constructed and loaded in accordance with such
design.
5.40.8. Purchaser shall obtain a test and inspection report for tubing from supplier or
manufacturer, which shall be in English.
Date Published:
Date Revised:
current version.
5.40.9. Couplers shall meet the requirements of BS or EN standards.

5.40.10. Every scaffold and scaffolding components shall be capable of supporting, without failure,
its own weight (dead load) and at least four times the maximum intended load (live load)
applied or transmitted to it. Self-weight of platform units (including planks) shall be
considered as dead load.
5.40.11. Scaffold components from different manufacturers shall not be intermixed unless the
components are compatible and the scaffold structural integrity shall maintained.
5.40.12. Scaffolds, where exposed to extremes of weather, adverse location conditions, shall not
be left in positions for a period in excess of one (1) month without a thorough inspection
of the components.
5.40.13. Scaffold components shall not be exposed to acids or other corrosive substances unless
adequate precautions have been taken to protect the component from damage.
5.40.14. Scaffold components shall be properly stored to prevent damage.
5.40.15. Special precautions shall be taken to protect scaffold members when using Ma’aden
Aluminium Reduction areas.
5.40.16. The footing or anchorage for scaffolds shall be sound, rigid, and capable of carrying the
maximum intended load without settling or displacement. Unstable objects such as
barrels, boxes, loose brick, or concrete blocks shall not be used to support scaffolds.
5.40.17. Timber sills (sole boards) at least 225 mm (9 in) wide by 38 mm (1 1/2 in) thick shall be
used to spread the load on sand, made-up ground, asphalt pavement, wooden floors and
other soft or slippery surfaces.
5.40.18. The ground beneath sills shall be level and compact. A sill shall extend under at least two
posts (standards), unless that is not feasible because of uneven or sloping ground. In this
case, sills under individual posts (standards) shall be at least 765 mm (30 in) long.
5.40.19. All scaffold posts (standards) shall be pitched on steel base plates at least 150 mm (6 in)
x 150 mm (6 in) and 6 mm (1/4 in) thick. For “special scaffolds,” the base plates shall be
designed to safely support the maximum scaffold post (standard) load.
5.40.20. Screw jacks shall be used to compensate for variations in ground level. Screw jacks shall
not be adjusted to more than 2/3 of the total length of the threaded section.
5.40.21. The poles, legs, or uprights of scaffolds shall be plumb, and securely and rigidly braced
to prevent swaying and displacement.
5.40.22. Cross bracing shall be installed across the width of the scaffold at least every third set of
posts horizontally and every fourth runner vertically. Such bracing shall extend diagonally
from the inner and outer runners upward to the next outer and inner runners.
5.40.23. Longitudinal diagonal bracing shall be installed at approximately a 45-degree angle from
near the base of the first outer post upward to the extreme top of the scaffold. Where the
longitudinal length of the scaffold permits, such bracing shall be duplicated beginning at
Date Published:
Date Revised:
current version.
every fifth post. In a similar manner longitudinal diagonal bracing shall also be installed
from the last post extending back and upward toward the first post. Where conditions
preclude the attachment of this bracing to the posts, it may be attached to the runners.
5.40.24. All working platform planks shall be closely laid and secured properly. If planks are
securing with ropes then both ends shall be lashed with either 8- mm fiber rope or 4 mm
wire rope.
5.40.25. Only fabricated approved steel platforms shall be used in Ma’aden Aluminium Refinery
areas.
5.40.26. Scaffold planks shall extend over their end supports not less than 6 inches or more than
18 inches.
5.40.27. Planks overlap shall occur only over support (bearers or plank bearers). Planks shall not
be nailed together.
5.40.28. Each platform unit (scaffold plank, fabricated plank, fabricated deck or fabricated
platform) shall be installed so that gaps between platform units are less than 25 mm (1
in) wide.
5.40.29. Platform units that have become slippery with oil, sand or any other substance shall be
cleaned, or otherwise removed and replaced, prior to continuing use.
5.40.30. Plank ends shall not be split more than 25 mm (1 in) without metal banding. Even with
banding, plank ends shall not be split over 300 mm (12 in).
5.40.31. Planks shall not be twisted from end-to-end or curled from side-to-side more than 13 mm
(1/2 in).
5.40.32. Planks shall not be painted, treated or coated in any way (except at the ends/edges).
5.40.33. Relevant test reports, certificates, etc., for planks/ fabricated steel platforms shall be
immediately made available to Ma'aden Aluminium upon request.
5.40.34. Guardrails not less than 36 inches or more than 42 inches high, with a mid-rail and toe
boards shall be installed at all open sides on all scaffolds.
5.40.35. Mid-rail shall be installed approximately halfway between the walking/working surface
and the guardrail.
5.40.36. Holes or gaps in scaffold platforms and stair/ladder landings shall have a guardrail system
erected around them or they shall be securely covered with structural sustainable
material.
5.40.37. Scaffolds shall be secured to permanent structures, through use of anchor bolts, reveal
bolts, or other equivalent means. Window cleaners' anchor bolts shall not be used.
5.40.38. Guardrail system shall be completely installed before a scaffold platform or stair/ladder
landing is used by personnel other than scaffold craftsman.
5.40.39. Planks shall not be placed on guardrail or mid-rails.
Date Published:
Date Revised:
current version.
5.40.40. Toe boards shall be a minimum of 4 inches in height.

5.40.41. Toe boards shall not be nailed to scaffold planks.
5.40.42. Girder couplers shall be used in pairs and shall be clamped on opposite sides of the
structural section.
5.40.43. An access ladder shall be provided.
5.40.44. Safe landing shall be provided at the top all ladders and at least every 9 meter of ladder
height. Landings shall be closed planked and protected by a guardrail system.
5.40.45. Portable ladders shall not be used on top of scaffold platforms.
5.40.46. Scaffolds shall not be altered or moved horizontally while they are in use or occupied.
5.40.47. Scaffolds, where exposed to extremes of weather, adverse location conditions, shall not
be left in positions for a period in excess of one (1) month without a thorough inspection
of the components.
5.40.48. Whenever a scaffold is damaged or dislodged by incident, it shall be dismantled to a point
where any damaged components can be removed and replaced.
5.40.49. Any scaffold component, which is damaged as a result of an incident, shall be destroyed
(after investigation of cause of damage).
5.40.50. Scaffold craftsmen shall continuously wear a full-body harness with shock absorbing
lanyard while erecting, altering or dismantling a scaffold.
5.40.51. System scaffold from different manufacturers shall not be intermixed, unless permitted in
writing by each manufacturer whose system will be intermixed.
5.40.52. Unless otherwise specified in the system scaffolding manufacturer’s instructions, all
outdoor system scaffolds shall be vertically braced in both directions with diagonal braces
to its full height.
5.40.53. System scaffold connections shall be tightened with a single hammer blow to the wedge
or cup to provide a high degree of rigidity.
5.40.54. The locking-pin type of system scaffolding shall not be used.
5.40.55. Plan (horizontal) bracing shall be installed at the base lift, at the top lift and at least every
third lift of all mobile scaffolds to prevent racking (twisting).
5.40.56. Mobile scaffold rated for light duty shall have steel caster wheel not less than 13
centimeter in diameter and for medium duty shall have heavy-duty steel caster wheel not
less than 18 centimeter in diameter.
5.40.57. Caster wheels shall be fitted with a positive wheel lock (which cannot be accidentally
released) to prevent movement while the mobile scaffold is being used.
Date Published:
Date Revised:
current version.
5.40.58. The working area of any platform shall not extend outside the scaffold base dimensions.
Cantilevered working areas are not permitted for mobile scaffolds.
5.40.59. For mobile scaffolds, the uppermost platform height shall not exceed three times the
scaffold’s minimum base dimension.
5.40.60. Underhung scaffolds shall be hung from structures capable of safely supporting the loads
imposed on them by the scaffold.
5.40.61. Suspension points of hanger tubes shall be securely attached to the overhead supporting
structure in order to prevent their being dislodged by all potential forces acting upon them.
5.40.62. Check (safety) couplers shall be installed at the top and bottom of all hanger tubes. Check
(safety) couplers shall also be installed directly beneath all trapeze tubes.
5.40.63. In all underhung scaffold trapeze tubes shall be installed approximately 61 centimeter
below the lowest platform level to assist in erection, alteration and dismantling.
5.40.64. Only drop-forged girder couplers shall be used for the support of underhung scaffolds.
Pressed girder couplers shall not be used for the support of hanging scaffolds.
5.40.65. Any person who works from a light duty suspended stage shall not sit or stand on the mid
or top rail of an underhung scaffold.
5.40.66. Persons using or working from a light duty suspended stage shall remain within the
confines of the stage
5.40.67. Scafftag is an internationally used scaffold safety system and through its simplicity,
encourages and controls the safety of scaffolding, and of those who erect/dismantle and
use it.
5.40.68. The ‘Scafftag System’ shall be used as a visual warning system to display the status (i.e.
safe versus unsafe) of scaffolding.
5.41. Grating or Chequer Plate Removal and Installation
5.41.1. An approved floor opening/grating removal permit is required prior to removal of grating
or chequer plates.
5.41.2. Open manholes and openings in grating on elevated levels shall be properly barricaded.
Hard barricades and warning signs shall be installed prior to removing a manhole cover
or grating. Manhole and grating shall be immediately put back in place upon completion
of the work activity.
5.41.3. Contractor shall develop a detailed program for installation of grating or chequer plate as
per Ma’aden Aluminium Grating Removal Floor Opening Program.
5.41.4. Temporary flooring shall be inspected for integrity by a competent person prior to the
commencement of work, on each working day.
Date Published:
Date Revised:
current version.
5.41.5. Any refurbishment works creating floor openings, a Job Safety Analysis and Safe
Sequence of Work Plan shall be developed before commencing the works and Ma’aden
Aluminium Safety shall approve the plan.
5.41.6. Every open-sided floor (temporary or under construction) where there is a risk of injury to
employees from falling shall be protected by a guardrail constructed of metal tubing.
5.41.7. Standards covering platform hole covers, guards and handrails on steps, stairs, elevated
walkways, elevated platforms are designed to eliminate the risk of a fall to the workforce.
5.41.8. No person shall remove any part of any permanent handrail, mid rail, platform, kick plate
or stairway from any site fixed installation without specific prior approval from Ma’aden
Aluminium.
5.41.9. Rope or chain shall not be used as a temporary handrail.
5.41.10. Metal decking and grating shall be tightly installed and immediately secured (i.e.,
fastened) upon placement.
5.41.11. A minimum of four fasteners per metal decking and grating panel shall be used.
5.42. Safe Loading and Unloading Of Trucks
5.42.1. No standing or climbing on to a flatbed truck without fall prevention or fall protection in
place.
5.42.2. To unload a truck safely it has to be loaded in a safe way. It is required that where
possible, loads shall be unitized to enable safe lifting from the truck. Flat racks, cradles,
crates and pallets are all examples of unitized loads. Where equipment is larger than can
be accommodated by these means focus on preventing people from accessing onto the
load for unloading. This can be done by leaving slings attached to the load when loaded
onto the truck and secured for the duration of the journey.
5.43. Crane and Lifting
5.43.1. Crane lifts shall be conducted as per MA Crane Program and applicable local standards.
5.43.2. Lifting equipment records shall be kept in a register along with test certificates for each
piece of equipment.
5.43.3. All crane operators shall be properly licensed and certified for the crane type/model they
are operating.
5.43.4. No person shall be permitted to operate and fix, davit or pillar cranes unless trained and
recorded by the contractor as competent to do so.
5.43.5. All cranes operated by contractors shall carry the current Log Book and crane
manufacturer’s Operation and Maintenance Manual/s at all times.
5.43.6. Crane operators shall have the final decision on crane lifts that affect the safety of the
crane.
Date Published:
Date Revised:
current version.
5.43.7. Crane operation and limitations shall be in accordance with crane manufacturer
recommendations and or Ma’aden Aluminium requirements.
5.43.8. Crane operator shall perform an inspection of the crane prior to each shift and record the
information on an inspections checklist.
5.43.9. Any crane that is not in a safe operating condition shall be tagged out by attaching the
Yellow Equipment Warning Tag to a disconnect or the crane controls by a plastic tie wrap
with a minimum breaking strength of 22 kg until appropriate repairs are made.
5.43.10. Take operating signals from only certified rigger, unless it is the “STOP” or “Emergency
Stop” signal. A stop signal shall be obeyed, regardless of who gives it.
5.43.11. Crane shall not be operated beyond its rated capacity and limits.
5.43.12. Do not handle a suspended load over people. No person shall be allowed to pass or
stand under the elevated portion of any crane load.
5.43.13. All power-operated cranes shall be fitted with an emergency hoist stop limit switch. The
safe working load (S.W.L.) of each crane and its lifting elements shall be clearly posted.
When maintenance/repair work is necessary, the main power supply shall be locked,
tagged and verify (by an authorized person) in the OFF position in accordance with the
Lockout Tag out Verification Program.
5.43.14. All guards and safety devices shall be in position before the cranes are brought into
service. Crane operators shall not leave their position at the controls while the load is
suspended.
5.43.15. Before leaving the crane unattended, the operator shall land any attached load and place
the pendant control in the OFF position.
5.43.16. In the event of failure of the crane functions whilst a load is suspended, the crane operator
shall barricade off the load landing area to ensure no other person enters that area and
notify his Supervisor. The barricade shall remain in place until repairs are complete.
5.43.17. Where monorails are used and the pendant operator is required to walk with the pendant,
the aisles or access ways shall be kept clear to avoid tripping hazards.
5.43.18. Where a suspended load on a monorail crane can swing as a result of travel, a person
rope shall control the load swing.
5.43.19. Cranes with a free fall facility (e.g. Manitowoc) shall have the facility locked out while on
Ma’aden Aluminium premises.
5.43.20. Crane operators shall be instructed that the crane is to be immediately isolated, and
tagged out should there be any failure of a crane, crane component or lifting equipment.
5.43.21. All lifting gear shall be visibly marked with safe working load (SWI).
Date Published:
Date Revised:
current version.
5.43.22. All slings shall be inspected regularly by a competent person for the purposes of
determining their suitability for safe use. The inspection shall be recorded in a rigging
register. Some items to be considered in the inspection are:
5.43.22.1. Wear or deterioration.
5.43.22.2. Elongation or deformation.
5.43.22.3. Cuts, nicks, breaks or chafing.
5.43.22.4. Legibility of markings including safe working loads.
5.43.22.5. Chemical attack.
5.43.22.6. Unauthorized repairs.
5.43.22.7. Deteriorating stitching or
5.43.22.8. Any other defect that may render the equipment unsafe for its designated
application.
5.43.23. Job or shop hooks and links, or makeshift fasteners, formed from bolts, rods, etc. or other
such attachments, shall not be used.
5.43.24. All ferrules on slings shall be steel. Slings with aluminum & alloy ferrules shall not be
permitted on Ma’aden Aluminium premises without written approval.
5.43.25. Lifts that require a significant lift study are defined as:
5.43.25.1. Lifts that exceed 40 tons or
5.43.25.2. 85% of crane capacity or
5.43.25.3. Where it is proposed to use more than one crane or
5.43.25.4. More than one hook on the crane is used to lift one load or
5.43.25.5. Where a load is to be lifted over or within 6m of a critical service or
5.43.25.6. where there is potential to damage underground services or
5.43.25.7. Lifting over the operational facilities.
5.44. Hydraulic and Mechanical Jacks, and Equipment Support Stands
5.44.1. All hydraulic and mechanical jacks shall comply with latest version of ASME B30.1 with
respect to stability, durability, loss of height under load, ease of operation, labeling and
load capacities.
5.44.2. All equipment support stands shall identified with SWL.
5.44.3. All hydraulic and mechanical jacks shall be installed in accordance with manufacturer’s
instructions.
Date Published:
Date Revised:
current version.
5.44.4. No person shall remain on or in any equipment being lifted or supported by a mechanical
or hydraulic jack.
5.44.5. All lifting support equipment shall be inspected prior to use to ensure safe operating
conditions. Packers shall not be placed between the lifting support equipment and the
load; if packers are required they shall be designed for the purpose and be placed
between the lifting support equipment and the supporting floor.
5.45. Workboxes and Lift Boxes
5.45.1. Lift Boxes are best described as “non-fixed load-lifting attachments” and are intended to
lift equipment and/or material loads (not personnel).
5.45.2. Work from or transported by crane suspended personnel carrying workboxes
(Manbasket) shall only be allowed when conventional means of performing the work or
reaching the work site (such as personnel hoist, ladder, stairway, aerial lift, elevated work
platform or scaffold) would be more hazardous or is not practical because of structural
design or work site condition.
5.45.3. Workboxes are intended for personnel use (Manbasket) and shall not be used as general-
purpose material or equipment hoists.
5.45.4. Personnel carrying workboxes shall be inspected by a Ma’aden Aluminium approved third
party.
5.45.5. All personnel carrying workboxes shall display the following minimum information.
5.45.5.1. Workbox identification number.
5.45.5.2. Empty weight.
5.45.5.3. Rated capacity.
5.45.5.4. Maximum number of personnel allowed.
5.45.6. During raising and lowering of workboxes with persons therein, no part of the person(s)
shall extend beyond the confines of the workbox.
5.45.7. Personnel carrying workbox lifts shall not be performed if the crane operator has been
working more than 10 continuous hours prior to the start of the lift.
5.45.8. Cranes shall not travel with an occupied personnel carrying workbox.
5.45.9. Free fall devices equipped cranes shall not be used for hoisting personnel carrying
workbox.
5.45.10. No person shall ride on, or in, a lift box.
5.45.11. Whenever equipment or material is raised or lowered in a lift box, such material or
equipment shall not protrude from the confines of the lift box.
Date Published:
Date Revised:
current version.
5.45.12. Workboxes and lift boxes shall be purpose built and conform to engineering standards.
Each workbox and lift box shall have available an approved design and drawing.
5.45.13. Lift boxes shall be fitted with a lid that is capable of containing any loose items that may
inadvertently fall, should the lift box tip on its side whilst being landed.
5.46. Health Surveillance
5.46.1. Ma‘aden Aluminium requires that an employee of a Contractor who is engaged to work
at a Ma‘aden Aluminium facility for a period exceeding three months at any one time shall
undertake a health assessment comprising:
5.46.1.1. A record of the persons work history.
5.46.1.2. A respiratory questionnaire
5.46.1.3. A lung function test.
5.46.1.4. An audiometric test.
5.46.2. “Initial” and “periodic” health assessments shall be carried out in accordance with the
above. A health assessment is carried out on each employee at intervals not exceeding
5 years.
5.47. Noise
5.47.1. Noise is any unwanted or damaging sound. Noise induced hearing loss is the main
consequence of exposure to excessive noise, and is closely related to the average
amount of noise received by a person over a working day.
5.47.2. A persons exposure to noise in the workplace shall be managed in accordance with
Ma‘aden Aluminium hearing conservation program.
5.47.3. Noise exposure shall be reduced as far as practical by controlling noise at the source.
Hearing protection shall be worn in areas where noise-warning signs are posted. Hearing
protection shall be worn when using portable tools such as:
5.47.3.1. Jack hammers.
5.47.3.2. Rivet busters.
5.47.3.3. Grinding tools.
5.47.3.4. Air operated chisels.
5.47.3.5. Impact wrenches.
5.47.3.6. Circular saws.
5.47.3.7. Power drill.
5.47.3.8. Air arc gouges.
Date Published:
Date Revised:
current version.
5.47.3.9. Any tool where the noise generated exceeds 85dbA.

5.47.4. In some situations, double hearing protection may be required. Consult the Ma’aden
Aluminium Business unit Health Specialists for assistance.
5.47.5. Where a person is required to wear hearing protection, they shall be trained annually in
the principles of hearing conservation and in the correct use and maintenance of hearing
protection.
5.48. Heat Stress
5.48.1. The contractor shall develop and implement a written heat stress management program
based on the results of the heat stress evaluation, as well as Ma’aden Aluminium Heat
Stress Program requirements.
5.48.2. Where exposure to heat stress may result in ill health effects such as heat stroke, the
Contractor shall control exposures by implementing a prevention program consisting of
acclimatization, water replacement, provision of shade, ventilated work-areas and
personal protective equipment as appropriate.
5.48.3. Prior to performing work during hot weather, the contractor shall conduct a thorough heat
stress evaluation to identify tasks and conditions that present a potential heat stress
hazard. This evaluation shall include observations, discussions with workers and
supervisors, review of any previously reported heat-related illnesses.
5.49. Dust, Fumes, Mists, Gases and Vapors.
5.49.1. Persons required to wear respiratory protection shall be trained in its use and fit tested
for the specific respirator annually.
5.49.2. Point of source extraction equipment shall be used when welding in workshops, confined
spaces and during welding of stainless steel and galvanized materials. In addition
respiratory protection for the protection against welding fumes shall be used in confined
spaces.
5.49.3. Do not weld on painted or chemically treated surfaces.
5.49.4. No angle grinding shall be carried out on materials which contain asbestos, synthetic
mineral fibers (glass fiber, ceramic fibers, etc.) and polyurethane or on any piping or
vessel lagging, plastic, rubber or any other synthetic material.
5.50. Hazardous Materials
5.50.1. A “HAZARDOUS MATERIAL” is defined as any workplace substance (liquids, gases,
powders, fibers, chemicals) which can be inhaled, ingested, or come in contact with the
skin or eyes and has the potential to cause injury by way of it’s chemical, physical or
toxicological properties or has the potential to harm the environment.
5.50.2. The storage of chemicals including fuel, oil and other hydrocarbons and gases shall be
in accordance with Royal Commission Environmental Regulations (RCER). Certain
stores of chemicals and gases shall be manifested and audited as part of Ma’aden
Date Published:
Date Revised:
current version.
Aluminium site permits and RCER requirements. These stores require the approval of
the BU EHS Department and shall meet Ma’aden Aluminium and Royal Commission
requirements.
5.50.3. All chemicals brought onsite are required to undergo a Hazardous Materials assessment,
carried out by the Business Unit EHS department. Approval needs to be obtained before
the chemical can be used onsite.
5.50.4. Chemical and hydrocarbon containers shall be stored and transported securely to
minimize the risk of spillage and have secondary containment such as a designated bund,
dike or cabinet with the ability to contain leaks and spills.
5.50.5. The Contractor shall minimize the number of drums brought on to site. Contractors shall
take all measures possible to minimize the risk of contaminants entering unsealed ground
especially with regard to run-off within contractor yards or during onsite activities.
5.50.6. All spills of chemicals or hydrocarbons shall be cleaned up and reported to Ma’aden
5.50.7. The Contractor shall maintain a hazardous materials register containing copies of
MSDS’s for all hazardous materials used on site. A copy of MSDS, material register and
updates for new hazardous materials shall be submitted to the Business Unit EHS
department prior to using these hazardous materials.
5.50.8. Hazardous materials shall be managed in accordance with the Royal Commission
Environmental Regulations.
5.50.9. The Contractor shall ensure that all hazardous materials used on site are handled in
accordance with the Manufacturer’s Material Safety Data Sheet (MSDS).
5.50.10. The MSDS shall be made available to all end users of hazardous materials and they shall
be instructed on their safe use.
5.50.11. The critical elements of the MSDS shall be referenced in the JSA, or alternatively the
MSDS shall be attached to the JSA for the job being done.
5.50.12. Hazardous waste materials such as PCB’s, asbestos or fibrous materials shall be
disposed of in a manner approved by Ma’aden Aluminium and RCER.
5.50.13. Ozone depleting substances e.g. trichloroethane of BCF fire extinguishers and asbestos
are not permitted to be used in Ma’aden Aluminium premises.
5.50.14. Waste hazardous materials shall be disposed of in a manner approved by Ma’aden
Aluminium.
5.50.15. No asbestos or asbestos containing substance shall be brought onto site without written
approval from Ma’aden Aluminium.
5.50.16. Existing asbestos containing materials shall only be handled in accordance with
hazardous material management.
Date Published:
Date Revised:
current version.
5.50.17. Silica shall not be used for abrasive blasting. Where possible abrasive blasting shall be
wet garnet, blasting shall have approval from the site Health, Environmental and the
Department Manager prior to commencing work.
5.50.18. Paints and polyurethane containing isocyanides shall not be used, unless written
approval is obtained from Ma’aden Aluminium.
5.50.19. Synthetic mineral fibers (glass fiber, rock wool and ceramic fibers) shall be handled in
accordance with site policies and procedures.
5.50.20. No ceramic fiber or ceramic fiber containing substance shall be brought onto site without
approval from Ma’aden Aluminium.
5.50.21. No Polychlorinated biphenyls (PCB) or PCB containing substances shall be brought onto
site without written approval from Ma’aden Aluminium.
5.51. Caustic
5.51.1. Caustic is found in most pipes and tanks within alumina refineries and residue storage
areas. Caustic can create significant chemical burns when contacting the skin. When
contact with caustic occurs it can penetrate deep into the layers of skin.
5.51.2. If any contact with any chemical, including caustic take the following actions:
5.51.2.1. WASH the affected area for a MINIMUM of 20 MINUTES under a safety
shower/eyewash station
5.51.2.2. Call the emergency response number for the site and obtain treatment from
a medical professional
5.51.3. All chemical contacts shall be reported immediately to the Ma’aden Aluminium Medical
Centre.
5.52. Chemical Exposure
5.52.1. In the event of chemical coming to contact with part of your body you shall:
5.52.1.1. Remove any contaminated clothing.
5.52.1.2. Wash the affected area for a minimum of 20 minutes under a safety
shower/eyewash station
5.52.1.3. All chemical contacts shall be reported immediately to the Ma’aden
Aluminium Medical Centre. Walk around spills and drips
5.52.1.4. Ensure that the equipment you are working on has all caustic removed prior
to leaving an Ma’aden Aluminium site.
5.52.2. Ensure that the equipment you are working on has all caustic removed prior to leaving
the area.
Date Published:
Date Revised:
current version.
5.52.3. For further regulations contractor shall obtain Business Unit Hazardous Materials
Management Program.
5.53. Molten Metal
5.53.1. Where contractors are required to work in molten metal areas, approved fire retardant
clothing is to be worn. Where exposure to molten metal may occur, molten metal face
shields shall be worn at all times. Fire retardant tops shall not be tucked in to the trousers,
as in the event of contact with molten metal there is a risk that it may enter the pants.
5.53.2. Anything containing moisture or water shall be well segregated from molten metal, as
liquid causes rapid expansion of the metal and can cause explosions.
5.54. Explosives and Blasting
5.54.1. All explosive materials shall be transportation and storage shall be in accordance with
HCIS SAF-14 Safe Manufacturing, Transportation, Storage, and Use of Explosive
Materials and Pyrotechnic Articles.
5.54.2. No explosives shall be brought onto site without prior approval of Ma’aden Aluminium.
5.54.3. Explosives shall be registered with Ma’aden Aluminium when brought onto and taken
from the site. Detonators shall be stored separately from explosives.
5.54.4. Report immediately to Ma’aden Aluminium any theft, loss or disappearance of explosives
or detonators.
5.54.5. When electric blasting caps are used, warning signs against the use of mobile radio
transmitters shall be displayed on all roads and areas within 300 meters of the blasting
area.
5.54.6. Explosives shall be stored in approved, registered facilities.
5.54.7. Smoking and open flames shall not be allowed within 20 meters of storage facilities. Only
authorized and licensed persons shall be permitted to handle and use explosives.
5.55. Radiation Procedures
5.55.1. The use of radioactive substances in the Kingdom of Saudi Arabia is governed by King
Abdullah City for Atomic and Renewable Energy (KACARE).
5.55.2. The contractor shall develop and implement a written Ionizing Radiation Control program
based Ma’aden Aluminium MA-EHS-HP-12 Ionizing Radiation Control Program
requirements.
5.55.3. All radiation devices shall isolate before removal. No maintenance/construction work
shall be done on or adjacent to radioactive instruments without permission from Ma’aden
Aluminium Radiation Safety Officer (RSO) or delegate.
5.55.4. Under no circumstances shall untrained or inappropriately qualified personnel or
unauthorized persons attempt to remove, or in any way interfere with, the radioactive
Date Published:
Date Revised:
current version.
sources or carry out any maintenance, adjustment or modifications to radiation gauges

or remove any pipe work which has a radiation gauge mounted or attached.
5.55.5. Portable radiation sources, eg welding, x-ray testing equipment, observe the appropriate
procedures and clearance requirements.
5.55.6. Contractors’ employees shall acquaint themselves with and obey all radiation notices
displayed in places they occupy and all instructions issued to them to protect their safety
and the safety of others.
5.55.7. Contractor's employees shall use, in a manner required by the statutory authority, devices
or equipment furnished to them to assess their personal radiation exposure when
required.
5.55.8. Employees shall be provided with and use the necessary personal monitoring and
protection measures while using/handling ionizing radiation equipment.
5.55.9. All portable radiation sources shall be surveyed before and after use or movement using
proper and calibrated radiation survey equipment
5.55.10. Contractor’s employees shall report to Ma’aden Aluminium RSO if they notice any defects
in equipment that they believe are likely to cause a radiation exposure or contribute to
one arising.
5.55.11. Any person possibly contaminated shall be referred to the Medical Centre. If any
radiation incident occurs, Ma’aden Aluminium RSO shall be informed immediately.
5.56. Environment
5.56.1. It is the responsibility of the contractor to manage themselves in accordance with
Ma’aden Aluminium EHS Policy and applicable rules and regulations, which include but
are not limited to those outlined in MA-EHS-MS-01-EHS Policy Leadership and
Commitment Requirements
5.56.2. The contractor shall require assistance each facility and site has an Environmental or
EHS Department that is available to provide advice on environmental issues.
5.57. Yard Management
5.57.1. It is the responsibility of the Contractor to manage their yards in accordance with Ma’aden
Aluminium standards and Royal Commission Regulations. The yards are located on or
adjacent to the facilities and mine sites shall be managed according to the same laws
and regulations.
5.58. Above Ground Storage Tanks and Bund
5.58.1. All above ground storage tanks shall be contained in accordance with the requirements
of Royal Commission Environmental Regulation. Secondary containment facilities shall
be regularly inspected to ensure good maintenance and integrity. All tanks owned by
contractors shall meet requirements of Royal Commission Environmental Regulation and
good engineering practice.
Date Published:
Date Revised:
current version.
5.58.2. Underground storage tanks are not permitted on Ma’aden Aluminium sites.
5.58.3. Any water discharged from secondary containment to the environment shall be first
confirmed by testing to be uncontaminated, or be rerouted to an appropriate disposal
system approved by Ma’aden Aluminium.
5.59. Chemical Contamination
5.59.1. Chemical contamination (such as caustic or hydrocarbons) of soils, groundwater and
surface water shall be avoided. In the event that a spillage occurs an immediate response
is required to contain, remove and clean up the area according to the procedures detailed
in Section 5.59 Spill Control and Clean-up. Depending on the severity of the spill,
Ma’aden Aluminium Environmental staff shall be notified according to the Loss of
Containment Reporting and Investigation Guideline. For a spill >20L offsite or onto
unsealed ground the site Environmental or Environmental Manager shall be notified
immediately and an investigation shall be conducted. Any spill >20L inside a
bund/containment facility or on sealed ground or any volume offsite or on unsealed
ground shall have an environmental incident raised as soon as possible (see Section
Environmental Incident Reporting).
5.60. Spill Control and Clean Up
5.60.1. Contractor shall prepare site Emergency Response Plan which contains Inventory of
hazardous materials (MSDS), Spill response and prevention procedures and Notification
requirements.
5.60.2. It is the responsibility of the Contractor to be familiar with the specific site emergency plan
and what to do in the event of a spill.
5.60.3. Spills >20L in a contained area (sealed surface) or any volume offsite or on unsealed
ground shall be recorded on the Environmental Incident Reporting system.
5.60.4. Contractor shall take all reasonable precautions to prevent the spillage of caustic fluids,
hydrocarbons or chemicals.
5.60.5. In the event of a spillage, implement immediate temporary control to stop the spillage
from spreading (e.g. earthen bund wall).
5.60.6. Arrange the removal and disposal of contaminated soil according to Ma’aden Aluminium
direction.
5.61. Waste Disposal
5.61.1. The Contractor is responsible for the disposal of its own waste unless otherwise agreed
to with Ma’aden Aluminium. All waste shall be disposed of in accordance with the
requirements of RCER.
5.61.2. Ma’aden Aluminium operates a waste segregation system, where waste types are
segregated in accordance with the type and disposed of appropriately. Bins and
Date Published:
Date Revised:
current version.
dumpsters are labelled and color coded to assist with segregation of waste. Bins are
regularly assessed for cross contamination.
5.61.3. Waste from other premises, the public, or your home is not permitted for disposal in
Ma’aden Aluminium bins or any waste facility or accumulation area at each Ma’aden
Aluminium Operation.
5.61.4. Process wastes such as residue material, scale, alumina or sand shall not be placed in
general waste or recycling bins. Process waste dumpster bins are located around site to
safely dispose of process wastes.
5.61.5. Contractors handling or transporting hazardous or large volumes of wastes should
consult with the Ma’aden Aluminium environmental department to ensure that they meet
Ma’aden Aluminium standards and the relevant legislation. All contractors disposing or
receiving waste from Ma’aden Aluminium shall be audited prior to commencing work to
ensure they meet these requirements and shall be subject to regular audits thereafter.
5.61.6. All wastes travelling offsite shall be transported by Ma’aden Aluminium approved
contractors and disposed of at Ma’aden Aluminium approved facilities. The details of
each load shall be recorded on a Ma’aden Aluminium standard Waste Manifest form
report and shall be reported to the site Environmental Department.
5.61.7. For more information on correct waste disposal contact the site contractor waste
coordinator or the site Environmental Dept.
5.62. Vegetation Clearing
5.62.1. No clearing of vegetation shall occur on any Ma’aden Aluminium land without approval
from the Environmental Department. A Ma’aden Aluminium Vegetation Clearing Permit
is required for clearing of any vegetation unless it is an ornamental plant planted in an
ornamental garden. Native vegetation includes live trees, dead trees, bushes and
grasses. If you are unsure, contact the Environment Department.
5.63. Dust Management
5.63.1. The facilities operate under environmental permits that have specific dust management
requirements and emission limits.
5.63.2. Dust suppression controls and monitoring shall be used when a Contractor is conducting
work that has the potential to generate dust. Where work has the potential to generate
significant dust, e.g. large construction projects, dust suppression plans and controls shall
be in place and approved by the Environmental Department prior to the commencement
of the work.
5.63.3. Significant dust emissions shall be raised as an Environmental Incident Report in
HEMAYA.
5.63.4. At the mine, dust suppression is also a safety issue, particularly on haul roads.
Contractors shall liaise with their Ma’aden Aluminium Responsible Person to manage
dust within the Mine.
Date Published:
Date Revised:
current version.
5.64. Emission Management

5.64.1. The Contractor shall not install, remove or modify any noise or air emission control
equipment unless they have received prior approval from Ma’aden Aluminium. The
Contractor shall familiarize itself with the emission control equipment installed in the area.
5.64.2. The site Environmental department or their representative is available to instruct the
Contractor.
5.65. Water Management
5.65.1. Water supply shall be standalone aboveground water tank provided by the contractor.
However if this is not possible, connection to the Plant water supply system shall be
approved by the Ma‘aden Aluminium Environmental Department. If connection is granted
Plant water use shall be minimized and a minimization plan submitted to the Ma‘aden
Aluminium Environmental Department for prior approval.
5.65.2. Wastewater streams from the site shall be managed by the contractor and a wastewater
management plan submitted to the Ma‘aden Aluminium Environmental Department for
approval prior to constructing the facility. Note that all wastewater is treated by the
Naturally Engineered Wastewater Treatment (NEWT) system and the treated effluent is
reused on the site. Therefore Ma‘aden Aluminium does not discharge wastewater from
the site. The contractor wastewater may be accepted for treatment by the NEWT but
only upon application to the Ma'aden Aluminium Environmental Department.
5.65.3. No wastewater is permitted to be discharged in an uncontrolled manner from the
contractor site.
6. Reference
6.1. HCIS SAF-02- Environmental, Health and Safety (EHS) Management
6.2. Ma’aden EHS-S-009 Contractor, Subcontractor and Contracted Services Environment, Health
and Safety Process
6.3. Ma’aden EHS-S-010 - Contractor Prequalification and Selection Process
6.4. Ma’aden EHS-S-011 - Contractor Prequalification Form
6.5. OSHA 3080-2002 (Revised) Hand and Power Tools
6.6. OSHA 29 CFR 1910
Date Published:
Date Revised:
current version.
7. Revision History
Versio
Author Date Reviewed by Description of Changes
n
10-05- Steve
Shabeer Ali 0.0 New
2013 Borkowski
Shabeer Ali 1.0 26/02/201 1. Ahmed G. I. To include HCIS SAF-02-
7 Al-Harbi Environmental, Health and
2. Central Safety (EHS) Management
Environment requirements
Manager II. To include Ma’aden Corporate
3. Refinery EHS-S-009 Contractor,
EHS Subcontractor and Contracted
Manager Services Environment, Health
4. Smelter and Safety Process
Environment requirements
Manager III. To include Ma’aden Corporate
5. Smelter H&S EHS-S-010 - Contractor
Manager Prequalification and Selection
6. Rolling Mill Process requirements
EHS IV. To include MA EHS
Manager Management System and
Program requirements.
8. Attachments
Attachment # Description Attachment File
Ma'aden Aluminium Weekly and Monthly EHS

Attachment 1 Ma'aden Aluminium
Statistics Report Form
Weekly and Monthly E

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Approved by Magdal Al-Khaldi – ISD Director

5.3.2.6. Theft, abuse, or deliberate destruction of property, tools, or equipment of

5.3.2.25. Prohibited items: No cardiac pacemakers, finger rings or loose jewelry is

Activities Ratio EHS Experience

1 safety supervisor for: 50

5.11. EHS Meetings

5.15.2.5. Operating or cause to operate equipment without a valid operator’s license.

5.17.16. Ensure unauthorized persons are not transported in vehicles.

5.17.28.6. Mobile air compressors and other such equipment

5.27.12.3. Do not overfill fuel tank.

5.27.21. Noncombustible or flameproof welding screens shall be provided around/under cutting,

5.31.4.2. Expected surface moisture and groundwater conditions.

5.33.2.7. DO NOT block access to substations or other electrical equipment.

5.33.5.13.6. Fixed equipment and installations such as huts, workshops,

5.34.22.3. Store electric tools in a dry place when not in use.

5.34.25.7. A hammer shall be discarded if it shows dents, cracks, chips, mushrooming,

5.34.37. Nail gun

5.35.7.1. No person shall operate a bench or pedestal drill, grinder or buffer in a

are identified as Class A systems. Jetting systems with a capability in excess

energized, immobilized, disabled, relived, disconnect restrained in

5.38. Elevated Working Platform (EWP)

5.40.9. Couplers shall meet the requirements of BS or EN standards.

5.40.40. Toe boards shall be a minimum of 4 inches in height.

5.47.3.9. Any tool where the noise generated exceeds 85dbA.

sources or carry out any maintenance, adjustment or modifications to radiation gauges

5.64. Emission Management

Ma'aden Aluminium Weekly and Monthly EHS

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