nyumba site safety manual eng v.2

8/18/2019 Nyumba Site Safety Manual ENG v.2

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CPC A/SCement Plant Consultants

Site Safety Manual: Rev. 2

Site Safety Manual

Nyumba Ya Akiba SA siteFLS order no. 13-45327

Bas Congo provinceDR Congo

Written by: Torben Pedersen

Version: 2

Date: 21.11.2015

Received, Date:________________ Supervisor/Spec: ____________________


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Site Safety ManualPlant name: Nyumba Ya Akiba SA - Cement PlantPrepared by: Torben PedersenEdition: 1

Date: 21-11-2015 Page 2 of 29 CPC A/S

Contents

1. Introduction ............................................................................................................................... 3

2. Safety organisation ..................................................................................................................... 4

3. Emergency plans ........................................................................................................................ 4

3.1. At site ................................................................................................................................. 5

3.2. In the client KCZ guest house ............................................................................................... 6

4. Site safety regulations (summary) ............................................................................................... 7

4.1. Client KCZ regulations .......................................................................................................... 7

5. Workplace hazards ..................................................................................................................... 7

6. Accident prevention .................................................................................................................... 8

6.1. Work at heights ................................................................................................................... 8

6.2. Confined spaces ................................................................................................................... 9

6.3. Electrical safety.................................................................................................................. 10

6.4. Lockout/tag out ................................................................................................................. 11

6.5. Housekeeping .................................................................................................................... 12

7. Personal Protection Equipment (PPE) .......................................................................................... 12

8. Transportation safety ................................................................................................................ 15

9. When the accident occurs .......................................................................................................... 16

10. Health & Hygiene .................................................................................................................... 17

10.1. Heat stress ...................................................................................................................... 18

10.2. Work in cold climate ......................................................................................................... 18

10.3. Severe weather conditions ................................................................................................ 20

11. Personal security .................................................................................................................... 22

12. Safety administration .............................................................................................................. 22

12.1. Bulletin boards & signs ...................................................................................................... 22

12.2. Regular safety meetings .................................................................................................... 22

12.3. Introduction courses ......................................................................................................... 22

13. Safety reporting ..................................................................................................................... 23

13.1. Regular reports ................................................................................................................ 23

13.2. Incident reports ............................................................................................................... 23

14. Hazard Analysis and Risk Management...................................................................................... 24

Appendix 1: Contacts on site ......................................................................................................... 27

Appendix 2: External contacts ....................................................................................................... 27

Appendix 3: Incident Report form .................................................................................................. 29

Appendix 4: Template for safety risk assessment............................................................................. 30


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1. Introduction

Nobody goes to work to get hurt. Accidents unfortunately do happen far too

frequently, and therefore preventive measures must be taken.

It is important to understand that almost all accidents are preventable. They are

caused by people and the mistakes of people.

FLSmidth and CPC A/S has a policy which states that the goal for any project site is

zero ( 0 ) accidents. This may sound difficult to achieve, but in fact we can get very

close if everybody on site is made fully aware of the risks of accidents and how to

prevent them. Discipline, awareness and attention are required no matter where or

when.

The following manual serves as an introduction to safety at the Nyumba Ya Akiba SA

Cement Plant site, and must be studied carefully by all employees who are to work at

this site.

At Nyumba Ya Akiba SA Cement Plant we have a so-called Supply Contract ( EP ),

where the client will carry out all work on site, construction, installation, etc.

The contractor(s):

INDEC ( Kiln to Packing plant ) and Al Razi ( RM feed to Pre Heater ) perform the

actual work for the client. The role of the FLSmidth and CPC A/S representatives at

site is accordingly only advisory, and we do not have direct influence on the health &

safety behaviour of the other parties.

Any issue identified must be relayed by the CPC Site Management through the official

communication channels to the client. On the other hand, the FLSmidth / CPC

Supervisors are still responsible for their own safety and must follow the guidelines

below.

In case e.g. a location is not safe to enter, the Supervisor / Specialist must refuse to

do so, and report the issue to the Site Management and Site Safety manager

immediately.


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2. Safety organisation

CPC DRC safety organisation diagram:

CPC DRC Site Manager: Torben Pedersen, +243 81 949 9349

CPC DRC Safety Manager / Coordinator: ( Torben Pedersen ) Xxxxxx Xxxxxxxxxx

Client Nyumba Ya Akiba SA - Safety Coordinator: Jack TshibanguMob. +243 81 615 2626, email: [email protected]

Contractors Safety coordinator: Mr. Shakeel Ur Rehman on behalf of Nyumba.

Mob +243 81 049 5711, e-mail: [email protected]

3. Emergency plans

The following emergency plans will briefly describe the actions to be taken in case of

an accident, fire, earth quake or similar.

No two incidents will be similar, and the initial action to be taken depends on the

circumstances. See section 9 for some general guidelines.

If an evacuation alarm sounds everyone must immediately leave their present location

and move towards the evacuation meeting point(s), see below. If possible, and

without any increase of the danger, lights and electrical appliances should be switched

off, machines stopped and doors and windows in buildings closed. Nobody should

carry any items along, this will impede the movement.

A serious effort must be made to check that everybody is alerted and evacuating.

mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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3.1. At plant construction site

In case of an emergency, the following persons should be contacted:

CPC DRC (FLSmidth): Torben Pedersen, CPC Site manager , +243 81 949 9349

FLSmidth A/S: Bo Allan Josefsen, Project manager, +45 36 18 29 90

Outside ( FLS Safety): Sergey Avramenko, Site safety manager, +7 926 356 9284

For full contact details, please see Appendices 1 and 2.

In case of an evacuation the following signal will be given: Xxxx ( Sirene )

The evacuation meeting points (red circles) are shown at the following site map:


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3.2. In the client Camp area 1 and Camp area 2

In case of an emergency, the following persons should be contacted:

CPC DRC (FLSmidth): Torben Pedersen, CPC Site manager , +243 81 949 9349

FLSmidth A/S: Bo Allan Josefsen, Project manager, +45 36 18 29 90

Outside (FLS Safety): Sergey Avramenko, Site safety manager, +7 926 356 9284

For full contact details, please see Appendices 1 and 2.

In case of an evacuation the following signal will be given: SIRENE

The meeting point is shown at the following map of Yuku camp:


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4. Site safety regulations (summary)

FLS Safety Handbook most be observed with special attention to the “10 safety rules”.

Further please pay attention to the below highlighted issues.

• Everybody must attend the Site Safety Briefing prior to doing any work on site.

• Hard hat, safety shoes & safety visual vest must be worn at all times on site.

• Safety goggles (glasses) & hearing protection to be carried everywhere on site,

ready to wear when needed.

• Working at heights is only allowed if proper railings are in place, otherwise

safety harness and line must be used, please refer to FLS Site Safety rules.

• Other items of Personal Protection Equipment to be used whenever indicated by

signage ( boards ) or Site Management instructions.

• Never enter dangerous locations (e.g. confined spaces) alone.

• Strictly comply with safety measures around energized machinery and

equipment, including items with a potential for being energized (e.g.

lockout/tag out).

• Restrictions on smoking and use of open fire to be strictly obeyed.

• Everybody must act on evacuation alarms / sirenes without any delay.

• All unsafe behaviour and installations observed to be reported.

4.1. Client regulations

N/A

5. Workplace hazards

The following list contains examples of typical hazards that can be encountered on a

cement plant site:

• Falling objects

• Falls from heights

• Hot activities, e.g. welding, gas cutting & grinding

• Electric shocks

• Impact from transportation / lifting of heavy equipment / earth moving

• Toxic or corrosive chemicals

• Fire or explosions

• Radiation, e.g. from material test equipment

•

Heat stroke from working in a hot ambient climate


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6. Accident prevention

6.1. Work at heights

Falls

Fatalities from construction workers falling from heights are all too common all around

the world. Falls are basically prevented in two ways:

• Stairs, walkways and platform or deck edges are furnished with proper

guardrails. Guardrails should be set up with a kick plate at the bottom, a kneerail half way up and a handrail at a height around 1100 mm.

• Anyone working in an elevated location without guardrails must be equipped

with a safety harness and line, and the line must be securely fastened, to e.g. a

safety wire close by.

Scaffolding and ladders must be of good and approved quality, well maintained and

properly set up and secured. Floors of walkways & steps of stairs must be strongly

made and no holes or openings are to be accepted. Guardrails must be continuous,

with no gaps left open.

Tools or materials are not to be carried by hand while climbing up or down scaffolding

or ladders. Shoulder bags, backpacks or tool belts must be used for this purpose.

Dropped items

Items brought up in elevated heights may for a lot of reasons fall down, with the

potential of injuring people below.

• Construction or installation workers may accidentally drop something they are

holding in their hands.

• Items left on an elevated platform or deck may fall down due to not being

secured properly, or left too close to the edge. Strong wind may have an

influence here. Guardrails will provide considerable protection against such

occurrences.

• Items may be dropped from cranes or other lifting equipment, due to

inadequate fastening or poor-quality equipment.

• Parts under installation are often initially fastened temporarily, e.g. by tack-

welding. The fastening, if not properly done, may fail and the part may falldown.


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Care must be taken by everyone working in elevated places, whenever handling or

placing items, temporarily or permanently. Crane operators and - loaders must ensurethat items are properly fastened and that hooks, chains, wires or belts are in good

condition.

Finally, people on the ground should consider where they are. It should be avoided to

stand right below areas where activities above are ongoing. If close to a building

under construction, it is more safe to stay below a deck than just outside.

6.2. Confined spaces

Working in a confined space may be a required regular part of the job or it may be a

one-time emergency. Confined spaces must always be considered dangerous.

Confined spaces have few or very small openings. They are not meant for workers to

stay in. Ventilation is usually poor. While working inside a shell, silos, tunnels,

cyclones etc. focus must be kept on the available openings and ventilation.

There are four main dangers in confined spaces.

1. There may not be enough oxygen to breathe. Rust, sewage, or chemicals can

use it up. Even if there is enough oxygen when the person enters, it can beused up by his/her presence and the work more quickly than expected.

2. Chemicals and gases can explode suddenly, from cigarettes, static electricity,

sparks, or heat. Fire and explosions can cause immediate death or serious

injury. But even if they do not, they may use up oxygen quickly enough to

prevent escape and cause death within minutes.

3. In confined spaces there is the danger of poisonous and toxic elements in the

air. They can harm the breathing and nervous system. Often, a human being

cannot see or smell them. Some gases, vapours and dusts can burn or poison

the person quickly. Others may have a more long-term health impact.

4. There are physical dangers such as loud noise, intense heat, and falls. Thesecan be very hazardous in confined spaces.

Preparations

Before entering a confined space, careful preparations must always be made, no

matter how great an emergency it is. The right Personal Protective Equipment must

be at hand, and needed ventilation must work. All equipment must be tested and

grounded.

• Gas, power, steam or water lines into the confined space must be disconnected.

A sign stating that people are inside must be set up in a conspicuous place.


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• If the confined space is inside a machine - or in any way connected to a

machine - the power supply should be interrupted in the substation, followingthe lockout/tag out system (see section 6.4).

• If in any doubt concerning the oxygen level, either a control measurement must

be arranged or a fresh-air supply must be worn.

• It must be ensured that the entrance stays open by use of a chain or similar.

• At least one colleague must remain outside, in visual or audible contact.

• Anyone working inside a confined space must stay alert and refrain from

smoking or eating inside.

• If there is any risk of poisoning or other harm when climbing down into a tank,

the employee must wear a safety harness and have the line attached to a winch

or hoist above, so the colleague posted outside can pull the person out in case

of loss of consciousness.

6.3. Electrical safety

Site Supervision must give special attention to the electrical safety. It is very

important for the persons who are involved on the job as well as for the equipment.

The following important rules for electric safety must be followed:

•

Electrical equipment, machinery and work areas must be kept clean. Oil, dust,waste and water can be fire hazards around electricity.

• Access to panels and junction boxes must be kept clear.

• Machine energy supplies (in the substation) must be disconnected before doing

any work, following the lock-out/tag out procedure (see below).

• Appliances must be unplugged before cleaning, inspecting, repairing or

removing anything from them.

• Unauthorized & incompetent persons should not work on electrical equipment.

• The location of fuses and circuit breakers must be well known. If a fuse blows,

the reason must be found before it is replaced. If a machine blows its fuses

repeatedly it is never a solution just to install bigger fuses. Also, electricalcircuit should not be installed with fuses that carry more amperage than the

rating of the wiring of the circuit.

• All electrical equipment must be properly grounded.

• A check with the local utility Co. and the necessary permission in writing are

required before any digging or work is done near suspended/ routed power

lines.

• If someone has received an electric shock, the victim must be separated from

the source of current before any first aid is done. If the electricity cannot be

turned off easily, a rope, wood or some other insulator must be used to pull the

victim away.

• Employees, who are not trained to work in high voltage areas, are not to enter

them, even in an emergency.


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• Necessary PPE must be put on before entering / working in an electrical

equipment area.• As far as possible, the employees working with electrical equipment should

avoid having contact with metal or wet surfaces.

• All electrical rooms are to be kept closed to avoid unauthorized entry and for

the safety of the equipment.

• The necessary log book system must be implemented in all electrical

substations.

• Safety circuits, fuses and programs are not to be by-passed.

• No electrical panels / switchboards may be left open without proper protection,

warning sign boards etc.

• Keep flammable materials away from electric heat sources and lights.

Reporting of unsafe conditions

Unsafe conditions such as the following must be reported without delay:

• Electric equipment & machinery giving electric shocks, sparks, smoke or which

is overheating.

• Corroded outlets, switches and junction boxes

•

Exposed wiring; broken plugs, outlets, missing box covers or faceplates• Improper wiring/ installation of any equipment

• Unauthorized / unskilled operation

• Persons working with improper tools/PPE etc

• Improper/unsafe maintenance of electrical equipments

6.4. Lock out / Tag out

"Lock-out/Tag-out "(LOTO) refers to specific practices and procedures to safeguard

employees from the unwanted energizing or startup of machinery and equipment, or

the release of hazardous energy during service or maintenance activities.

Before any machine or equipment is entered, or before any inspection /maintenance

activities, all the emergency switches must be closed and the connected electrical

breaker must be pulled out and locked with a safety padlock by the person who enters

/ works on the equipment. Also, a lockout/tag-out permission sheet shall be signed off

before entering or working on any equipment.

Supervision should make sure that the equipment is thoroughly inspected, the doors

are closed and safety devices are in place before giving permission for the (re-)

starting of the equipment.


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6.5. Housekeeping

Good housekeeping is an essential part of the tools to prevent accidents. Besides, it

will improve the working efficiency and minimize the number of mistakes made.

Good housekeeping consists of the following elements:

• Keeping the working environment cleared of all unnecessary waste and

materials.

• Organizing the storage (& temporary location) of tools, building material and

parts so they are easily accessible and do not block other activities.

• Keeping lanes and roads for traffic and emergency use clear at all times.

• Keeping machines, installations, operating panels & displays clean for easy

access and handling.

• Maintaining an overall state of cleanliness of the whole plant.

All FLSmidth / CPC DRC supervisors and specialists should facilitate/recommend

proper housekeeping in their working area in coordination with the client and

contractor(s).

7. Personal Protection Equipment (PPE)

PPE are important tools to protect the employees against work-related hazards, which

may endanger their health & safety. All supervisors must bring and maintain their own

PPE unless otherwise agreed with FLSmidth / CPC DRC site management prior to their

travel. All FLSmidth / CPC DRC employees must use PPE wherever required according

to the site regulations.

All PPE must be carefully maintained and kept clean. Any defective items are to be

replaced without delay.

Basic Personal Protective Equipment (PPE)

Basic and minimum PPE requirements are defined as:

• Safety helmet, manufactured in conformance with standard. The helmet must

be in good condition, no cracks or other damage.

• Safety footwear with steel toe and sole protection manufactured in compliance

with standard. The construction and sole materials shall be chosen in

accordance with the activity and must be adequate for the place of work.

• Safety vest in a conspicuous color, to make the supervisor more visible.

• Safety glasses & hearing protection. To be carried but maybe only worn when

needed.


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The basic PPE must be worn at all times all over the plant site, from the time of the

initial excavation until completion of commissioning.The only exception is when the employee is indoors with a ceiling height below 2.5

meters - or indoors in completed buildings where no more construction or installation

work is done.

Hard hats are to be worn according to local regulations in warehouse buildings with

racks higher than 3 meters.

Eye and face protection

Face/head protection scarves are only allowed if specially designed and worn in such a

way that there is no impairment of the wearer’s vision, and no danger of scarves

getting caught in moving machinery.

Suitable protective goggles, face shield or screens shall be worn by personnel involved

in, assisting with or adjacent to any activity where there may be a danger of flying

debris, dust, sparks or other particles; corrosive fluids or mists; excessive heat, light

or other harmful radiation. Such work situations include, but are not limited to:

• Working with rotating equipment such as grinders, drills, lathes

•

Cutting and welding• Chipping, chiselling or caulking

• Using powder bolt driving tools & nail guns

• Spraying with abrasives (sand blasting) or high-pressure water

• Working with chemicals, e.g. mixing drilling fluids

• Working with paints, disinfectant, pesticides or other toxic or hazardous fluids

• Working with strong sources of light, e.g. welding (darkened eye protection)

• Working in the open with winds blowing sand

• Safety sun glasses should be worn in strong sun glare to reduce eye strain and

fatigue.

Respiratory protection

Respiratory protective equipment must be used by anyone entering areas where there

is a possibility of the atmosphere being (or becoming) deficient in oxygen or

containing any harmful substance, whether particles (dust), toxic vapour or gas.

Basically, 3 types of protection exist:

• Dust mask

• Gas (solvent) mask

• Fresh-air mask


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It is important always to use the correct type of mask for the situation in hand. Ifthere is enough oxygen in the ambient air, then either the dust mask or the gas mask

should be used. The dust mask will only protect against particles in the air; it is of no

use against toxic gases. The dust mask is used e.g. where powder materials (including

cement) are handled; stones, ceramics or concrete are cut, blasted or ground; or

during grinding of metal parts.

The gas mask is equipped with a filter (often based on active carbon) which will

absorb the gas. It is important to choose the correct gas mask for the given chemical

risk and the user must be aware that the lifetime of the filter is limited, it will become

saturated, and thereafter the mask provides no protection. The gas mask is used

where the ambient air is polluted by poisonous gases, organic vapours (e.g. from

painting) or liquid aerosols. Using a gas mask puts strain on the lungs, and the use

should be limited to maximum 2 hours per day.

The fresh-air mask is connected to a compressed-air container and will provide clean

air with enough oxygen to the user. A fresh-air mask would be used e.g. in confined

spaces short of oxygen or in areas with suspected very heavy pollution by toxic gases.

Hearing protection

Hearing protection should be used by all supervisors exposed to noise levels of 85 dB

(A) or above. The selection of type of protection shall be in accordance with the type

of noise hazard and the work being performed.

Hand and arm protection

Adequate hand and arm protection should be used wherever required. The

type of protection to be selected depends on the actual hazard, e.g.:

• Impacts, cuts, abrasions and infections

• Extreme temperatures

• Chemical, toxic, corrosive and other hazardous substances.

Typically, gloves will be used. For abrasive work heavy protective gloves are best,

whereas for high temperatures, special heat insulating ones should be chosen.

For chemicals, like solvents, special gloves made of polymers are to be used, it should

be noticed that ordinary rubber or cloth gloves provide absolutely no protection

against chemicals. The specification on the polymer glove should be checked to

confirm that it does protect against the chemical to be handled.


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Chemical-resistant gloves only have a limited lifetime, and should be frequently

replaced.

Harnesses and lifelines

Harnesses and lifelines shall be provided, worn and properly secured in all locations

where any of the following dangers exist:

• Falling from a height greater than 2m (6 feet)

• Succumbing to toxic atmospheres or oxygen deficiency

Such situations include, but are not limited to:

• Working on scaffolding with incomplete rail protection

• Work on any high structure

• Work over (deep) water

• Work in confined spaces

When working at height the lifeline system must be fastened with care, so there is no

risk of it loosening itself in case of a fall. Also, it should be considered that the

maximum fall height before being caught by the line should not be more than 1.2meters. Accordingly, the employee should never be attached to a long free line,

which would result in a drop of several meters before the fall is arrested.

8. Transportation safety

Road safety is an important issue while considering safety. Public roads in many

countries are prone to accidents due to mixed traffic, traffic violations & speeding.

FLSmidth and CPC DRC employees must strictly follow the below-mentioned

instructions:

Supervisors driving themselves are not allowed, only local Congolese drivers:

• Only authorized and competent local Congolese drivers are permitted to drive

CPC transport vehicles on public roads as well as on site.

• All road safety rules & speed regulations must be strictly followed while driving

a vehicle, regardless of whether on public road or on site.

• Safety belts must be used at all time while travelling.

• Loads shall be within the safe weight limit for the vehicle and shall not project

beyond the vehicle body in such a manner as to present a hazard to other

vehicles, pedestrians or adjacent structures.


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• Passengers shall not be carried unless a proper seat for each person is available.

• Parking signs & regulations must be followed.

The use of drivers

The qualifications of local Congolese hired drivers has been ascertained by client

transport management and skills confirmed to the CPC Site Management, and the

drivers have at least have a rudimentary knowledge of English.

The local Congolese drivers is expected to:

• Take full responsibility for the vehicle, the load and passengers being carried.

• Check of the vehicle prior to the start of a (longer) journey.

• Always wear a seat belt.

• Inform the manager in charge of site transport at the destination to notify about

the arrival of the car and passenger/goods.

• Refrain from picking up unauthorized persons (e.g. hitch hikers).

If an FLSmidth / CPC A/S supervisor or specialist feels uncomfortable with the driver's

performance (reckless or careless driving), the supervisor / specialist must report the

issue to the CPC DRC Site Manager, who then will have to find an effective solution. Invery bad cases, the supervisor / specialist may resort to asking the driver to stop

immediately, and then contact the CPC DRC Site Manager for alternative transport on

the spot.

9. When the accident occurs

Whenever an accident, incident or fire occurs, the first few minutes may be crucial for

the ultimate outcome. Loss of life and major loss of property may be avoided by doing

the right things from the start.

The first employee arriving at the location of the incident (or already present, but

unhurt) will have to make the initial decisions on the course of action. The very first

thing to do is always to get an overview of the situation:

• Is anyone hurt and how badly (life-threatening)?

• Can the victims stay where they are, or are they threatened (e.g. by a fire or

risk of falling items)?

• Is there any danger to others in the vicinity or on site in general?

• What is the most important thing to do initially

• Immediate first-aid / moving of victim

• Fire-fighting or removal/neutralizing of dangerous objects?


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• Call for help (walkie-talkie, mobile phone, or?), to whom?

• Sound an alarm for evacuation (fire or explosion risk)• Anyone nearby who can help?

Spend no more than 10-20 seconds on the overview and then take action in the order

deemed most efficient. The CPC DRC and Nyumba Site Management must be alerted,

the victim(s) tended to and if outside assistance (medical, fire brigade) is required, it

must be alerted without too much delay.

A representative from CPC DRC Site Management must take charge as soon as he or

she arrives and ensure that all the acute actions are completed.

Once the initial actions have been taken, and e.g. the victims have been removed,

the more long-term actions must be considered:

• Eliminating immediate dangers

• Preventive measures against recurrence

• Handling the staff and outsiders like client, contractor, local authorities, the

media etc.

• Reporting the incident (see below).

10. Health & Hygiene

FLSmidth / CPC DDRC employees must take good care of their health during their

assignment. It is very important to have a healthy mind and constitution to deliver

our obligations effectively. CPC DRC Site Management will set up an arrangement with

a doctor & a dentist to be available to handle any minor health issues. The site office

must maintain a first-aid box for any minor first aids. The site offices should include

clean toilets & washing facilities. To maintain good health, the following directions

shall be followed.

Before travelling to site, all FLSmidth / CPC A/S employees are advised to have a

detailed medical checkup with report to document that they are fit to undertake the

assigned responsibilities.

If any known medical issues exist, the CPC DRC Site Manager and FLSmidth Project

manager must be informed prior to the employee's arrival at site. It must be ensured

that all necessary medicines are available on site.


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• Follow good health and hygiene practices.

• As far as possible, get some physical exercise every day.• Consumption of alcohol to be done with prudence.

• It is strictly prohibited to be under influence of alcohol during work time.

• Make sure to eat sufficient, varied and nutritious food.

• Use only bottled drinking water and drink enough water.

• While working in the sun use sun glasses and protective clothes.

10.1. Heat stress

Heat stress is usually the result of work being performed at elevated temperatures. If

the body’s physiological processes fail to maintain a normal body temperature

because of excessive heat, a number of physical reactions can occur, ranging from

mild to fatal. Heat stress is one of the most common and potentially serious illnesses

that afflict construction workers. In areas where high temperatures are normally

encountered, regular monitoring and other preventative measures are vital.

Any occurrence of the below-mentioned conditions must be reported to the CPC DRC

Site Manager and treated as soon as possible.

Heat stroke

In heat stroke the body temperature rises so high that brain damage and death will

result if the person is not cooled quickly.

• Symptoms

Red, hot, dry skin, although the person may have been sweating earlier;

nausea; dizziness; confusion; extremely high blood pressure; rapid respiratory

and pulse rate; unconsciousness or coma.

• Actions

Casualty must be cooled down and medical aid sought immediately with theperson transported to the site medical facilities.

Heat exhaustion & heat cramps

Heat exhaustion and heat cramps are both caused by excessive sweating, not

compensated by drinking enough water, leading to a loss of fluids in the body.

Heat exhaustion is a state of serious weakness or exhaustion. Both heat exhaustion

and heat cramps are much less dangerous than heat strokes, but must be treated

early on to prevent progressing to heat stroke.


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• Heat exhaustion symptoms

Pale, clammy, moist skin, profuse perspiration, and extreme weakness. Bodytemperature is normal, pulse is weak and rapid, and breathing is shallow. The

person may have a headache, may vomit, and may be dizzy.

• Heat cramp symptoms

Acute painful spasms of various muscles; e.g., abdomen and extremities.

Heat rash

Heat rash is caused by continuous exposure to heat and humid air and is aggravated

by chafing clothes. The condition decreases ability to tolerate heat.

• Symptoms

Mild red rash, especially in areas of the body in contact with protective gear.

10.2. Work in a cold climate

n/a

10.3. Severe Weather Conditions

Early notification about severe weather conditions may become necessary to provide

safety and welfare to our employees and to prevent or reduce damage or loss to

project property.

Definit ions (Severe Weather)

• Lightning - All large-scale, high tension, natural, electrical discharge in theatmosphere; the visible flash of light accompanying such discharge.

• High Winds and Rain - When the winds or rain become a hazard to the work

force or the work being performed. Wind approximately 30 mph (50 kph) and rainlimiting visibility or footing.


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Client’s site Safety Department Responsibilities

Site Safety Officers of each construction site are responsible to prepare a procedure

indicating

• how to obtain information about severe weather conditions from their localweather bureau in a timely manner• ways of distributing information

• measures to be taken in case of anticipated severe weather conditions

Site Safety Officers should keep CPC DRC Site Manager updated as to location and

intensity of a storm on a routine basis.

Severe Weather Actions

Lightning

Avoid exposing personnel at high elevations, such as on structural steel

members, pipe racks, roof tops, process columns, antennas, etc. Make sure that personnel do not group together and/or huddle under or

near tall structures.

Avoid a depression with standing or running water or a stream.

Have all crane booms lowered to the ground or retracted to the shortestboom length.

All cranes, derricks, gin poles, and erection rigs unable to be boomed

down must be grounded from their booms to the ground.

High Winds and/or Rain

When high wind creates a hazard to craftsmen or work being performed, i.e.,

instability in elevated areas,limited visibility due to dust or particles in the air,unmanageable materials, etc. Supervision will stop work activities, re-assign work andarea, properly store and secure material which might blow away, injure or damage,

lower/tie down crane booms and obtain further instruction from CPC SiteManagement.

When rain creates a hazard to craftsmen on work being performed, i.e., unstable

footing conditions due to slippery structural steel, muddy and flooded workenvironments, unstable trenches or excavations, poor visibility due to rain or eyeprotection, supervision will stop specific work due to hazard, re-assign work duties

and/or areas, and obtain further instructions from Project Management.


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11. Personal security

Personal safety & security for FLSmidth and CPC DRC personnel is of paramount

importance to the Management. All employees (and family members) at site should

use their common sense to assess their safety, no matter where they are.

The CPC DRC Site Management will evaluate the situation regularly in coordination

with FLSmidth Travel Security Department and the client.

n/a [Site specific information must be entered here. Points may be added to or

deleted from the general list below ]

The following general guidelines are in all cases recommendable:

• Follow directions from Safety/Security department.

• Obtain knowledge & understanding regarding local law, traditions & habits.

• Consider personal behavior while dealing with other nationalities/locals.

• Follow & respect local law & regulations.

• Do not discuss religion & politics with any other nationalities.

• Do not wear clothes which can attract public attention or which may offend.

• Avoid all religious symbols & practices which could expose to public attention.• Try to be unnoticed in the local society.

• Avoid ethnic gatherings in public.

• Assess the safety situation around you and inform the Site Manager if you find

anything suspicious.

• Evaluate the safety & security in your weekly meeting.

• Pass important information quickly to FLSmidth / CPC A/S Site Management

• Stay updated with local news/ incidents /events

• Keep all important emergency contact details in case they are required.

• Keep contact with your National Embassy in coordination with Site

Management.

• Do not allow unknown /unauthorized people to enter your residence / office /

vehicle etc.

• Keep all your valuable belongings locked away in a safe place only known to

you and be aware, that Site Management will not be responsible for any

loss/damage.

Entrances and boundaries

All FLSmidth / CPC DRC employees at site should have a detailed understanding about

the plant entrance & boundaries. FLSmidth / CPC DRC personnel should not leave the

site without informing the CPC A/S Site Management.


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12. Safety administration

The FLSmidth / CPC DRC site organisation is not alone on the plant. The client and

contractor(s) have numerous employees and a tremendous amount of activities on

site. They may engage in a lot of unsafe practices, which the FLSmidth / CPC DRC Site

Management will require to be stopped.

[For Supply Contracts, any health & safety complaint may have to go through the

client (management), typically at site meetings.]

Safety violations are to be taken seriously, and sanctions will be imposed. Blatant or

repeated disregard of well-known safety regulations can result in dismissal from site;

any FLSmidth / CPC DRC employee will in such cases be sent home, and the parent

department will decide on further actions to be taken.

12.1. Bulletin boards & signs

The CPC DRC Site Health & Safety Coordinator shall maintain a bulletin board and

display at a prominent location within the site office for the awareness about health &

safety, news and actions taken.

FLSmidth / CPC DRC supervisors and specialists should inform the client /contractor if

any awareness signboards are required in any part of their working area.

12.2. Regular safety meetings

Internal health & safety site meetings should be conducted on a weekly basis chaired

by the CPC Site Manager. The FLSmidth / CPC DRC team members should participate

effectively to evaluate and improve the health & safety conditions at site. This

meeting should be recorded and the Minutes of Meeting sent to CPC, FLSmidth & the

FLS Project Manager.

12.3. Introduction courses

Every FLSmidth / CPC A/S employee arriving at site must be given a safety briefing by

the CPC DRC Site Safety Manager (or Coordinator). The contents of the briefing

should roughly follow the contents of this manual, with special emphasis on the

particular local conditions to be aware of.

The briefing must include instructions in the emergency response procedures (alarms,

meeting points, etc.) and mandatory use of Personal Protection Equipment.


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All FLSmidth / CPC DRC employees who are to work with construction, installation orcommissioning at site, are to receive a copy of this manual with instructions to read it

without delay.

13. Safety reporting

13.1. Regular reports

All Supervisors, Specialsits, Department Managers & the CPC A/S Site Manager should

report on health & safety conditions at site in their monthly report.

If any situations need to be addressed in between, the CPC A/S Site manager/Safety

Coordinator should be informed in writing. Also the same information must be brought

up at the site weekly safety meeting. At any time, the site safety organisation must,

besides the reporting to the line organisation, also report directly to FLSmidth Safety

& Health Manager regarding any extraordinary safety issues like accidents and near

miss accidents at the site.

13.2. Incident reports

Accidents are unexpected, unplanned and undesirable. However, it is important that

whatever experience may be gained from their occurrence is made available to

everyone concerned.

Hence, accident investigation and reporting are the first steps towards avoiding future

injuries and financial losses.

The investigation determines what, why and how the accident happened. Its purpose

is not to blame someone. A good investigation looks at how a system makes it

possible for accidents to take place. Often, the investigation will reveal that many

similar incidents (small, less serious accidents) have happened before.

The reporting may put spotlight on e.g. dangerous conditions and careless attitudes,

which apart from the accident risk also in general may lead to decreased performance

and productivity.

Incident Reporting

• As soon as an incident occurs, the Supervisor will immediately inform the

FLSmidth / CPC DRC Site Manager/Safety Coordinator who will communicate the

incident to the relevant authorities.


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• Together with the client/contractor all available information, including photos if

relevant, must be collected and handed over to the FLSmidth / CPC DRC SiteManager/Safety Coordinator.

• Any accident involving staff under the control of FLSmidth / CPC DRC must be

reported to the FLSmidth Management within 2 days by the Site Management.

• FLSmidth / CPC DRC Site Manager/ Safety Coordinator should prepare a detailed

FIR if the issue is related to FLSmidth / CPC DRC in any manner.

Any near miss accident with a potential high risk must be reported - at least internally

on site, for example:

• Big parts falling down in an uncontrolled manner where staff under the control

of FLSmidth / CPC DRC might have been injured.

• Traffic accidents at site where staff under the control of FLSmidth / CPC DRC

might have been injured.

• Any other known conditions that might have resulted in a dangerous situation

for staff under the control of FLSmidth / CPC DRC.

Use the form in Appendix 3 when reporting accidents and near miss accidents to the

CPC DRC Site Manager and the FLSmidth Project Management. If more than one

person was injured, a separate report should be issued for each victim.

All reports must be sent to the FLSmidth Project Manager without delay.

14. Hazard Analysis and Risk Management

In some cases the local authorities or the client may request that hazard analyses are

being carried out by the FLSmidth / CPC DRC safety organisation. Often the format of

the analysis will be specified by the requester.

In other circumstances the FLSmidth / CPC DRC Management may deem it desirable

to carry out the hazard analysis for primarily internal use.

In Appendix 4 is a suggested template for a simple hazard analysis, where different

aspects of the site safety may be selected and evaluated more closely. Any item found

to be unsatisfactory must be taken up with the party responsible in order to have the

risk reduced.

Possible areas of focus are listed below:

Above-ground potential hazards:

• Overhead power lines, list kV rating


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• Micro wave / communication towers

• Electrical wires• Fuel / chemical / pressure vessels and systems

• Roadways & Ditches

• Obstruction & unstable soil

• Fences/walls & traffic flow

• Adverse weather conditions

• Hazards from nearby operations, etc.

Underground potential hazards:

• Buried utilities

• High water table & underground water waste

• Building foundations

• Chemical / trash dump area

• Underground fuel / chemical / pressure systems and vessels

Safety management issues:

• Existing emergency evacuation procedures

• Emergency communication system

• Traffic flow

•

Special personnel• Protective equipment requirements

• Hazardous waste disposal

• Flammable liquid / chemical / compressed-gas storage

• Gas release into proposed area


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Appendix 1: Contacts on site

Company Function Name Telephone /

mobile

e-mail

CPC DRCSupervisionteam

Site SafetyManager

Site Manager

Camp ManagerNyumba

Torben Pedersen

Torben Pedersen

Christian Ngoy

+243819499349

+243819499349

+243816139388

[email protected]

[email protected]

[email protected]

Nyumba YaAkiba SACement Plant

Plant Manager

Safety Manager

Tanveer Ahmad

Jack Thsibangu

+243827358702

+243816152626

[email protected]

[email protected]

Contractor 1:

INDEC Site Manager

Safety Manager

Xxxxxx Xxxxxxxx

Xxxxxxxx Xxxxxxx

+243xxxxxxxx

+243xxxxxxxx

xxxxxxxxxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxxxx

Contractor 2:

Al Razhi Site Manager

Safety Manager

Xxxxxx Xxxxxxx

Xxxxx Xxxxxxxxxx

+243xxxxxxxx

+243xxxxxxxx

xxxxxxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxx

Xxxx Xxxxx

mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Appendix 2: External contacts

Institution Address Contact person / title Telephone No. E-mail address

FLSmidth office Valby, etc. Travel SecurityManager

Control Risk 24 hGlobal Security

Project managerBo Allan Josefsen

+4530931111+4530181111

+442079398590

+4536182990

Local Police

At Nyumba site SecurityManager

Denis Bariat

Jean de DieuLuwembi

+24382926686

+243819013035

[email protected]

Local Hospital KimpeseHospital

Kimpese CentralHospital

+ 7484466026 [address]

Doctor Nyumba YaAkiba SA Siteclinic

Dr. [name] [ phone No.(s)] [address]

Dentist To be found inKinshasa or

Matadi

[name] [ phone No.(s)] [address]

Danish Embassy/

Consulate

Pretoria, South

Africa

Royal Danish

Embassy South Africa

[address]

……..

mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Appendix 3: Incident Report form

FLSmidth / CPC A/S - Site Incident Report

Name of victim: Date of incident:

Site name: Department name & No.

Location of accident:

Type of accident (mark with X): Accident: Near miss:

Name and position of supervisors involved (if any relation to FLSmidth):

Describe incident - what happened? (use photos and drawings):

Type of injury (if any):

What caused the incident?

Responsible for incident (who or what caused it?):

Immediate action taken:

Longer-term medical treatment (may be reported later):

How can a similar incident be avoided (may be reported later)?

Report prepared by: Report date:


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Appendix 4: Template for safety risk assessment

Date: _____________________________

Plant: _Nyumba Ya Akiba SA____________

Department: ________________________

Green

Yellow

Red

Problems and Actions

Housekeeping:

Access roads:

Traffic control:

Safety situation in

department:

Scaffolds

Stairs

Railing

Control of: Gas, Oil, Coal

Fire fighting prevention and

protection:

Electrical issues:

Confined spaces:

Safety situation at heights:

Lockout/tag out procedures:

Other:

Action plan:

• Green: The conditions are acceptable.• Yellow: The conditions are not acceptable.

Corrections need to be made within 3 days.

• Red: The conditions are not acceptable.All access is prohibited until corrections are completed.

nyumba site safety manual eng v.2

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