Mine Safety Management Plan 2017

Mine Safety Management Plan [MSMP]

Mine Safety Management Plan NSW WHS (Mines and Petroleum) Act 2013

NSW WHS (Mines and Petroleum) Regs 2014

AS 4801 Safety Management

Work Health and Safety Laws NSW

Heavy Vehicle National Laws NSW

Mine Safety Management Plan MSMP

Controlled copy available electronically Page 2 of 61 Printed copy current on day of printing only: 27/09/17 Revised: 17 July 2017

CONTENTS

SCOPE OF MSMP ...................................................................................................................................... 4

EXEMPTIONS ............................................................................................................................................. 5

1. STRATEGIES, POLICIES, OBJECTIVES AND TARGETS ..........................................................10

2. REGULATORY AND STANDARDS ..............................................................................................12

3. THE INTEGRATED MANAGEMENT SYSTEM [IMS] ...................................................................15

4. DOCUMENT AND RECORDS MANAGEMENT ............................................................................16

5. RESOURCES PROVISION AND MANAGEMENT ........................................................................17

Fixed ladders .................................................................................................................. 26

Rung Ladders ................................................................................................................. 27 Step Ladders .................................................................................................................. 27

Portable Ladders ........................................................................................................... 27

6. TRAINING AND COMPETENCIES ................................................................................................30

7. CONSULTATION. CO-OPERATION AND CO-ORDINATION ......................................................34

8. RISK PLANNING AND HIRAC ......................................................................................................36

9. MANAGEMENT PLANS, CONTROL PLANS AND PROGRAMS ................................................44

10. OPERATIONAL CONTROLS – SERVICE DELIVERY .................................................................47

11. PERFORMANCE MONITORING AND MEASUREMENT – AUDITS, INSPECTIONS & OTHER MONITORING.................................................................................................................................49

12. EMERGENCY MANAGEMENT .....................................................................................................51

13. INCIDENT REPORTING, INVESTIGATION, CORRECTIVE AND PREVENTIVE MEASURES ..53

14. ANALYSIS AND REPORTING ......................................................................................................58

15. MANAGEMENT REVIEW ..............................................................................................................61



No index entries found.DOCUMENT HISTORY

Date Prepared by

(Name)

Reviewed by

(Name)

Approved by

(Name and Signature)

Change Remarks

(Include Section, Page and Details)

08/05/14 Kurt Bezjak Legislative updates

28/08/14 Cruse Partnership Aust Replaces previous MSMP to form part of the integrated system - legislation & compliance to AS 4801

15/10/14 Cruse Partnership Aust Referencing the Blast Management Plan throughout the IMS

14/01/16 Kurt Bezjak Kurt Bezjak Update legislation

14/01/16 Leonie Lockhart Leonie Lockhart Update organizational structure and Australian Standards

24/06/17 COR Australia Andrew Watt Heavy Vehicle National Law Chain of Responsibility RMS GC 21 Contract

17/7/17 Kurt Bezjak Kurt Bezjak

Add DOP+E reporting number Removal of Prescribed Hazard and replace with Principle Hazards and Control Plans

27/9/17 Leonie Lockhart Leonie Lockhart Update organizational structure



SCOPE of MSMP

Northern Rivers Quarry and Asphalt form part of the Lismore City Council, NSW, providing quarry and asphalt products to customers on behalf of the Council. This Plan must be read in conjunction with the Blast Management Plan operating at NRQA.

Products include:

Aggregates

Drainage rock

Road base

Basalt and argillite products

Metal dust

Fill material

Services include:

Dispatch of plant, equipment and materials from site

Operation of heavy vehicles with or without goods, plant, equipment and materials

Receival of plant, equipment and materials to site

The quarry, also known as Blakebrook Quarry is located at 540 Nimbin Rd, Lismore, NSW.



The ISO /AS Standards and legislation applicable to the IMS include however are not limited to:

AS/NZS 4801 Work Health and Safety Management System – certification

WHS Act and Regs – compliance references

Mine Health and Safety Act and Regs - compliance references

Heavy Vehicle National Act and Regulations

ISO 31000 Risk Management – compliance to methodologies

Exemptions

Nil exemptions.



STANDARDS AND LEGISLATIVE REFERENCES

AS 4801: 2001 WHS/COR/Enviro & Mines Regs

4.1 General requirements WHS (mines) Act 2013

Mine Health & Safety Regulation 2014

NSW Work Health & Safety Act 2011

NSW Work Health & Safety Regulation 2011

NSW Heavy Vehicle National Act


NSW Heavy Vehicle (Fatigue Management) National Regulation

NSW Heavy Vehicle (General) National Regulation

NSW Heavy Vehicle (Mass, Dimension and Loading) National Regulation

RMS NSW Contract GC 21

4.2 Safety Policy

4.3.1 Planning identification of hazards, hazard/risk assessment & control of hazards/risks

WHS (mines) Act 2013


[SWA Australian Explosives Code]





SWA Codes of Practice – as applicable



NSW Heavy Vehicle (Fatigue Management) National Regulation

NSW Heavy Vehicle (General) National Regulation

NSW Heavy Vehicle (Mass, Dimension and Loading) National Regulation

RMS NSW Contract GC 21 (additional requirements may need to be listed – worker on foot, etc)

Traffic Laws

4.3.2 Legal and other requirements

4.3.3 Objectives and targets

4.3.4 WHS management plans




Road Access conditions imposed by RMS and/or Lismore City Council

4.4.1 Structure and responsibility NSW Work Health & Safety Act 2011


NSW Code of Practice – Managing the Work and Facilities

NSW Code of Practice – How to Manage and Control Asbestos in the Workplace

Electricity (Consumer Safety) Act 2004

4.4.1.1 Resources

4.4.2 Training and competency Refer NSW Work Health & Safety Regulation 2011 for High Risk Work Licences, Hazardous Chemicals, Falls, Confined Spaces, and General Workplace

WHS Reg., Schedule 3, WHS Regulation 2011 (National) – operator competency assessment

4.4.3 Consultation, communication and reporting Refer NSW Work Health & Safety Regulation 2011 for Duty to Consult, Health & Safety Committees & issue Resolution.

NSW Code of Practice – Health & Safety Consultation, Cooperation and Coordination 4.4.3.1 Consultation

4.4.3.2 Communication

4.4.3.3 Reporting WHS (mines) Act 2013


NSW Code of Practice – Managing Noise & Preventing Hearing Loss

Mine Safety Design Guides – refer website for complete and current listing (1000 Series)

4.4.4 Documentation

4.4.5 Document and data control




4.4.6 Hazard identification, hazard/risk assessment and control of hazards/risks

Refer NSW Work Health & Safety Regulation 2011 for General Workplace HIRAC Management, Asbestos, Confined Spaces, Electricity, Excavation Work, Falls, Hazardous Chemicals, Manual Tasks, Noise & Plant.

NSW Code of Practice – Asbestos

NSW Code of Practice – Manage Safety Risks

NSW Code of Practice – Risk of Falls at Workplaces

NSW Code of Practice – Managing Noise & Preventing Hearing Loss

NSW Code of Practice – Managing Risk of Falls

NSW Code of Practice – Work Environment & Facilities

NSW Code of Practice –How to manage work health and safety risks




National Transport Commission – Load Restraint Guide 2nd edition (3rd version under revision)

4.4.7 Emergency preparedness and response WHS (mines) Act 2013




4.5.1 Monitoring and measurement WHS (mines) Act 2013


4.5.1.2 Health surveillance WHS (mines) Act 2014


4.5.2 Incident investigation, corrective, and preventive action WHS (mines) Act 2013



NSW Code of Practice – Health & Safety Consultation, Cooperation and Coordination 4.5.3 Records and records management




4.5.4 WHS M&S audit Schedule 3, WHS Regulation 2011 (National) - Incident Reporting

4.6 Management review

Website links:

Department of Industry (Mines) www.resourcesandenergy.nsw.gov.au

NSW WorkCover www.workcover.nsw.gov.au

Safe Work Australia http://www.safeworkaustralia.gov.au

NMSF http://www.industry.gov.au/resource/Mining/NationalMineSafetyFramework/Pages/default.aspx

Quarry Safety Alerts http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/safety-alerts

Quarry Publications http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/publications

Quarry Updates/Bulletins http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/mine-safety-update

Mine Safety Design Guides http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/new-mine-safety/publications/mdg/1000

Legislation http://legislation.nsw.gov.au/

https://www.nhvr.gov.au/

http://www.resourcesandenergy.nsw.gov.au/

http://www.workcover.nsw.gov.au/

http://www.safeworkaustralia.gov.au/

http://www.industry.gov.au/resource/Mining/NationalMineSafetyFramework/Pages/default.aspx

http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/safety-alerts

http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/publications

http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/safety-and-health/mine-safety-update

http://www.resourcesandenergy.nsw.gov.au/miners-and-explorers/new-mine-safety/publications/mdg/1000

http://legislation.nsw.gov.au/

https://www.nhvr.gov.au/



1. Strategies, Policies, Objectives and Targets

AS 4801: 2001

4.2 WHS Policy

COR Policy Drug and Alcohol Policy Smoking Policy Communication, Consultation, Coordination & Cooperation Policy Risk Management Policy Bullying Policy Fitness for Work - Fatigue Policy

4.3.3 Objectives and targets

Support documentation

WHS Policy Drug and Alcohol Policy Smoking Policy

COR Policy Fitness for Work - Fatigue Policy Communication, Consultation, Coordination & Cooperation Policy

Issue Resolution Risk Management Policy

Bullying Policy Return to Work – Rehabilitation Policy

Operating Approval Conditions

A condition of the NSW Government Department of Planning approval to operate Blakebrook Quarry is to ensure that a copy of any approved strategies/plans/programs required under the approval are made publicly available on the Lismore City Council website. NRQA are also required to make a summary of any monitoring results, to update them on regular basis (six monthly) and to make these publicly available on the Council website. Following website displays the most recent plans and monitoring results.

Refer: http://www.lismore.nsw.gov.au/cp_themes/default/page.asp?p=DOC-RAI-45-38-11

Policies and Objectives

It is the policy of our organisation to conduct our business in such a manner that includes proper consideration for safety, health and welfare in everything we do. Our conduct must include compliance with all safety legislation – Mine Safety, Work Health and Safety and Chain of Responsibility. Throughout this document health and safety includes compliance matters arising under Mine Safety, Work Health and Safety and Heavy Vehicle and hazards on site or associated with the chain of responsibility off site.

In striving for continuous improvement in our safety performance we will:

Provide safe and healthy systems of work for all our staff, contractors visitors and road users and construction sites that we supply;

Strive to identify all hazards to health, hygiene and workplace safety to eliminate hazards or control them in the best practicable manner;

Hold all levels of management accountable for health and safety matters in their areas of responsibility. We further recognize that each employee has direct and legal responsibilities to follow practices that ensure their own health and safety and that of their fellow employees and people included in the chain of responsibility;

Train employees in health and safety issues affecting their work;

Monitor and measure our safety performance;

http://www.lismore.nsw.gov.au/cp_themes/default/page.asp?p=DOC-RAI-45-38-11



Regularly review work areas, management systems and practices to improve health and safety in our organisation.

These objectives summarise the commitment of zero harm to people and continual improvement in all aspects of Northern Rivers Quarry and Asphalt activities.

Everyone is encouraged to carry the safety commitment from our workplace to their homes in order that its influence and example benefit those who are important to us. There is no task we undertake that is so urgent that we cannot take the time to find a safe way to do it.

Policies applicable to the IMS are referenced under: Sect. 1 Strategies, policies, objectives and targets/Support documentation. Documents are available at induction, displayed on site or made available to interested parties on request.

Objective Target Measurement

IMS Legal & regulatory compliance

Mines, WHS / HVN legislation

100% compliance Annual compliance audit

AS 4801 Compliance Zero major non-conformances Internal/External/Council Audits – annual review

RMS NSW Contract compliance Zero major non-conformances Internal/External/Council Audits – annual review

Management commitment to comply and improve

Improvement projects – at least one identifiable improvement initiated per manager

Annual: Improvement initiatives directly measurable to IMS systems compliance &/or improvement

Performance measurement & monitoring undertaken

- internal audits

- inspections

Safety performance measures in place & undertaken

Outcomes of measurement/monitoring reviewed for compliance acted on – measured 6 monthly

Trained, competent workforce Personnel training needs known & delivered

Performance reviews - annual

PD – quals/competency met

PD – licences/permits current

Task observations

Safety and

Chain of Responsibility

Risk management – HIRAC process

R/A, SWMS &

Zero harm LTI / MTI / measured continuously

Safety culture Safety culture evidenced in tool box meetings

Investment in training

No. of & attendees at meetings – measured 6 monthly

Inductions & awareness

Manager Commercial Services ( Commercial Services Coordinator ( Employee Representative

(Date) (Date) (Date)



2. Regulatory and Standards

AS 4801: 2001

4.3.2 Legal and other requirements

Support documentation Hard copy folders retained in Quarry office

Always confirm hard copy currency via website links below

Standards and Regulatory Matters

Legislation – Safety on Site

The regulatory authorities to which Northern Rivers Quarry and Asphalt are the Mine Safety Branch of the NSW Department of Industry (Mine Safety) and WorkCover NSW. The Department acts for WorkCover NSW on quarry sites as they are the primary body for managing mine safety.

Access the following websites for current legislation and information.

Dept of Industry www.resourcesandenergy.nsw.gov.au

Mine Safety Design Guides


Quarry Safety Alerts


Quarry Publications


Quarry Updates/Bulletins


WC www.workcover.nsw.gov.au

Codes of Practice http://www.workcover.nsw.gov.au/lawpolicy/codes-of-practice/Pages/default.aspx

Mine Safety Design Guidelines are the essential criteria to be met for all quarry infrastructure and process matters. Guidelines must be referred to when any new development or changes to current quarry systems and infrastructure are made or intended to be made.

Mines and WHS Acts and regs plus supporting codes of practice are held as hard copy and electronic for office use. The Quarry Manager reviews annually for compliance.

Always access the direct website for the most current information and confirm hard copies are current versions. Bulletins and Safety Alerts should be printed and displayed on notice boards and also tabled at safety meetings. Also note when Bulletins and Safety Alerts are issued, please refer to the Mine Safety Design Guide website link for current requirements.

Additional to NSW legislation and support material, Safe Work Australia has developed model Work Health and Safety (Mines) Regulations in cooperation with the National Mine Safety Framework (NMSF) Steering Group to be included in the model WHS Regulations. Once these regulations are finalised it is intended they will be progressively implemented by the jurisdictions.

http://www.resourcesandenergy.nsw.gov.au/







http://www.workcover.nsw.gov.au/

http://www.workcover.nsw.gov.au/lawpolicy/codes-of-practice/Pages/default.aspx

http://www.ret.gov.au/resources/mining/framework/Pages/default.aspx

http://www.ret.gov.au/resources/mining/framework/Pages/default.aspx



For further information go to:

Safe Work Aust http://www.safeworkaustralia.gov.au/sites/swa/model-whs-laws/public-comment/pages/draft-model-whs-regulations-and-cop-for-mines-public-comment

NMSF http://www.industry.gov.au/resource/Mining/NationalMineSafetyFramework/Pages/default.aspx

Legislation – Safety Heavy Vehicle

The National Heavy Vehicle Regulator administers the Heavy Vehicle National Law (NSW) with RMS NSW being the enforcement agency in NSW. Internal controls in place or to be developed include:

Mass Management

Load Management

Route Selection and Plans

Scheduling Procedure

Fatigue Management Plan (this needs to be updated for COR)

Changes to contract or regulatory matters

Review of Quarry Plans and update as required. Communications, consultation and training as a result of the need for change occurs at this time.

http://www.safeworkaustralia.gov.au/sites/swa/model-whs-laws/public-comment/pages/draft-model-whs-regulations-and-cop-for-mines-public-comment

http://www.safeworkaustralia.gov.au/sites/swa/model-whs-laws/public-comment/pages/draft-model-whs-regulations-and-cop-for-mines-public-comment

http://www.industry.gov.au/resource/Mining/NationalMineSafetyFramework/Pages/default.aspx



Australian Standards

Australian Standards set out the specifications and provide minimum requirements for selection, maintenance, construction and safe operation for a broad range of equipment and work practices in compliance with industry and legislative standards.

Standards are legally binding if referenced by legislation and when incorporated into a contract, purchase order or agreement entered into by NRQA. The following indicative list outlines the broad standards applicable to the quarry activities, not including the NATA related laboratory standards. For these standards, refer to the Laboratory Manual.

Reference No. Standard Name

AS 1418.8 – 2008 Cranes, hoists and winches – Special Purpose appliances

AS 4024.3610 Safety of machinery - Conveyors – safety requirements

AS 1657-2013/Amdt 1 Fixed Platforms, walkways, stairways and ladders

AS 2467 - 2008 Maintenance of electrical switchgear

AS 1674 Set 2007 Safety in welding and allied processes Part 1: Fire Protection

AS 1674 Set 2007 Safety in welding and allied processes Part 2: Electrical

AS 4457.1 – 2007 Earthmoving machinery – off the road wheels, rims and tyres – maintenance and repair Part 1: Wheel assemblies and rim assemblies

AS 4457.2 – 2008 Earthmoving machinery – off the road wheels, rims and tyres – maintenance and repair Part 2: Tyres

AS 2187 Explosives – Terminology

AS 2187.1/Amdt 1 – 2000 Explosives – Storage, transport and use Part 1: Storage

AS 2187.2 – 2006 Explosives – Storage, transport and use Part 1: Use of explosives

AS 2865 - 2009 Confined Spaces

AS 3007 - 2013 Electrical equipment in Mines & Quarries - Surface Installations & associated processing plant

AS 4509.1 - 2009 Stand-alone power systems - Safety & installation

AS 4024.1 SERIES 2014 Safety of machinery - Terminology - Terms and definitions

AS 3190-2016 Approval and test specification - Residual current devices (current-operated earth-leakage devices)

AS 3760 - 2010 In service safety inspection and testing of electrical equipment

AS 3100 - 2017 Approval & Test Specifications - General Requirements for Electrical Equipment

AS/NZS 4801 - 2001 Safety Management System - Requirements



3. The Integrated Management System [IMS]

AS 4801: 2001

4.1 General requirements

4.4.4 Documentation


IMS Manual Mine Safety Management Plan Emergency Management Plan

Blast Management Plan

Structure of the IMS Systems

The documented system forming the IMS is represented in the following structure:

Lismore City Council policies and protocols applicable to the NRQA are those overarching documents applicable to the whole of the organisation.

NRQA Manuals and Plans

These are the core documents that form the basis of the management of the quarry and support services.

The IMS Manual is the reference document capturing the primary facets of the Northern River Quarry and Asphalt operations. The IMS Manual references AS 4801 plus mine safety management planning.

Plans are developed from the IMS Manual and in compliance with recognised legislative and product/service needs. The Blast Management Plan is the core supporting plan to the MSMP.

Other Documents

Risk management processes, all other procedures, forms and templates pertinent to the NRQA systems and plans are referenced throughout the plans.

Lismore Council

NRQA Manuals and Plans

NRQA Quarry Risk Management

N RQA Quarry Products NRQA Aggregale Prod ucts

NRQA Procedures - General NRQA Forms and Templales

Reference Material Lat>oratory I nfonnation



4. Document and Records Management

AS 4801: 2001

4.4.5 Document and data control

4.5.3 Records and records management


LCC Written Communication Guide Lismore City Council Policy - Plain English Policy

Document and Data Control - General

The following Lismore City Council Written Communication Guide general protocols apply:

Every document shall have a plain English name – on front page and footer where practical

Page numbering – use Page 2 of 2 or Page 2.

Dates – DD/MM/YYYY – this may act as a version control or an alternative version number may be used

Refer to sample signature block for emails Page 36 LCCWCG.

Retention of copies of documents and records

TRIM is the repository for corporate truth data, no copies of documents, once finalised, held within TRIM shall be held elsewhere.

The NSW State Records Act 1998 requires public officials to make and keep full and accurate records of their business activities.

The NSW Public Sector Code of Conduct require public officials maintain adequate documentation to support any decision made in the performance of their duties.

The Ombudsman’s Good Conduct and Administrative Practice Guidelines for Public Authorities states that public officials must make and create records to support accountability and corporate memory.

Refer to Page 39, LCCWCG for a list of documents/records to be held in TRIM.

Such records include, but are not limited to:

Safety performance – all aspects of safety performance related to NRQA activities

Plant and equipment records including maintenance, calibration, inspection and testing

Staff and contractor records as stipulated for employment and as per subcontractor agreements

All emergency situations including incidents and investigations, first aid, injuries and others as stipulated in the various plans.

Objectives and targets monitoring and measurement

Records of meetings related safety.

Records retention period:

Safety – 10 years unless designated longer by legislation.

Personnel - work history plus 7 years unless health surveillance occurs, then 45 years.



5. Resources Provision and Management

AS 4801: 2001

4.4.1 Structure and responsibility

4.4.1.1 Resources


Position Descriptions – refer LCC people Services Dept.

Mine Safety Management Plan assessment

Northern Rivers Quarry and Asphalt Induction

Contractor Management Procedure Position Descriptions Customer/Driver Induction

Crushing Plant Inspection Checklist Material Safety Data Sheets Preferred contractors list

Asphalt Plant Inspection Checklist Risk Assessment Form Visitors Registration form

Registers – plant/equipment/chemicals

Fitness for Work Policy

Immunisation and Health Surveillance Program

Pre-Employment Functional Assessment

Health & Fitness Monitoring Program

Heavy Vehicle daily checklist Driver fit to work checklist

Organisational Interfaces

COMMERCIAL SERVICES Operating Structure December 2016

Commercial Servlce~anager Phil Klepzlg



Responsibility and Authority

All employers are required under the WHS (Mines) Act 2013 and Mines Regs 2014, and the Work Health & Safety Act 2011 to ensure the health and safety of all people at the site

These Acts and Regs hold employers accountable for the health and safety of their employees while at work.

All parties in the supply chain are required to ensure that they do not by their actions or inactions breach the HVN Laws to ensure the safety of all people that might be affected by heavy vehicles.

These Laws hold all parties in the chain of responsibility accountable for their actions as the transport operator, consignor, consignee, loaders, unloaders, packers, schedulers. This extends to include the supervisors, managers and executives who are responsible for the people that undertake these tasks (whether included in the position description or not). Accordingly the commitment to chain of responsibility extends to the health and safety of people on our sites and travelling to or from our sites or undertaking heavy vehicle activities to or from third party sites.

Employees also have a legal obligation to carry out their duties in a safe and proper manner in conjunction with procedures laid down by the employer.

Title Primary Role Additional Responsibilities

Commercial Services Manager

Sets and provides the directions, standards and framework for the safe operation of the quarry

Overall responsibility for the deliverables of the IMS including legislative compliance

Provide clarity of expectations and commitment

Consistency with compliance and safety needs

Ensure people can comply with the requirements

CoR management implementation (all aspects)

Commercial Services Coordinator

Responsible for the achievement of compliance of the site by, with the Commercial Services Coordinator having the ultimate responsibility

Delegated responsibilities for implementing and managing the IMS

Annual review of this document

Ensuring Policies and Procedures are in place, known, understood and followed

Establishing risk prevention and reduction strategies

Managing improvements and corrective action programs

Providing leadership in fostering a positive, safe and productive culture

Allocate staff and resources as necessary to achieve the program

CoR compliance (all aspects)

Reporting on CoR communication between project management and offsite senior management through weekly meetings.

Appropriate training is provided to employees re WHS and CoR requirements

Supervisors/Team Leaders

Ensure that the quarry operates so as to ensure the safety and health of all persons on the site.

Supervision responsibilities of activities under their control

Develop positive team commitment to safe work practices

Ensure a balance of production/safety focus in everyday operations

CoR compliance (all aspects)

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Subcontractor Management

Subcontractors are appointed through the Lismore City Council contractor approval process and managed through the NRQA Contractor Management Procedure.

The Quarry Operations Coordinator determines contractor compliance with the NRQA systems through review of their safety management plan and safety performance. Once qualified, the contractor is placed on the preferred contractors list and may be given opportunity to undertake work for the NRQA.

Contactors must complete the Commercial Services Contractor Permit to Work depending on the nature of works to be undertaken. Contractors shall be inducted into the NRQA site using the Contractor Induction Checklist or, for the purposes of driver/visitors the Visitor/Driver Induction Checklist is used.

Heavy vehicles and drivers on site (inbound or outbound) will be assessed for compliance with NQRA including:

Driver Licence – currency

Other licences required for the Task (high risk, plant, etc) – currency and/or evidence of competency

Record of heavy vehicle daily checklist

Record of driver work and rest hours

Availability of driver hours and nominated delivery process (route, times, slots, etc)

Load plans for plant and equipment

Load Mass requirements

Load Dimension requirements

Route Plan

Maintenance

Site conditions

Currency of approvals (vehicle registration, driver licence, whitecard, high risk licence)

These records will be maintained by the NQRA,

The Production Supervisor defines scope of works (including production and delivery) ensuring an initial risk assessment is conducted to manage operational risk. This role also controls persons entering the site under level 1 induction and completes level 2 and 3 onsite inductions.

The contractor has an obligation on receiving a work order to undertake an initial risk assessment of the scope of works to ensure it is safe to proceed. This process is documented and provided to the Production Supervisor for review and approval.

Supervision of works is managed by the Quarry Operations Coordinator with delegations to the Production Supervisor. Works are inspected at contract completion or stages of completion according to scope of works.

Customer/Driver Induction

This induction checklist is to be used for the induction of persons entering Northern Rivers Quarry & Asphalt for the purpose of obtaining or purchasing goods. This induction is to compliment the Work Health & Safety Regulations and Safety Instructions of Northern Rivers Quarry & Asphalt, NRQA.

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PHYSICAL RESOURCES RESPONSIBILITIES - PLANT AND EQUIPMENT, HEAVY VEHICLES AND TRAILERS

Plant and vehicle registration and maintenance is managed through the Lismore City Council Workshop.

Purchase of New plant and vehicles

Prior to purchasing new plant and equipment that will be available for transport and new heavy vehicles or trailers, there will be an assessment of the suitability of the asset and asset’s the ability to meet load placement, mass, dimension and load restraint requirements as part of the NQRA operations

New plant

Upon purchase maintenance requirements are determined according to the need for daily prestart and shutdown checks, periodic maintenance according to calendar and usage triggers as determined by the manufacturers recommendations. A plan is developed for the plant/equipment and included in the overall maintenance planning of the workshop along with daily requirements from operators.

Load plans (or load guidance) will be developed to ensure proper placement and load restraint for the heavy vehicle and trailer combinations. As required the load placement will be validated through use of the weigh bridge.

Communications and training of operators and maintenance personnel is undertaken accordingly.

Maintenance Plan

A maintenance plan is managed by the workshop in conjunction with NRQA management and operators to ensure plant remains fit for purpose.

Daily checks

According to need, plant daily start up checks are undertaken by operators and issues of maintenance or the need for immediate repair is flagged. This is then communicated to maintenance personnel for action. Daily checks include safety aspects as well as operational fit for purpose checks.

Aging Plant

As plant ages the maintenance program shall be reviewed and the need for additional maintenance or increased frequency of maintenance shall be considered in consultation with operators and manufacturers as necessary.

Other equipment subject to safety controls includes:

Lifting Chains and Slings - Lifting equipment calibration and checks

Electrical leads – electrical safety checks

Pressure Vessels – registration and checks as per requirement

Fire Fighting Equipment - periodic check

First Aid Facilities - periodic check

Air conditioners - periodic check and maintenance

Registers are kept on file in the weighbridge.



Hired Equipment

Hiring in of mobile plant on long term hire shall be undertaken through tender process. Lismore City Council shall take control of the maintenance for long term arrangements. Short-term arrangements on a needs basis requires equipment to be maintained by the hire company.

Utilisation

Prior to movement of plant, equipment and materials, assessments will be made to ensure the load

is compliant with road access conditions or requirements and that the preferred route is selected and advised to the heavy vehicle driver.

Safety Aspects – Plant and Equipment Operations

General

Machines must be stable and secure with all moving parts properly guarded.

The blades on power driven saws and similar equipment must be properly guarded.

Controls must be accessible and properly labelled. In particular, ensure that emergency stop buttons are fitted to all power driven machinery.

Where excess dust is generated, extraction and collection systems should be installed and maintained.

Power driven machinery shall be serviced and maintained as per any applicable maintenance service requirements or standards.

Noise generated by plant and machinery shall be kept to a minimum through purchasing control and good design techniques (note the national standard of 85 dB(A) should be applied when purchasing new equipment).

Conveyors must be fitted with emergency stop systems and guarded in accordance with AS 4024.3610 ‘Safety of Machinery - Conveyors – Safety Requirements’.

Guarding of nip points on all movable parts is a requirement of plant regulations and must be undertaken in accordance with AS 4024.3610 ‘Safety of Machinery - Conveyors – Safety Requirements’.

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Emergency Stop Controls

Australian Standard 4024.3610 requires that conveyors be fitted with emergency stop controls.

Inaccessible conveyors which are 2.5m above ground or walkway levels should have emergency stop controls at ground or walkway level with no more than 100m spacings between emergency stop controls.

Conveyors closer than 2.5m from the floor or normally accessible walkways or platforms shall have emergency stop controls at spacings of no more than 30m or a pull wire/lanyard type stop control.

The pull wire/lanyard stop control is most appropriate for most situations as regardless of where a person is standing by the conveyor, he can usually reach the lanyard. In some cases the conveyor is used to raise material for a crushing, screening or stockpiling process.

In this case, provided less than 30m of the conveyor is below 2.5m above ‘access’ level, then one emergency stop button is adequate.

Where access is provided on both sides of a conveyor, stop controls are also required on each side. Emergency stop controls should also stop all downstream feed conveyors or processes.

Lanyards shall be supported at least every 4.5m. Breaking, slackening or removal of the lanyard shall automatically stop the conveyor. Emergency stop buttons must conform to the following:

Coloured red

Suitably and prominently marked

Readily accessible

Mushroom head latch in or lock in with manual reset.

Guarding

Moving machinery should be guarded to protect against the possibility on injury. The guards must be fixtures of the machinery, interlocked where possible, or needling tooling for removal. ‘Interlocked’ means the removal of the guard preventing the equipment from running or being started.

Appropriate clothing should always be worn when working with this equipment. Loose clothing, long hair and jewellery easily become caught in the moving parts of machinery.

Machine/conveyor guards can range from a simple wire mesh cover, to a complicated system preventing access through physical locks and/or electrical interlocks. The problem with guards is that, if they are poorly designed and make the operation or maintenance of the machinery difficult in any way, employees will remove or override them.

Guards fitted to new machinery and in-house built guards are commonly found to be inadequate, particularly in respect to their design specifications, eg. holes in mesh large enough to still allow access to the hazard.

With regard to the legislation there is no specific requirement which says that a machine or conveyor must be guarded in any particular way. It is just required to be “effectively guarded”. If the guard can be removed or overridden for employee convenience the machine is not considered to be effectively guarded.



Where guards are fitted in the vicinity of the moving parts, mesh size and reach distances must be considered (refer AS 4024.3610).

Live Access – Moving/starting during maintenance

In certain circumstances movement of machinery may be needed during maintenance. Live access procedures should be followed at all times.

The person in charge of maintenance must ensure all staff are in a safe position, and tools and locks are removed.

Warning devices should be sounded.

When movement is completed (even temporarily) ensure that power is switched off, and the machinery is locked out again.

No work is to begin before the all clear is given by the person in charge.

Isolation – Plant and equipment

Isolation and/or “lock-out” procedures are closely associated with machinery guarding.

Whenever a guard is to be removed from a machine or conveyor, specific procedures must be in place to ensure that the machine/conveyor cannot be started while a person is working on the unguarded hazard.

These procedures can incorporate a combination of:

Interlock switches on the guard

Isolation and locking or tagging procedures on the switches

Standard written isolation procedures

Written “Special Circumstances Procedures” (where the machine/conveyor may have to be run for testing or adjusting without the guard being operative).

Interlocks may in some instances prove impractical as they frequently fail in the harsh conditions of a quarry environment, and further more, they can be quite easily overridden, either intentionally or unintentionally.

Mobile Plant – Under and Overhead Power Lines

The operation of mobile plant under or in the vicinity of overhead power lines is potentially dangerous. Overhead conductors shall be installed to provide clearance from the tallest vehicle or machine of:

Not less than 1 metre for 650V max cables

Not less than 1.5 metres for 33kV max cables

Not less than 2 metres for 66kV max cables



Not less than 6 metres for 275+kBV cables

Lower clearance may be allowed under special circumstances where the movement of the vehicle or plant is supervised by a competent person and where the vehicle or plant does not remain stationery or work under the overhead conductors.

Material should not be stockpiled or pushed up by equipment close to power lines. Remember to allow for full extension of booms and maximum tray height.



LADDERS, STAIRS, PLATFORMS AND WALKWAYS

Walkways and Platforms

There are specific requirements that apply to walkways and platforms:

The minimum clear width of any walkway should be 550m.

Walkways and platforms should be fitted with guard railings of between 900mm and 1.1m in height.

Toe boards of at least 100mm should be fitted to elevated walkways or platforms.

Walkways with an angle of between 7 and 20 degrees should be constructed of expanded metal mesh or cleated. Where the angle exceeds 20 degrees, steps with landings should be installed.

Elevated walkway and platform floors should be slip resistant, even and be designed so that objects cannot fall through to the area below. Gaps in metal plates should not exceed 100mm.

Stairways

Stairways should be constructed as follows.

Have a minimum clear width of 600mm.

An angle of between 26.5 and 45 degrees.

A rise of no less than 150mm and no more than 215mm.

A going of no less than 215mm and not more than 305mm.

Have an actual tread depth of at least 10mm greater than the going.

All stairs must be fitted with a handrail between 800 and 1000mm when measured from the nosing of any tread. Stairways greater than 1000mm in width must be fitted with a handrail to both sides.

Ladders

Ladders are used throughout the workplace as:

Fixed ladders (rung and step)

Single ladders (portable metal/timber)

Extension ladders (portable metal/timber)

Step ladders (portable metal/timber)

Portable ladders should comply with Australian Standards:

AS 1892.5 section 3– Portable Ladders – Metal

AS 1892.5 section 5– Portable Ladders – Timber

Fixed ladders

Fixed ladders and their installation should comply with the requirements of Australian Standards 1657 ‘Fixed Platforms, Walkways, Stairways and Ladders’.



Rung Ladders

Angle of slope between 60 and 75 degrees, although rung ladders go beyond 75 degrees to 90 degrees, these are not in breach of the standard. Ladders with a slope of greater than 75 degrees are not universally accepted and the need for a vertical ladder should be reviewed.

The ladder shall not be less than 375mm wide and not more than 525mm wide.

Rungs should be spaced no less than 250mm and no more than 300mm apart, except in ladders shorter than 1.5m, where the minimum spacing may be 200mm. All spacings must be equal.

Rungs shall be of solid material not less than 20mm diameter.

Where the ladder provides access to a platform or walkway, the styles of the ladder shall extend no less than 900mm above the opening. The width between the extended styles should be no less than 525mm and the top rung should be level with the landing.

Where a person may fall 6m or more, a ladder cage should be fitted or the ladder have a fall protection safety device installed. Access to ladders where safety devices are provided should be restricted to authorised personnel.

The clearance behind ladders affixed to walls etc, shall be no less than 200mm.

Timber ladders shall not be used in situations where they are constantly exposed to weather or other conditions likely to promote decay.

Step Ladders

Angle of slope between 60 and 70 degrees.

Minimum clear width of 450mm.

Treads shall be no less than 100mm deep and multi-rung treads are not acceptable.

The rise should not be less than 200mm and not more than 250mm.

The vertical distance between and landings should not exceed 6m.

Where a person can fall more than 6m, the ladder system should be enclosed.

Portable Ladders

The top three rungs should not be stood upon when using the ladder.

All ladders should be “tied off” at the top to prevent them slipping down or off, or sliding along, supporting structures.

When a ladder is being used to gain access to work platforms, mezzanine floors or the like, they must extend at least 1 metre above the platform or landing.

Ladders should have a secure non-slip feet fitted.

When placing a ladder for use it should always be at a slope of approximately 1 in 4 (75o), eg. 1 metre out from the wall for every 4 metres up

Damaged ladders should be removed from service and tagged or preferably destroyed



Physical Resources Responsibilities – Hazardous Chemicals [incl. blasting]

Northern Rivers Quarry and Asphalt is committed to eliminating or minimising exposure of workers, visitors when handling, using and storing hazardous substances and dangerous goods.

The Quarry Operations Coordinator and Production Supervisor shall manage and monitor the purchasing, storage, use and disposal of hazardous substances and dangerous goods in consultation with workers. They shall ensure through operational management that workers do not exceed exposure standards.

Workers are responsible for complying with instruction on the management of hazardous substances and dangerous goods and ensure controls are used to enable the safe handling and storage.

Chain of Responsibility – Mass

Northern Rivers Quarry and Asphalt is committed to eliminating over mass vehicles from its roads. All materials, plant and equipment leaving the site will be weighed using the weigh bridge to ensure compliance with the HVN Law or an approval under that law.

Where a non-conformance is detected:

excess material will be tipped off

plant and equipment will be either moved or loaded onto an appropriate combination

an approval will be obtained

A non conformance will be raised in the IMS software system and automatic emails generated to notify relevant stakeholders including management and RMS Principle Authorised Representative within two days.

Chain of Responsibility – Dimension

Northern Rivers Quarry and Asphalt is committed to eliminating unnecessary over dimension vehicles from its roads. All materials, plant and equipment leaving the site will be assessed for dimensions to ensure compliance with the HVN Law or an approval under that law.





Chain of Responsibility – Load

Northern Rivers Quarry and Asphalt is committed to ensuring safe loads on vehicles on its roads. All materials, plant and equipment leaving the site will be loaded to NQRA load plan so that the load can be safely transported and unloaded.







Chain of Responsibility – Unload

Northern Rivers Quarry and Asphalt is committed to ensuring safe unloading of vehicles on its sites. All materials, plant and equipment arriving on site will be unloaded to NQRA SWMS so that the load can be safely unloaded.


unloading is to stop, until a competent NRQA person can review the load and the possible unloading strategy

unloading will be at the direction of the nominated NQRA person

a non-conformance will be raised and directed to the external party

Chain of Responsibility – Load Restraint

Northern Rivers Quarry and Asphalt is committed to ensuring safe loads on vehicles on its roads. All materials, plant and equipment leaving the site will be restrained to NQRA load plan so that the load can be safely transported and unloaded.



suitable load restraint will be used



Chain of Responsibility – Load Unload Exclusion Zones

Northern Rivers Quarry and Asphalt is committed to eliminating or minimising exposure of workers, visitors when on site. The site plan sets out permanent exclusion zones.

No person is to approach moving vehicles on site. UHF channels have been designated for communication.

A non conformance will be raised in the IMS software system and automatic

emails generated to notify relevant stakeholders including management and RMS Principle Authorised Representative within two days.

Chain of Responsibility – Maintenance

Plant and vehicle maintenance is managed through the Lismore City Council Workshop to current asset management standards.

Chain of Responsibility – Route

Northern Rivers Quarry and Asphalt is committed to ensuring safety on its roads. All materials, plant and equipment leaving the site will have a nominated route, task can performed safely for all road users.




the relevant parties, scheduler, route manager, driver etc will be interviewed to determine the basis for non-conformance

the relevant documents will be updated


Chain of Responsibility – Scheduling

Northern Rivers Quarry and Asphalt is committed to ensuring safety on its roads. All materials, plant and equipment leaving the site will have been assessed for appropriateness of the schedule (and/or nominated departure and arrival times and transit times) so that task can performed safely for all road users and people on a site.


the relevant parties, scheduler, route manager, driver etc will be interviewed to determine the basis for non-conformance



Chain of Responsibility – Speed

Northern Rivers Quarry and Asphalt is committed to ensuring safety on its roads. Our trucks are fitted with speed limiters and GPS coupled with telemetrics to identify driving habits and to flag any non conformance .


the relevant parties, scheduler, route manager, driver etc will be interviewed to determine the basis for non-conformance.



6. Training and Competencies

AS 4801: 2001

4.4.2 Training and competency


Contractor Management Plan TRIM Induction records Operator Competency Assessment Sheets

Annual performance reviews



General

Lismore City Council provides a staff development program for employees. Staff are subject to annual performance reviews using the LCC procedure. This is further enhanced by NRQA activities including inductions and competency assessment.

Training needs are identified:

When workers initially commence work with NRQA

As a regulatory requirement

When developing Safe Work Method Statements or undertaking risk assessments

When new equipment is being introduced

At the request of a worker

At an annual review of resource requirements

Licences and permits to undertake specific tasks including mobile and fixed plant operations will form part of both the annual review and specific planning needs.

NRQA inductions are undertaken for all persons entering the site specific to their role on site.

Training, whether in-house or externally provided, shall be reviewed to determine whether:

Content of the program meets the needs of the audience,

Content of the program includes regulatory compliance,

trainer was informative and presented material well,

Trainee feels competent to undertake the assigned task, and

Managers are confident the trainee was provided with sufficient knowledge and understanding.

The outcome of the evaluation review will be taken into account when reviewing future training.

General Contractor Inductions

Contractors visiting the site must undertake a site induction, and complete a Contractor Induction Form which is then filed in a Contractors Register.

Each contractor’s induction is valid for a period of 12 months, after which time a fresh induction must be carried out.



Contractor management also includes:

Contractor Register held in Statewide Mutual CIMS database

Risk Assessments pertinent to work to be undertaken are reviewed and contractor signs off.

Permits to Work are included in this process.

Risk Assessment Register TRIM: Risk Assessment Folder: Permit No/Contractor person name/ Company/ Work commence date/ Task/ Equipment to be worked on & location/ Work completed date/Reference to Permit to Work.

Driver and Visitor Inductions

This induction checklist is to be used for the induction of persons entering Northern Rivers Quarry & Asphalt for the purpose of obtaining or purchasing goods or services including those having an element of transportation services. This induction is to compliment the Work Health & Safety Regulations and Safety Instructions of Northern Rivers Quarry & Asphalt, NRQA.

Visitor / Driver Induction checklist used, signed off when completed and filed.

Driver licences etc photocopied and retained in hard copy file

Register of persons inducted maintained on TRIM.

Operator Competencies

Operational competencies are key to work safety on the NRQA site.

Practical assessment of competency for plant and key skill requirements shall be undertaken for all new or existing worker abilities to operate plant in a safe and effective manner.

Assessment shall be undertaken by the Quarry Supervisor (or designated person) who maintains licenses or competency and has extensive experience with the use of the plant or process.

Assessor to determine whether the worker is competent to operate the plant or process on the results of this assessment.

If areas of competency are not achieved and are considered high risk, the worker will require retraining and assessment. If considered low risk, the assessor shall provide immediate training and reassess the worker’s competency.

Load Shifting Equipment Competencies

Operators of particular types of mobile plant, load shifting equipment, must obtain a “Notice of Assessment” from a Registered Assessor if they have not had prior operating experience on the appropriate piece of equipment.

Load shifting equipment is mobile plant that is used to move material of any sort, be it rubble, or any other product or substance etc.

The National Guidelines for Work Health and Safety Competency Standards for the Operation of Load shifting Equipment and Other Types of Specified Equipment [NOHC:7019(1992)], lists the types of plant where an operator must be assessed as competent. This should be read in conjunction with Schedule 3, WHS Regulation 2011 (National).



Electrical Services Supplier Competencies

NRQA shall have an appropriate electrical qualified contractor to ensure that:

Electrical installations and electrical plant for which the total connected power at the operation exceeds 1,000kW, or for which high voltage is utilised, are designed and periodically reviewed by a qualified electrical engineer, and (b) installation, commissioning, maintenance and repair of all electrical installations and electrical plant (other than extra low voltage automotive plant or electrical plant fed via plug and socket outlets operating at a voltage no greater than 240V) are undertaken or supervised by a qualified electrical tradesperson or qualified electrical engineer, and

Installation, commissioning, maintenance and repair of extra low voltage automotive plant or electrical plant, fed via plug and socket outlets operating at a voltage no greater than 240V, are undertaken by a competent person or a person supervised by a qualified electrical tradesperson or qualified electrical engineer. This is the current procedure at NRQA.

NRQA shall co-operate with an electricity supply authority (has the same meaning as in the Electricity (Consumer Safety) Act 2004) to ensure the health, safety and welfare of persons undertaking maintenance of an electricity supply authority’s infrastructure at a mine.

The electricity supply authority “Country Energy” was consulted in the preparation of this MSMP, particularly in relation to the supply authorities High Voltage power lines feeding the NRQA site, and power disconnection in case of an electrical emergency.

Emergency Response Personnel

Onsite emergency responders roles require training in:

First aid

Operation of emergency equipment

Chemical users and handling certificates

Chain of Responsibility

NRQA will identify all people that will require training and or verification of competency across:

Load, Unload, Load Restraint

Driving a heavy vehicle

Awareness of Chain of Responsibility

Fatigue management



7. Consultation. Co-operation and Co-ordination

AS 4801: 2001

4.4.3 Consultation, communication and reporting

4.4.3.1 Consultation

4.4.3.2 Communication


Communication and Consultation Procedure

Toolbox Meeting Record Form General Meeting Agenda and Minutes – as per various meetings

Risk Management Forms – SWMS, Risk Assessments

Issue Resolution Guidelines Refer Blast Management Plan for communications when blasting

Communication and Consultation Arrangements

NRQA will consult with workers when:

identifying hazards, assessing risks and deciding on measures to control those risks

deciding how to control risks/aspects, workers who will be affected by this decision, shall be consulted.

This is typically when risk assessments are undertaken or through toolbox and other meetings.

Workers shall be given access to information such as technical guidance about workplace hazards/aspects and risks (plant, equipment and substances).

NRQA will communicate safety information to workers and external stakeholders and senior management offsite. This may include meeting minutes, legislation changes, policy and procedure updates, annual reports and significant incident and injury trends and information relating to WHS training and CoR compliance.

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Program of regular communication, consultation, coordination and cooperation

Toolbox Meetings are deemed to be a mechanism for communication and consultation, review and planning for workplace safety. They are also an opportunity for just-in-time training. A Pre-Work site toolbox meeting is conducted every morning before work starts, with the aim of focusing employees attention to any specific issues (particularly safety, environmental and product quality) affecting the operations. The meeting shall be run by the Quarry Operations Supervisor or Team Leader, documented on a Toolbox Meeting Record Form, and reviewed daily by the Quarry Manager.

The toolbox meetings also provide a formal method for employees to raise any issues they feel are relevant to the quarry operations, and have those issues addressed by the quarry management.

Information pertinent to the days activities, including WHS standards shall be disseminated.

MEETING/S Stakeholder Groups Frequency

Toolbox meeting – safety / COR / enviro Involved persons on the day including contactors

Daily – pre-start

Health, safety / COR / enviro meeting - Quarry

All Quarry personnel including contractors when on site

Monthly

LCC – health and safety / COR meetings H&S Rep attends At least Quarterly

Operations meeting H&S Manager/Rep

COR Rep

Quarry Production Supervisor

Lab Manager – asphalt & aggregate

Weekly

LCC Supervisor’s meeting Reps across the organisation

Commercial – water/waste

Roads

Finance

At least quarterly

LCC Continuous improvement meeting Reps across the organisation Annual

Minutes of meetings shall be hard copy on site and shall be scanned to TRIM at the discretion of the Production Manager.

PCBU and IMS Representative Co-operation and Coordination

The Commercial Services Coordinator is both the PCBU and the IMS Representative for NRQA.

Issue Resolution

The Lismore City Council Issue Resolution guidelines are used by NRQA for the management of a dispute requiring resolution. This guideline in used in conjunction with Safe Work Aust WHS Act Part 10 and Regulation Part 2.2



8. Risk Planning and HIRAC

AS 4801: 2001

4.3.1 Planning identification of hazards, hazard/risk assessment & control of hazards/risks

ISO 31000 Risk Management


Risk Management Procedure HAZID and R/A Form HAZID ID Reference

SWMS Procedure SWMS Form SWP Form

Laboratory Manual & Standards Plant Assessments Confined Space Entry Procedure

Electrical Safety Registers Chemicals Management Procedure Confined Space Permit

Electrical Safety Test Logs Chemical Register Hot Work Procedure

Height Work Risk of Fall Procedure SWP’s Hot Work Permit

Working at Height Permit Workplace Inspection Checklist

Blast Management Plan Blast: Risk Assessment Program Decontamination & maintenance of explosives handling equipment

Definitions

Hazard Anything (including work practices or procedures) that has the potential to harm the health or safety of a person

Hazard Identification The process of recognising that a hazard exists and defining its characteristics

Risk The likelihood and consequence of potential injury or harm arising from a hazard

HIRAC Hazard identification, risk assessment and risk control process

Informal Risk Assessment (IRA)

An informal pre-work assessment tool provided by The Institute of Quarrying, that considers the tasks and work environment. This will help to identify potential hazards arising from the job, and any associated risks to personnel & property. If the job was to become a regular activity, the IRA would be further developed into a Safe Work Method Statement

Job Safety Analysis Breaks the job down into manageable steps to identify assess and control the hazards of non standard jobs or jobs that have no SWMS relating to it

Safe Work Method The technique or method devised to carry out a particular job that will eliminate or minimise the risks arising from the identified hazards of the job

Safe Work Method Statement (SWMS)

The final published safe work method for each type of job, listing the steps required to do the job, the potential hazards that could be encountered in each step, and the control measures incorporated into each step to ensure the safety of the persons carrying out the job

Policy A directive developed for the site

Procedure An established method of doing something, that is more general in nature and doesn’t have the same specific job risk, as a job that would require a SWMS e.g example a site First Aid Procedure



Safety HIRAC

Risk management is fundamental to safety legislation. The law prescribes the following in relation to NRQA activities:

Legislature Clause Obligations – Prescribed Hazards

NSW WHS (Mine & Petroleum sites) Reg 2014

S4. Obligation to control risk

An obligation to control risk to health & safety where it cannot be eliminated

Minimise risk to the lowest level reasonably practicable

S6 Regulation to be read with OHS Legislation

Obligation to assess & eliminate or control risk is in addition to & do not denigrate from the obligations of an employer under the WHS legislation

Part 3/Div 1 MSMP

MSMP provides the framework for HIRAC for reliable implementation & control

Part 4 Div 2 WHS risk assessments relating to prescribed hazards

Risk assessment takes into account such factors as relevant to the hazard [S35]

Ground instability risk takes into account such factors as relevant to the hazard [S36] – Only as it applies to above ground quarrying

Inrush of water, gas, rock etc risk takes into account such factors as relevant to the hazard [S37] – Not applicable to above ground quarrying activities, however flooding could occur during heavy rainfall

Use of conveyors & earth moving equipment risk takes into account such factors as relevant to the hazard [S39]

Fire & explosion risk takes into account such factors as relevant to the hazard [S40] – Only as it applies to above ground quarrying such as blasting

Handling of explosives risk takes into account such factors as relevant to the hazard [S41]

Electricity risk takes into account such factors as relevant to the hazard [S42]

Road design & construction risk takes into account such factors as relevant to the hazard [S43]

Part 4 Div 3 Documentation of R/A

The risk assessment process shall be documented

Risk assessments shall be documented and records kept

Part 5 Div 1 Risk Controls

Ground stability risk controls as prescribed [S46]

Inrush risk controls as prescribed [S47]

Explosives risk controls as prescribed [S55 - 57]

Fire & explosion risk controls as prescribed [S53]

Electrical safety risk controls as prescribed [S58 - 68]

Part 5 Div 2 Risk Controls – documented

The operator must ensure risk control measures relating to each prescribed hazard are documented and retained for the life of the control measure.

Part 5 Div 3 Risk Controls - areas

The operator must eliminate or control risks to health & safety through excavation activities as per [S76]

Part 6 Div 2 Working arrangements

Fitness for work program to be implemented for the health, safety and welfare of all persons employed at the site.

Drugs and alcohol prohibition

Part 6 Div 4 Working arrangements

Health surveillance of persons at work in relation to hazardous substances & other exposure risks. Records to be retained & made available [S 86 – 89].

WHS Act /Reg 2011

WHS Act Section 274 The Act and Regulation require persons who have a duty to ensure health and safety to ‘manage risks’ by eliminating health and safety risks so far as is reasonably practicable, and if not reasonably practicable to do so, to minimise those risks so far as is reasonably practicable.

Code of Practice How to Manage WHS Risks

The Act requires:

Worker consultation [S47/48]

Consultation, cooperation and coordination with other PCBU’s [S46]

Specific PPE o be used [Reg 44-47]

HVN Law https://www.nhvr.gov.au/files/201706-0564-fin-year-penalty-indexation.pdf

https://www.nhvr.gov.au/files/201706-0564-fin-year-penalty-indexation.pdf



To ensure compliance with the above, NRQA shall initiate a risk management program to eliminate wherever practicable workplace health and safety risk.

The program shall follow the typical Plan/Do/Check/Act PDCA cycle as recommended by regulators and ISO Standards in order to achieve continual implement in the elimination of risk.

Hazard Identification, Risk Assessment and Control - HIRAC Process

Legislation requires a systematic approach to the identification of hazards, the assessment (valuating) of risk levels, the implementation of control measures and review to ensure they are working as planned.

The five step process takes into account:

Step 1: Hazard identification

Step 2: Risk assessment

Step 3: Determine risk controls

Step 4: Implement risk controls

Step 5: Monitor and improve

Hazards may or may not be obvious e.g. broken earth-wire, a chemical, a gas, etc., or may be a potentially developing hazard e.g. worn brakes in vehicles, worn slings, ropes, hooks, clamps in lifting equipment.

The process must be documented and take into account the relevant the legislative requirements as referenced below.

PLAN – Resources & Review

Identify stakeholders & train personnel

Identify agreed HIRAC process, periodic review & improvement

method

DO - HIRAC

1. Identify HAZARDS in each step of process

2. Undertake risk assessment proof each hazard

3. Agree on risk control measures

CHECK - HIRAC

4. Confirm controls against legislation

5. Assign responsibilities & authorities to implement & monitor

6. Implement control measures

ACT – Implement & Monitor

Complete risk assessment & document SWMS

Monitor & test controls

Continually review for improvement – review planning process



STEP 1 Hazard Identification

It is primary responsibility of the employer (PCBU) in consultation with worker representation to identify hazards (safety) including high-risk work that occurs during quarry operations.

The Hazard Identification Process is undertaken by employing a mixture of the following methods.

Workplace Inspections incorporating the DPI General Workplace Inspection Checklist, conducted on a quarterly basis – this includes consideration of the “prescribed” risks detailed in the Mine Health & Safety Regulation 2007

General workplace inspections that are integral to the sites safety program:

- Mobile and fixed plant Inspection Checklists

- Equipment inspection checklist incl. electrical checks

- Emergency equipment checklists

- Pressure vessels and lifting, calibration equipment

Management/Employee Discussions (e.g. Toolbox Meetings, Safety Meetings, Job Planning Meetings)

Job Safety Analysis (normally limited to a single pre-selected work method or plant item)

Hazard and Operability Studies

Specialist technical inspections



Principle Hazards

Hazard identification shall take into account the following high-risk activities:

Hazard Categories Prescribed by Legislation

Other Common Hazard Categories

Conveyors MHSR Manual Handling

Electricity MHSR Lifting/Slings

Explosives MHSR Chemicals & other Dangerous Goods

Fire and explosion MHSR Compressed air or fluids

Ground Stability & Inrush MHSR Electromagnetic radiation hazards

Mine Road Design & Construction MHSR General Housekeeping

Earth Moving Machinery MHSR Lighting & Visibility

Structures & Buildings OHSR Machinery and tools

Confined Spaces OHSR Temperature hazards

Slips, Trips, Falls OHSR Moving Plant & Vehicles

Falling Objects OHSR Work Environment (Noise, vibration, dust, fumes

Working at Heights OHSR Work related stressors

Blasting - OHSR Drilling associated with blasting

Loading

Unloading

Load Restraint

Over Mass

Over Dimension

Maintenance

Speed issues

Fatigue issues

Airborne Dust contaminants



STEP 2 Risk Assessment

Risk assessments shall be undertaken of each identified hazard using the risk calculator as the indicator of ‘Likelihood’ (L) and ‘Consequence’ (C) levels associated with each hazard.

Note Mine H & S Reg 2014 NSW Part 4, Div 2 when calculating the risk assessment.

Part 4 Div 2 WHS risk assessments relating to prescribed hazards

Risk assessment takes into account such factors as relevant to the hazard [S35]

Ground instability risk takes into account such factors as relevant to the hazard [S36] – Only as it applies to above ground quarrying

Inrush of water, gas, rock etc risk takes into account such factors as relevant to the hazard [S37] – Not applicable to above ground quarrying activities, however flooding could occur during heavy rainfall

Use of conveyors & earth moving equipment risk takes into account such factors as relevant to the hazard [S39]

Fire & explosion risk takes into account such factors as relevant to the hazard [S40] – Only as it applies to above ground quarrying such as blasting

Handling of explosives risk takes into account such factors as relevant to the hazard [S41]

Electricity risk takes into account such factors as relevant to the hazard [S42]

Road design & construction risk takes into account such factors as relevant to the hazard [S43]

STEP 3 Risk Control

Identified hazards shall be addressed in terms of elimination or mitigation of safety risk. Those risks that have been assessed as being critical shall be addressed first. Likely affected workers to whom the hazard may apply shall be consulted as a part of this risk control process.

The hierarchy of controls shall be used to determine the best control options:

Ll ko llhood Co nsoquenco

L1 Almost Certa in C1 Cat astrophic Ll ko llhood

Expect to occur in mos t c ircumsta nces Dea th o r perma nent d isability Consequence

L2 Like ly C2 Maj or

Wi II proba bi)' occur sometime Serious injury or temporary d isa bility Catas trophic (C1 )

LJ Pou lble CJ Moderate

May occur som etime Medica l attention - Lost Time Inju ry Maj or (C2 )

L• Un li ke ly C4 Minor

C ou Id occur at so metime Firs t a id treatme nt o nly - Possible L TI Moderate (CJ)

LS Ra re CS Insig n ificant Mine r (C• I

Occurs only in exceptional c ircumstances First aid treatment o r less

Best Ellmlnal lon Con trof

Substitution

Isolation

Eng ineeri ng

Adm lnl&i rative Worst

Con tro t PPE

Ins ign ifica nt (CS)

Risk Ranking I Priority Ranking

Immediate Priority

I Med ium Risk 7-15 I Medium Priority

l ow Priority

"

la it possib!e to e liminate the hazard altogethe r?

Is it possible to replace the s balance or, equipment with something less haz.e rdo s?

la it possib!e to persons from inte racting witll the hazar-d e.g. Machine guarcl ing, re mote handling?

Action

Hard Controls Req uired

Take Immediate Action

Do Other R isks First

W here people have to interact w ith a hazard is it possible lo eng[nee r a less haza rdo s sol ion e.g. sta irs ins teed of a lad der, ventilation devices,

ref el machinery fro m the ground?

Is it possib!e to lesse n the expmmre or peopkl throllgh changing the way the job is done, rotating peep e through the job administrative contro ls such as training, high ris p-e rmlts?

Las t resort - Is PPE appro pria te lo lhe lype, le\lel of hazard a nd has it been selected correctly?



Note Mine H & S Reg 2014 NSW Part 5, Div 1,2 & 3 when determining risk controls

Part 5 Div 1 Risk Controls

Ground stability risk controls as prescribed [S46] – Only as it applies to above ground quarrying

Inrush risk controls as prescribed [S47] – Not applicable to above ground quarrying activities, however flooding could occur during heavy rainfall

Explosives risk controls as prescribed [S55 - 57]

Fire & explosion risk controls as prescribed [S53] – Only as it applies to above ground quarrying such as blasting

Electrical safety risk controls as prescribed [S58 - 68]

Part 5 Div 2 Risk Controls – documented

The operator must ensure risk control measures relating to each prescribed hazard are documented and retained for the life of the control measure.

Part 5 Div 3 Risk Controls - areas

The operator must eliminate or control risks to health & safety through excavation activities as per [S76]

STEP 4 Implement Risk Controls

Having agreed through consultation on the methods of risk elimination or risk control (risk reduction) the controls must be implemented with assigned responsibilities, resources provided, agreed methodology and within appropriate timelines.

As part of the implementation process, safe work method statements (SWMS) shall be developed. The SWMS includes a list of the steps required to carry out each job, a list of the hazards that may be encountered at each step, and the control measures to be used to help minimise the hazard.

Risk severity ratings are assessed before and after the controls are put in place, to help assess the effectiveness of the controls used.

Electrical Safety - Risk Controls

Electrical installations at the quarry comply with the requirements of AS 3007 & AS 3000. Audits to ensure compliance with the AS 3000 & AS 3007 are carried out on every 2 years as part of normal electrical maintenance schedule.

The following minimum standards apply:

All electrical work carried out on site is compliant with AS 3000 & AS 3007 & undertaken by fully qualified electrical contractors. Testing to these standards by a qualified/licenced operator is mandatory.

Residual Current Device protection (RCD), also referred to as an Earth Leakage Circuit Breaker (ELCB), is recommended for all general purpose 240v power outlets. It tools and equipment trigger an RCD unit, contact a qualified electrician for further advice.

Fixed RCD’s must be tested with the built in test facility every three (3) months, and at least once every three years in accordance with AS 3760.

Installed RCD’s set to protect machinery usually have too slow a shut off speed and too high a current setting to protect human life.

Fixed power driven machinery must be maintained in a safe operable condition and serviced on a regular basis. Any electrical repairs of maintenance must be carried out by a qualified electrician.

Never use any tool or machine if the power cord is damaged. Turn the power off at the main switch and remove the plug. Notify the Supervisor, who must ensure necessary repairs are completed before reuse. Ensure that power cords do not create a tripping hazard.

All electrical equipment must be effectively earthed unless of the “double insulated” or “all insulated” type.



Maintenance – General Risk Controls

All electrical works are subject to planned periodic inspection and maintenance to prevent impairment through wear and tear.

Live parts of the installations shall be periodically inspected to ensure it remains insulated, or protected, against inadvertent contact with any person.

Earthing systems are subject to periodic inspection and testing and not used beyond their operating limits or is a fire or environmental risk.

Electrical protection shall be provided and inspected on all electric circuits to ensure it has the capacity to interrupt supply of electricity in the event of a fault.

Portable Electrical Equipment - Risk Controls

Hand held power tools must be maintained in a safe working condition and checked on a regular basis. All maintenance and repairs of hand held power tools must be carried out by a qualified electrician. All power tools should be recorded in an appropriate register.

Ensure all electrical extension cords and portable electrical tool are in a sound condition and tagged appropriately prior to use.

Portable electrical equipment and flexible extension leads are required to be inspected and tested on a regular 6 monthly basis to ensure that it complies with AS3760 and is in a safe condition. Each item is then to be tagged with an appropriate colour tag and test results recorded.

All portable electrical equipment shall be used in conjunction with a fixed or portable Residual Current Device (RCD). These protection devices must be used wherever mains electricity is supplied to moveable electrical equipment through a flexible extension cord.

When using a portable RCD ensure that it is tested each time that it is used with the in-built switch and on a six monthly basis as required by Regulations and AS 3760. Portable units must be fitted with a tag showing the last inspection date.

Records must be kept for the testing of fixed and portable RCD’s. These must be retained for 5 years.

Out of Service Tags - Risk Controls

“Out of Service” or “Do Not Start” tags are commonly used to identify plant or equipment that is not to be used or started under any circumstances.

These are not suitable for an isolating padlock. Do not remove a tag or padlock placed by another person, only the person who placed the padlock can remove the padlock. In any case, they can serve as a warning where danger exists.

Under emergency or exceptional circumstances, the Quarry Manager or his appointee will have the authority to remove an isolating padlock to move an item of plant.

STEP 5 Monitor and Improve

Having effected either elimination, or reduction of the hazard, a system of monitoring needs to be put into place to maintain the standards and conditions established. This is an evolutionary process in reducing the hazards and the most appropriate course of action may change over time. It is necessary that periodic reviews of all hazards and control systems be carried out to ensure the most effective controls are in use at all times.

This will in time achieve continual improvement in workplace safety.



9. Management Plans, Control Plans and Programs

AS 4801: 2001

4.3.4 WHS management plans



Fatigue Management Plan FMP Emergency Control Plan ECP

Blast Control Plan BMP Traffic Management Plan TMP Contractor Management Plan CMP

Principle Hazard Management Plan Health Control Plan Electrical Engineering Control Plan

Mechanical Control Plan

Mine Safety Management Plan (MSMP)

The Mine Safety Management Plan is the core document in managing safety in accordance with the legislation. The MSMP is the responsibility of the Commercial Services Manager with delegations to the Ops Manager and Quarry Operations Coordinator. The MSMP designates:

Legislative compliance needs

Chain of Responsibility for Transporting requirements

Assigned roles, responsibilities and authorities in relation to mine safety and associated risk management practices

Identification of hazards and high risk activities

Risk management methodologies

Inter-relationships with Lismore City Council safety and Quarry safety

Incident and emergency management

Safety reporting and continual improvement

The MSMP references supporting documents throughout and also designates record keeping obligations.

Principle Hazard Management Plan (PHMP)

The Principle Hazard Management Plan is the core document in managing principle hazards as identified in the WHS (Mines and Petroleum) Regulation 2014. The definition of a principle hazard is “Any hazard on a mine site that has the potential to cause multiple fatalities”. Principle hazards relevant to;

1) Roads and other vehicle operating areas

2) Ground stability

3) Fire and explosion – Blasting/bitumen and tyres

4) Dust and other air contaminants

The PHMP can be found in the IMS management software and a hard copy can be found in the quarry weighbridge.

Blast Control Plans (BCP)

The Blast Control Plan (BCP) provide for a safe and standardised method of handling and using explosives at NRQA Quarry Sites, identifies and allocate each individual’s WHS accountabilities, responsibilities and to specify competencies for each of the roles defined and ensures compliance with the WHS (Mines and Petroleum) regulations 2014 and Australian Standards AS 2187.1/2 Handling and Use of explosives.



This plan incorporates all aspects of explosives handling including planning, transport, shot preparation, charging and stemming, tie up, firing, dealing with misfires, reporting and records, competencies and emergencies.

Also related to the BCP are the following:

Blast set up area

Loading and stemming blast holes

Planning – drill and blast

Decontamination and maintenance of explosives handling equipment

Transport of explosives

The BCP can be found in the IMS management software and a hard copy can be found in the quarry weighbridge and will be reviewed annually.

Emergency Control Plan (ECP)

The Emergency Control Plan (ECP) Blakebrook Quarry has been developed in accordance with Australian Standard AS: 3745-2010 (Planning for Emergencies in Facilities) to establish an effective systematic process for the management of emergency situations and response to protect life, property and plant and to comply with the WHS (Mines and Petroleum) Regulations 2014 which states a mine site must have in place an ECP.

The ECP shall consider the hazards identified in the risk assessment process and their associated controls. Where a risk remains the ECP shall consider the need for a planned emergency response. Also refer Explosives Safety Emergency Response – Blast Control Plan

The ECP can be found in the IMS management software and a hard copy can be found in the quarry weighbridge and will be reviewed annually.

Mechanical Control Plan (MCP)

The Mechanical Control Plan (MCP) Blakebrook Quarry has been developed in accordance with the requirements contained in the WHS (Mines and Petroleum) Regulations 2014 for the management of mechanical structures and plant be it fixed or mobile. Its main aim is to protect life to ensure that controls are in place to manage the design, use and maintenance of mechanical machinery and infrastructure on site.

The MCP shall consider the hazards identified in the risk assessment process and their associated controls.

The MCP can be found in the IMS management software and a hard copy can be found in the quarry weighbridge and will be reviewed annually.

Electrical Control Plan (ECP)

The Electrical Control Plan (ECP) Blakebrook Quarry has been developed in accordance with the requirements contained in the WHS (Mines and Petroleum) Regulations 2014 for the management of electrical installation and management of existing electrical infrastructure. Its main aim is to protect life to ensure that controls are in place to manage the design, use and maintenance of electrical installations and infrastructure on site.

The ECP shall consider the hazards identified in the risk assessment process and their associated controls.



The ECP can be found in the IMS management software and a hard copy can be found in the quarry weighbridge and will be reviewed annually.

Health Control Plan (HCP)

The Health Control Plan (HCP) Blakebrook Quarry has been developed in accordance with the requirements contained in the WHS (Mines and Petroleum) Regulations 2014 for the management of issues relating to the health of personnel working on site. Its main aim is to protect life to ensure that controls are in place to manage risk relating to the contact and ingestion of hazardous substances and situations that are harmful to the human body or the body’s senses.

The HCP shall consider the hazards identified in the risk assessment process and their associated controls.

The HCP can be found in the IMS management software and a hard copy can be found in the quarry weighbridge and will be reviewed annually.

Traffic Management Plans (TMP)

The Traffic Management Plan (TMP) describes the requirements for safety entry, traffic flow and exit following minimum standards required for quarries as specified by the Mines H&S Regulations and WHS Regulation, Lismore City Council requirements and taking into consideration local community needs.

The TMP is the responsibility of the Commercial Services Coordinator as delegated by the Commercial Services Manager. The Mines Regulation ‘Road design & construction risk takes into account such factors as relevant to the hazard [S43]” shall be considered in the development, maintenance and review of the TMP.

Fatigue Management Plans (FMP)

Northern Rivers Quarry and Asphalt provides a fatigue management framework designed to ensure workers are fit for duty at all times. Fatigue management includes the need to company with zero drug and alcohol – refer policies. This framework provides adequate opportunity for fatigue identification, recovery, rest and recuperation between work periods to ensure a workers performance is not affected by fatigue.

The FMP is the responsibility of the Commercial Services Manager with delegations to the Commercial Services Coordinator. It is also important for workers who are given the responsibility of operating a NRQA owned vehicle to recognise the signs of fatigue and take measures to avoid it.

NRQA uses appropriate risk assessment tools to measure, mitigate and monitor the risks associated with fatigue. In addition, mitigation strategies will be reviewed and audited to ensure compliance with WHS requirements. Additionally persons who operate a truck or other heavy vehicle, are required to abide by the New South Wales Roads and Traffic Authority legislation requirements regarding Fatigue Management.

NRQA will also meet the compliance requirements under the NHV Laws.



10. Operational Controls – Service Delivery

AS 4801: 2001

4.4.6 Hazard identification, hazard/risk assessment and control of hazards/risks

Refer Section 8: Risk Planning – HIRAC


Contractor Management Procedure Asphalt Production - SOPS TRIM Trades & Services Directory

Stockpiling Processes Pug mill Process

Measuring of holes and set up blast area

Loading and stemming of blast holes Tying up and firing of shots

Drill and Blast Planning Transport of Explosives Decontamination and maintenance of explosives handling equipment

Purchasing – Health and Safety and Chain of Responsibility

NRQA require any new product to be subject to a safety review process in consultation with users prior to any purchase. This process shall include:

Need for a new product to be introduced – replacing more hazardous product

Risk assessment to be undertaken prior to purchase to determine introduction of additional hazards or the need for storage, handling, PPE, training or other changes.

The purchasing procedure to be followed that takes into account health and safety and CoR requirements from the supplier.

As a result of the risk assessment, the need to proceed to purchase is made and a change management process initiated.

PURCHASING & DESIGN

MINES LEGISLATION RISK FACTORS

PROPOSED PURCHASE NEW

EQUIPMENT PRODUCT

1 Work Environment

Space, noise, lighting, temperature, contaminants, dust, radiation, vehicles

Involve Managers, Supervisors and “end users” of product or equipment in discussions.

Consult with employees, managers/supervisors, safety personnel, & other key personnel to consider the application of the Mines legislative factors to purchases & the construction or installation of plant/machinery.

2 Ergonomics

Manual handling, office layout, work station design.

3 Maintenance

Cleaning, plant & equipment, waste disposal.

List potential hazards and risks to employees

4 Operational Systems

Work processes, CoR requirements and methods.

Ensure product/equipment complies with all Mines legislation/CoR and Statutory requirements and SDS provided if necessary

5 Protection

Engineering, CoR conformance, admin controls & PPE

6 Organisational Systems

Overtime, training, supervision and resourcing for health and safety and CoR compliance.

Discuss requirements with Suppliers

Note: Each of the above six requirements should be considered with equal merit.

Agreement & Mines legislative/CoR requirements can be met.

Decision to purchase

Place order, ensuring that all Statutory and Mines legislative/CoR requirements are included in purchase order/contract.

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Production Processes

NRQA management recognises that a preventative approach is the most effective means of controlling an IMS.

The companies operate in the extractive and asphalt production industries which includes the undertaking of hazardous work requiring particular emphasis on the control of risks associated with:

Operation of heavy plant (fixed and mobile)

Moving equipment and work platforms

Work at height

Blasting and explosives

On ground working environment

Dust

Hazardous substances

Manual handling

Therefore a strong commitment to a proactive incident prevention strategy is necessary through the integration of workplace safety and health as part of the overall management process, where it ranks equally with all other activities of the organisation.

OPERATIONS SAFETY HAZARDOUS SITUATIONS

ASPHALT PRODUCTION and OPERATIONS



Work at heights


Dust generation

Manual handling activities related to lifting, weights, awkward positions and repetitive work

QUARRY PRODUCTION and OPERATIONS



Blasting operations

Work at heights


Dust generation

Hazardous substances use

Manual handling activities related to lifting, weights, awkward positions and repetitive work

LABORATORY and TESTING FUNCTIONS


Dust generation


LOADING for TRANSPORT to/from Quarry by customer

On ground working environment including traffic management

Dust generation

Work at heights

Operation of mobile plant


Manual handling activities



11. Performance Monitoring and Measurement – Audits, Inspections & Other Monitoring

AS 4801: 2001

4.5.1 Monitoring and measurement

4.5.4 WHS M&S audit

4.5.1.2 Health surveillance


Internal Audit Schedule Monthly Open Pit Quarry Inspection Checklist

TRIM Calibration Register

Internal Audit Form Monthly Workplace Inspection Checklist

Blasting reports and records

Performance Monitoring and Measurement – all stages of production

Inspection, Test and Monitoring – Goods / Services Received

Inwards purchased goods / services / equipment are checked to ensure they comply with the purchase order specifications

Subcontracted services received shall be supervised to ensure they comply with specified contract requirements and that services are carried out in the most effective and efficient manner available

Repair of company plant, equipment and premises including repair work / services carried out by subcontractors on a continuing basis

The NRQA Commercial Services Manager is ultimately responsible for service performance. Certain duties are delegated to specific managers to ensure that all inspection and testing is carried out in accordance with company / contract and safety requirements.

Inspection Responsibility

The relevant Manager is responsible for ensuring that all inspection, measuring and testing equipment needed to measure required accuracy’s, is maintained, registered and calibrated (as appropriate) at regular intervals and the results are recorded.

Devices – Calibration, Inspection and Test

The following protocols for the control of monitoring and measurement devices shall be adhered to:

A calibration database will be maintained. All other equipment as per the Calibration Register shall be calibrated by the laboratory as per the appropriate standard.

The scheduled service / calibration is completed to ensure tools, equipment and instruments are kept in or returned to service with minimal disruption to operations workplace health and safety, and to ensure that records associated with this process are updated or created, as necessary,



Audits

NRQA is typically subject to six types of audits on either a scheduled or unscheduled basis.

1. IMS documented system audit designed to establish compliance to NRQA defined documented safety systems. This is an annual desktop audit of systems in compliance with the ISO/AS standards and regulatory compliance and is incorporated into the process audit schedule.

2. Process internal audits to ensure NRQA processes are being followed. Process internal audits shall be scheduled on the basis of the status and importance of the related activity and according to risk. Only staff with sufficient audit experience and training shall be able to conduct internal audits. Refer Audit Schedule.

3. Council (HSE Dept) does an annual due diligence audit on the site and provides an action plan.

4. Second/third part audits by external bodies such as certification agencies or regulators to text compliance to ISO systems or regulations. Third part ISO/AS audits are on a 3 year plan whilst external regulator audits are ad hoc.

5. Daily informal audits/inspections aimed at general safety compliance. These are generally drive or walk through audits and are recoded in as a diary entry. Corrective actions may arise for these audits.

6. Audits conducted by NRQA post an incident or nonconformance to support investigations and determine whether corrective and preventive measures have been implemented and are effective. These audits are ad hoc.

The Commercial Services Manager is responsible for management of internal audits, auditors and reviewing audit report outcomes (along with relevant managers of the area audited).

Auditors undertaking internal audits for NRQA shall be trained and competent. An audit checklist and report format will be followed.

The results of the audit shall be recorded within the IMS and any resultant non-conformance will be documented and actioned by raising non-conformance and followed up and signed off by management. It is important to note that ONLY a Manager can sign off the various audit reports or non-conformances within the IMS.



12. Emergency Management

AS 4801: 2001

4.4.7 Emergency preparedness and response


Emergency Control Plan Emergency Equipment Register Explosives Safety Emergency Response – Refer Blast Management Plan

Emergency Preparedness and Response

In planning for quarry safety emergencies NRQA shall:

Identify potential emergency situations relevant to the NRQA site and initiate emergency response protocols for each perceived situation

Provide and maintain the equipment resources necessary to meet site emergency needs

Provide competent personnel to enact the emergency response arrangements

Develop and coordinate emergency response as deemed appropriate to activities

Emergency planning and response processes are available at the site office and displayed at site as deemed by the Safety Committee. Emergency protocols shall be tested periodically for effectiveness and any identified opportunities for improvement shall be recorded.

As a result of the above, an Emergency Control Plan [ECP] is developed for the quarry location. The plan is approved by the managers and WHS reps in consultation with other site stakeholders. The plan is provided to stakeholders including public, subcontractors on request for review, information and feedback according to contract specifications.

The plan shall provide emergency maps designating clear exit paths and locations of emergency equipment including fire extinguishers, hoses, first aid equipment as appropriate.

The principles of the ECP are:

1. PRESERVE LIFE

2. PRESERVE PLANT, EQUIPMENT

First person to the scene or to notice the emergency threat shall notify their immediate Supervisor or Manager. They will state “this is an emergency” and give their name, the nature and location of the accident or emergency. This will be done by himself or herself or another person they can immediately contact. Alert other personnel in the immediate area to the emergency.

In the event of an emergency, the Site Manager or person appointed will supervise the arrival of emergency services. A competent person will be stationed at the weighbridge to ensure that only emergency services and authorised personnel are admitted to the quarry.

No person shall become involved at the scene unless they are requested to do so or can offer genuine assistance. The site shall not be disturbed unless necessary to render assistance to an injured person or reduce the risk of an escalation of the emergency until the all clear is given by the Site Manager.



Emergency Equipment

Fire extinguishers are fitted to all mobile equipment and are clearly identified. They are also fitted throughout the crushing and screening plant, in the workshops, offices and near flammable fuel and chemical stores.

Emergency equipment is tested and calibrated annually via contract arrange arrangements with suppliers.

This equipment must be used for fire protection only. Any use of such equipment must be reported to the Supervisor or the Manager.

Type of Extinguisher

Class of Fire Water Wet Chemical

Alcohol Resistant Foam AFFF Type

Dry Chemical Powder

AB(E) B(E)

Carbon Dioxide (C02)

Halon

A Ordinary Combustibles (wood, paper, plastics)

Yes – most suitable

Yes Yes Yes AB(E)

No (B(E)

Yes limited effectiveness


B Flammable & combustible liquids

No No Yes (Non AFFF)

Yes (AFFF type foam) except for alcohol

Yes Yes Yes

B Fire involving cooking oils & fats

No Yes No No AB(E)

Yes B(E)


Yes limited effective Safety

warning

C Flammable gases No No No Yes No Yes

E Fire involving energised electrical equipment

No No No Yes Yes Yes

Classification

Extinguishers shall be classified by letter(s) designating the general class or classes of fire for which the extinguisher has been found to be effective. For the purpose of classification, the following letters apply:

Class A Fires in ordinary combustible materials such as wood, cloth, paper, rubber and plastics.

Class B Fires in flammable and combustible liquids and greases. Where an extinguisher has been shown to be electrically non-conductive as discharged from a given extinguisher, the extinguisher shall be identified with the marking (E).

Fire related signs are maintained throughout the sites and indicate the location of fire alarms and fire fighting equipment and facilities.



13. Incident Reporting, Investigation, Corrective and Preventive Measures

AS 4801: 2001

4.5.2 Incident investigation, corrective, and preventive action

Support documentation Incident Reporting Investigation & Notification Procedure

Incident Report Form

Non-conformance Reporting Procedure Non-conformance Report Form Regulator Report Form

Nonconformance, Incidents, Corrective Actions and Improvements

Non-conformance Management

The following process flow describes the management of non-conformances related to process or other failures of safety systems and CoR management. This information is captured via non-conformance reports and support any incident reports or investigations having been undertaken.

Manager to review, investigate &

assign corrective action through the

IMS system

Process or risk nonconformity

detected

Corrective action

effective?

Manager verifies action has resolved the nonconformity

Is further action

required?

Close out Non conformance

Review at next meeting

Raise Non-conformance Report in IMS

Corrective action process reviewed for

effectiveness

Initiate & take further corrective action

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Corrective Action

Corrective action is designed to ensure any significant deficiencies or defects are actioned at the earliest possible time to determine the cause. Where immediate corrective action is warranted, the responsible person shall take the appropriate action, particularly where continuation of a process or activity may add to the problem, or have the potential to do so. Corrective actions are recorded wither as part of non-conformities, hazards or audit reports.

Preventive Action

Preventive measures can come from positive initiatives or potential problems reported. These are raised at operational or safety meetings.

Procedures ensure that not only is corrective action initiated, but also preventive action is implemented to eliminate an occurrence.

Preventative action shall be based on new initiatives, results of investigations; use of appropriate information related to processes, work operations, inspection and test data, audit reports or subcontractor feedback, ensuring that relevant information on actions taken is submitted for management review.

The agreed implemented actions shall be monitored by the appropriate Manager and findings reported at the next management or operational meeting as appropriate.

It is the responsibility of supervisory staff to continuously monitor the work process and its documentation to ensure that the system is working smoothly.

Continual Improvement

The following demonstrates management of continual improvement that may result from an incident, non-conformance, corrective, preventive measures, objectives and targets or discussion through meeting forums.

Incremental improvements are typically process improvements. Major improvement projects are typically significant capital expenditure for new plant or major investment in a new product range. These are strategic Council decisions.

System Fai lures Knowledge Management

IDala An alysls . lndusiry Forums Outcomes . Non compliance . Slrategic Planning . Risk Management

I I

. Incremental improvem ent initi atives

. Major improvement projects



Incident Reporting, Investigation and Notification

The following represents regulator notifiable events: In any of these cases identified the Mine Operator must report any of these incidents by contacting the Department of Planning and Environment, Resources Regulator, Centralised Assessments Unit’s 24 hour reporting number on 1300 814 609

Health and Safety – reporting to WorkCover

Employers, occupiers and people who are in control of workplaces and high-risk equipment are required by law to notify WorkCover about incidents involving workplace health and safety and dangerous goods.

Notification is required where an incident at a workplace or equipment site results in:

Trigger Example

Immediate treatment as an in-patient in a hospital

Admission into a hospital as an in-patient for any duration, even if the stay is not overnight or longer.

It does not include:

Out-patient treatment provided by the emergency section of a hospital (i.e. not requiring admission as an in-patient) and immediate discharge.

Subsequent corrective surgery such as that required to fix a fractured nose.

Immediate treatment for the amputation of any part of the body

Amputation of a limb such as arm or leg, body part such as hand, foot or the tip of a finger, toe, nose or ear.


Bruising or minor abrasion or laceration to the skin.

Immediate treatment for a serious head injury

Fractured skull, loss of consciousness, blood clot or bleeding in the brain, damage to the skull to the extent that it is likely to affect organ/face function.

Head injuries resulting in temporary or permanent amnesia.

Immediate treatment for a serious eye injury

Injury that results in or is likely to result in the loss of the eye or total or partial loss of vision.

Injury that involves an object penetrating the eye (for example metal fragment, wood chip).

Exposure of the eye to a substance which poses a risk of serious eye damage.


Eye exposure to a substance that merely causes irritation.

Immediate treatment for a serious burn

A burn requiring intensive care or critical care which could require compression garment or a skin graft.


A burn that merely requires washing the wound and applying a dressing.

Immediate treatment for the separation of skin from an underlying tissue (de-gloving or scalping)

Separation of skin from an underlying tissue such that tendon, bone or muscles are exposed (de-gloving or scalping).

Immediate treatment for a spinal injury Injury to cervical, thoracic, lumbar or sacral vertebrae incl. discs & spinal cord.

Immediate treatment for the loss of a bodily function

Loss of consciousness, loss of movement of a limb or loss of the sense of smell, taste, sight or hearing, or loss of function of an internal organ.


mere fainting, or

a sprain, strain or fracture.

Immediate treatment for serious lacerations

Serious lacerations that cause muscle, tendon, nerve or blood vessel damage or permanent impairment.

Deep or extensive cuts.

Tears of wounds to the flesh or tissues—this may include stitching to prevent loss of blood and/or other treatment to prevent loss of bodily function and/or infection.

Medical treatment within 48 hours of exposure to a substance.



Notification is also required for the following prescribed serious illness:

Any infection to which the carrying out of work is a significant contributing factor, including any infection that is reliably attributable to carrying out work:

(i) with micro-organisms

(ii) that involves providing treatment or care to a person

(iii) that involves contact with human blood or body substances

(iv) that involves handling or contact with animals, animal hides, carcasses or waste.

The following occupational diseases contracted in the course of work involving handling or contact with animals, animal hides, skins, wool or hair, animal carcasses or animal waste products:

(i) Q fever

(ii) Anthrax

(iii) Leptospirosis

(iv) Brucellosis

(v) Hendra Virus

(vi) Avian Influenza

(vii) Psittacosis.

Dangerous Incidents – Near miss (NSW WorkCover reporting as per WHS Act)

Notification is also required of any incident in relation to a workplace that exposes a worker or any other person to a serious risk resulting from an immediate or imminent exposure to:

uncontrolled escape, spillage or leakage of a substance, implosion, explosion or fire

uncontrolled escape of gas or steam or from a pressurised substance

electric shock:

- examples of electrical shock that are not notifiable include shock due to static electricity, ‘extra low voltage’ shock (i.e. arising from electrical equipment less than or equal to 50V AC and less than or equal to 120V DC) or if defibrillators are used deliberately to shock a person for first aid or medical reasons

- examples of electrical shocks that are notifiable include minor shock resulting from direct contact with exposed live electrical parts (other than ‘extra low voltage’) including shock from capacitive discharge

fall or release from a height of any plant, substance or thing

collapse, overturning, failure or malfunction of, or damage to, any plant that is required to be design or item registered under the Work Health and Safety Regulations

collapse or partial collapse of a structure, excavation or of any shoring supporting an excavation

the inrush of water, mud or gas in workings, in an underground excavation or tunnel, or the interruption of the main system of ventilation in an underground excavation or tunnel.

Health and Safety – reporting to NSW Dept of Planning and Environment (mines dept)

The DII must be informed via the Notification of Incidents Form if there is an incident prescribed by the Mine Health and Safety Act 2013 (the Act) and Regulation 2014 (the Regulation) at a quarry.



Notify Cause of Incident Notification Period

Non Disturbance Period

Immediate tor present threat to life:

(i) damage to any plant, equipment, building or structure,

(ii) imminent risk of explosion or fire,

(iii) unintended activation or movement of vehicles or machinery

Immediate 24 hours

Electrical incident:

(i) consequence of which injury, medical treatment occurs or person unable (on medical advice) to attend work, or

(ii) vehicle, machinery or plant makes contact with an energised high voltage source involving a risk

(iii) person receives an electric shock from a source operating above extra low voltage (as defined by AS/NZS 3000)

Immediate 24 hours

Any of the following:

uncontrolled explosion or fire

fluid under high pressure endangering persons, uncontrolled gas or

fluids

collision involving vehicle, other machinery resulting in substantial

damage or impedes safe operation, or loss of control of vehicle/plant

incl. rollover

blast creating risk outside of blast zone or misfire

Immediate 24 hours

Spill or incident resulting in exposure or potential exposure of a person to a notifiable carcinogenic substance or a prohibited carcinogenic substance

24 hours n/a

Notify Nature of Injury Notification Period


Injury to a person that results (at any time after the injury) in any of the following:

(i) amputation of one or more fingers or toes or any part of a hand or foot,

(ii) fracture other than a fracture of a finger, toe, hand or foot,

(iii) loss of sight of an eye,

(iv) internal haemorrhage receiving hospital treatment,

(v) injection of fluid under pressure, or asphyxia.

Immediate 24 hours

Any event that presents immediate threat to life or permanent incapacity injury or serious burns

Immediate 24 hours

Notify Outcomes of Injury/Illness Notification Period


Incident resulting in death Immediate 24 hours

Injury to a person that results (at any time after the injury) in any of the following:

loss of consciousness of the person caused by impact of physical

force, exposure to hazardous substances, electric shock or lack of

oxygen

hospitalisation following an event

entrapment causing threat to life

Immediate 24 hours

Injury to a person that results in any of the following:

person being unfit or a period of 7 continuous days to undertake

normal duties

As soon as practicable, no later than 7 days

n/a

I



Notify Cause of Incident Notification Period


illness of a person that is related to work processes and results in

the person being unfit to work for a continuous period of at least 7

days

incidence of violence at a place of work and results in the person

being unfit to work for a continuous period of at least 7 days

14. Analysis and Reporting

AS 4801: 2001

4.4.3.3 Reporting


Reports to regulators Reports to LCC Product test reports

Blasting reports and records

General

NRQA shall provide quarterly MHSR Workplace Injury Reports to the Chief Inspector of Mines as required by Regulation 155. The report shall be logged online via the government portal gazetted form at end of each quarter, including the following:

Total no. Injuries

Total employee and total contractor injuries

Total employee hours worked

Total contractor hours worked

No. employees and total contractors receiving medical treatment

No. employees and total contractors undertaking suitable duties

No. employees and total contractors LTI’s

A copy of the reports shall also be held by NRQA for internal review and improvement process.

Analysis

Worksafe Australia Workplace Injury and Disease Recording Standard (as per Australian Standard 1885.1) is the measure for WHS statistical analysis.

Incidents that result in injury have been historically referred to as follow:

Lost Time Incident (LTI) An incident resulting in an injury causing death or permanent disability, or prevents an employee from working for one day/shift or more.

Medically Treated Incident (MTI) An incident resulting in an injury that requires an employee to obtain first aid or medical assistance for an injury (ambulance, doctor or hospital outpatient), but there is not lost time (ie, the employee returns to work before a whole day/shift is lost).

Importantly, the standard describes the methods of determining injury performance measures such as the Lost Time Incidence Rate (LTIR) and the Lost Time Incidence Frequency Rate (LTIFR).



WHS Performance Measurement Rates

Incidence rate

The Incidence Rate is the number of occurrences of injury/illness (MTI’s or LTI’s) for each one hundred workers employed and is actually calculated by:

Number of occurrences in the period x 100 Number of workers

The incidence rate is calculated quarterly unless otherwise agreed.

Frequency rate

The Frequency Rate is a number of occurrences of injury/illness for each one million man hours worked.

This measure is used where there workforce is not regular (eg, casual or contract labour is used), and is calculated by:

Number of occurrences in the period x 1,000,000 Number of hours worked in the period’

Average Time Lost

This is the average time lost per occurrence of injury/illness and is calculated by:

Number of working days/shifts lost in the period

Performance Reporting

Critical product characteristics and process methods shall be measured against key performance indicators are met. Corrective actions shall be documented and undergo review after completion.

Formal workplace safety inspections and audits shall be conducted as per the agreed audit schedule Internal Audit Schedule – Asphalt and Quarry

Reports are provided to Lismore City Council and regulators according to agreed arrangements – refer agenda of management meetings for reporting requirements.

Chain of Responsibility Reporting and Metrics

CoR performance shall be reported through weekly management meetings to off site senior management. Information will be gathered and presented by the quarry manager at this meeting and discussed between the business management staff to provide strategic direction.

Fatigue – Any non-conformance relating to fatigue will be raised as a CAI (Corrective Action Investigation) in the IMS software manager, this will identify opportunities for improvement. The Management Annual Review of the integrated management system will then collate and review these non-conformances and report metrics to relevant stakeholders.

Speeding - Any non-conformance relating to speeding will be raised as a CAI (Corrective Action Investigation) in the IMS software manager, this will identify opportunities for improvement. The Management Annual Review of the integrated management system will then collate and review these non-conformances and report metrics to relevant stakeholders.



Mass Management - Any non-conformance relating to mass management will be raised as a CAI (Corrective Action Investigation) in the IMS software manager, this will identify opportunities for improvement. The Management Annual Review of the integrated management system will then collate and review these non-conformances and report metrics to relevant stakeholders.

Load Restraint - Any non-conformance relating to load restraint will be raised as a CAI (Corrective Action Investigation) in the IMS software manager, this will identify opportunities for improvement. The Management Annual Review of the integrated management system will then collate and review these non-conformances and report metrics to relevant stakeholders.

Maintenance - Any non-conformance relating to maintenance will be raised as a CAI (Corrective Action Investigation) in the IMS software manager, this will identify opportunities for improvement. The Management Annual Review of the integrated management system will then collate and review these non-conformances and report metrics to relevant stakeholders.



15. Management Review

AS 4801: 2001

4.6 Management review


Management Review Procedure Minutes of meetings

Management Review of the IMS

Review of NRQA performance is an ongoing process. The management review of the MSMP is undertaken as an annual review process incorporating all facets of the IMS.

General MSMP review is undertaken during operational meetings as part of the general NRQA meeting processes conducted by the NRQA managers. Minutes are kept.

Additionally, an annual management review of the integrated management system shall be undertaken. This review meeting may include all aspects of the IMS for effectiveness and compliance.

The Commercial Services Manager shall ensure that management review occurs at least annually.

The annual review meeting shall include the following:

Legal and regulatory compliance status – currency and changes

Australian Standards compliance status – currency and changes

Policies – compliance with regulations, LCC and NRQA systems

Objectives and targets – refer IMS Section 1. Achievement to date – measure of success and opportunities for improvement

Mine Safety Management Plan – Need for review or additional support plans

Reportable incidents – 12 months review, regulator feedback

Non-conformance reports and trends – 12 months review

Subcontractor and supplier safety performance reviews – issues and changes

Plant and equipment resources – maintenance status, review, fit for purpose, safety

Training and competency – resources effectiveness and need for review of competencies

Documented systems – review to date, need for review, assigned responsibilities

Subcontractor performance and feedback

Legal and statutory compliance status – currency and changes for HVN Law

Review of and collation of CAI’s relating to CoR non-conformances.