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EXXARO - Grootegeluk Coal Mine (0252) MHSA TMM Regulations Promulgated 27 February 2015

Compliance Review

SACEA TMM/PDS SAFETY WORKSHOP

11 June 2015

CONTENT 1

SHE Committee Members

Vision and Purpose

Background

Amended MHSA Regulation Review

Summary and Closure

SHE Committee 2

NAME OF ATTENDEES REPRESENTATION DESIGNATION Att.

Employer Representative

Johan Wepener Employer Representative General Manager – Section 2(A)

Rico van Staden Mining Operations Operations Manager Mining – Sec 3(1)A P

Adrie Conradie Beneficiation Operations Operations Manager Beneficiation – Sec 3(1)A P

Health and Safety Representatives

Sipho Khumalo Employee Representative (GG) FT SHEQ Rep Eng. (Central) – Section 6(9) P

Hendrik Matlou Employee Representative (GG) FT SHEQ Rep Eng. (Plant)– Section 6(9)

Glorius Mabelane Employee Representative (GG) FT SHEQ Rep Eng. (Mining)– Section 6(9) P

Kwena Pitjeng Employee Representative (GG) FT SHEQ Rep Mining– Section 6(9)

Builoe Seleka Employee Representative (GG) FT SHEQ Rep Plant– Section 6(9)

Trade Unions

Robert Madonsela NUM Representative Fulltime Shop Steward

Hazel Pole NUM Representative Fulltime Shop Steward P

Amon Malaudzi NUM Representative Shop Steward

Jan Pretorius Solidarity Representative Fulltime Shop Steward

Herman Kriel Solidarity Representative Shop Steward P

SHE Committee 3

NAME OF ATTENDEES REPRESENTATION DESIGNATION Attendance

Management Representation

Caesar Nokwe Mining Operations Manager Mining – Reg. 2.6.1 P

Baltimore Miles Mining Operations Eng. Manager – Reg. 2.13.1 P

Tjaart v/d Walt Mining Operations Head SHE – Reg 2.17.4

Adam Wieruszowski Beneficiation Operations Manager Beneficiation – Reg 2.6.1

Job Sithole Beneficiation Operations Eng. Manager – Reg. 2.13.1

Susan Pheiffer Beneficiation Operations Head SHE – Reg. 2.17.4 P

Stompie Nel Central Engineering Eng. Manager – Reg. 2.13.1 P

Derrick van Zyl Central Engineering Head SHE – Reg. 2.17.4

Hasie Haasbroek SHEC SHEC Manager – Reg. 2.6.1

Wayne Mulligan SHEC Head Safety – SHEC P

Marietjie Hale Mining Operations Assistant Eng. Manager – Reg. 2.13.3.1

Tamara Qwatekana Mining Operations Pit Supt. – Reg. 2.6.1

Dominic Mpati Plant Operation Assistant Eng. Manager – Reg. 2.13.3.1

Ronnie Mvelase Plant Operation Pit Supt. – Reg. 2.6.1

SHE Committee 4

NAME OF ATTENDEES REPRESENTATION DESIGNATION Attendance

New TMM License Implementation

Willem Hoffman Human Resources Manager, HR Development P

Jacqueline Khalo Human Resources Training

PDS Implementation

François van Niekerk Exxaro Mobile Technology EXXARO PDS Champion P

Johann Kruger Exxaro HQ Projects Project Manager

Vicente Alvarado Engineering Development Manager, Engineering Development

Henry Lefawane Engineering Development Project Engineer P

Madele Nelson Human Resources PDS Adoption Change Manager

TMM COP Update

Marietjie Hale Mining Operations Assistant Eng.. Manager – Reg 2.13.3.1

Purpose of this Presentation

Primary Purpose is to address the risk associated with TMM / TMM / Pedestrian collisions in order to support Exxaro’s ZERO HARM Intent

Secondary purpose is to comply with the amendment to the MHSA regulations regarding TMMs promulgated on the 27 February 2015

5

Vision Through our innovation and growth we will be a powerful source of endless possibilities by producing 40 million safe tonnes of product

by 2020

Background

MINING METHODS Conventional opencast truck and shovel operation.

The pit is ±120 meters deep

Some 68 million tons of material is transported out of the pit.

Some 40 million tons is fed to 8 beneficiation plants

DESCRIPTION OF TMM’s (~1187) ~ 145 TMMs used for primary mining activates

~ 445 Service and Maintenance TMMs

~ 74 Contractor TMMs

~ 104 Coal link Trucks

~ 419 Employee Private Vehicles (V-Permits)

6

Background

Safety Performance

7

2010 2011 2012 2013 2014Collision 13 29 23 39 39Fatigue 2 2 2 6 1Damages 13 27 25 43 39Minor 1 3 2 1 3LTI 0 1 2 0 0Fatality 0 0 1 0 0

05

101520253035404550

Num

ber o

f inc

iden

ts

5 year historical data of TMM incident classification in mining

Background

1. Section 11 Employer’s Responsibility

1. Employer to assess and respond to risk

2. Employer must, after consulting the H&S committee, determine measures to: a) Eliminate any recorded risk b) Control the risk at source c) Minimise the risk d) In so far as the risk remains:

i. Provide for PPE ii. Institute a Program to monitor the risk to which employees are exposed to

8

Level of Risk Mitigation Administrative Control Probability of Fatal Engineering Control Probability of FatalEliminate Maintenance and Operations Time Shared Unlikely Autonomous/remote operations RareControl Following Distances, safe parking, Lock-out of areas Possible Segregated traffic Plan UnlikelyMinimise Proximity Detection Systems, blind Spot Camera's Likely Collision Avoidance System PossiblePPE Almost Certain Haul Truck Bumpers Likely None Almost Certain Almost Certain

Presentation Philosophy and Content 9

H&S Committee

Vision & Purpose

Background

Presentation Philosophy

Amended MHSA Regulations Audit

Summary

Comply (83%)

PDS, CWA, TMM running out of control

ROPS, FOPS, Braking Systems

Restricted Visibility, Fatigue, Battery Charging,

Diesel Refuelling

Wheels, Access, Visibility, Unauthorized operation

Isolation, Operating, Maintenance, Remote TMM

Trailers, Towing, Roadways, Operator

Selection

Pre-use, Stockpile Reversing, Inadvertent

movement, carrying license, regulations N/A

Non-Compliance (17%)

Selection, training, appointment and licensing

of trackless mobile machine operators

Actions to Address Non-Compliance

Battery Charging Facilities Actions to Address Non-Compliance

Collisions between trackless mobile machines

and pedestrians and between trackless mobile

machines

Significant Risk Evaluation Process TMM that require PDS PDS Roll Out Plan Summary and Closure

DMR Section 54 Methodology

Audit current systems against new regulations (24/29=83% compliance)

Ensure current gaps are Fixed such gaps

Investigate systems failures

• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier (Onsite Trials)

Implementation of action plans • Implementation of new TMM Licence • PDS Roll Out • TMM COP Update

Reference : TMM Regulations

Audit Summary : Amended MHSA Chapter 8 Regulation

10

TMM Regulations Yard Sticks ASPECTSTO BE ADDESSED IN THE MANDATORY TMM COP ComplianceCollisions between trackless mobile machines and pedestrians Pedestrian Detection (PD) System YCollisions between diesel powered trackless mobile machines Anti Collision Devices NCollisions between trackless mobile machines and rail bound equipment Anti Collision Devices YTrackless mobile machines running uncontrolled 8.4 Inadvertent movement of the TMM YOverturning of any trackless mobile machine Roll-Over Protection Systems (ROPS) 8.3 Protection of driver/operator or other persons YObjects falling onto operators and/or passengers of trackless mobile machines Falling Objects Protection Systems (FOPS) 8.3 Protection of driver/operator or other persons YPersons inadvertently falling out of or being ejected from trackless mobile machines. Brake Interlocking (Doors) 8.3 Protection of driver/operator or other persons YBraking systems Brake Test Ramp 8.2 Brakes YRestricted operator visibility. 8.8 Physical constraints to operator’s/driver’s vision. YFatigue while operating a trackless mobile machine. Fatigue Management YBattery charging facilities 8.10.9 Batteries control and safety NDiesel refuelling facilities YWheels, tyres and rims 8.10.4 Procedures for changing wheels, 8.10.5 Changing, Inflating and repairing tyres YAccess of persons to and from the trackless mobile machines 8.5 Safe boarding/alighting and/or access to/exit from TMMs YVisibility of trackless mobile machines, skid mounted machinery and trailers to persons. 8.18 Visibility ofTMMs and persons YUnauthorised access to or operation of trackless mobile machines. 8.12.6 Key control YIsolation and lock-out of trackless mobile machines 8.10.6 Procedures for any repairs that could endanger persons YOperating procedures 8.15 Operating rules YMaintenance standards and procedures Maintenance Systems 8.10 Maintenance YRemote and remotely controlled trackless mobile machines 8.9 Remote controlled TMMs N

Trailers8.6.2 Procedure for coupling, The methods and procedures to prevent inadvertent de-coupling of TMMsbeing towed or pushed. Y

Towing and recovery of trackless mobile machines 8.6 Design and operation of tow-bars and coupling devices YRoadway conditions 8.13 Design of excavations and road ways YSelection, training, appointment and licensing of trackless mobile machine operators Fitness to Perform Work (Medical) 8.12 TMMs to be operated/driven by competent, authorised persons NPre-use inspection procedures Pre-Use Checklists 8.10.2 Pre-use checklists NReversing over the edge of a stockpile 8.15 Operating rules YInadvertent movement of the trackless mobile machine 8.4 Inadvertent movement of the TMM YMandatory carrying of license 8.12 TMMs to be operated/driven by competent, authorised persons YCertain regulations not applicable Y

Illumination 8.17 Illumination of transport environmentContractors' PacksProcurementFire ExtinguishersFire SuppressionsEmergency PreparednessErgonomics AssessmentEquipment Noise MonitoringChecklist of all TMMs 8.10.2 Pre-use checklists

8.1 Safe use ofTMMs, equipment and tools Compliance 24 8.7 Lights fitted to TMMs

Non-Compliance 5 8.14 Inclined applications8.16 Raising/lowering, suspension and transport of persons

% Compliance 83% 8.19 Warning devices and signals8.20 Personal protective clothing

Audit : Amended MHSA Chapter 8 Regulation 11

Regulation Compliance Findings Actions DateCollisions between trackless mobile machines and pedestrians

Y Only applicable to underground Mines

Collisions between diesel powered trackless mobile machines

N GG Red Area has a significant Risk hence PDS is required

Implement PDS on all TMMs operating in the red permit area

09-Sep-16

Collisions between trackless mobile machines and rail bound equipment

Y

Although only applicable to underground; Access to rail bound equipment(RBE) in the plant area is restricted and a policy exists for TMM interaction. (Backfill spreader will be addressed as part of PDS roll out)

Trackless mobile machines running uncontrolled Y

TMM COP 8.2, 8.4.2, 8.10 & 8.15. Brakes are selected, maintenance and tested before use to prevent brake failures. Parking procedures on inclines/declines of which certain TMMs incorporate stop blocks. Steering's systems are maintenance to prevent failures. Operators are trained on safe operation of TMMs and emergency procedures. In open pit arrestor berms are provided on permanent haul roads


Regulation Compliance Findings Actions Date

Overturning of any trackless mobile machine Y

TMM COP 8.13, 8.14, & 8.15. TMM road ways are designed to prevent TMMs overturning. E.g. gradient < TMM safe gradient. Safety devices are provided for safe operation on inclines/declines. Operator are trained in the safe operation of TMMs. All Pit TMMs except LDV's are fitted with ROPS

Objects falling onto operators and/or passengers of trackless mobile machines Y

TMM Following distance of 50m and stand-off Distances to high walls to prevent objects from falling onto TMM operators/passengers. All Pit TMMs except LDV's are fitted with FOPS

Persons inadvertently falling out of or being ejected from trackless mobile machines. Y

No persons in load box of LDV, persons only seated in seats with seatbelts. All Cabs enclosed except skid steer loader

Braking systems Y

TMM COP 8.2 & 8.10. All TMMs are fitted with combined fail safe braking systems as per mines Risk assessment. Refer to TMM COP Annexure A. Service brakes are maintained to 19%*g for a fully loaded TMM. Off the road TMMs brakes comply to ISO 3450 specifications and on the road TMMs brakes comply with National Road Traffic Act roadworthiness requirements. All operators are required to check the operations of brakes as part of TMMs pre-use. TMMs entering the open pit incorporate a brake test ramp as part of the pre-use

Audit : Data : Braking Systems 13

8.10.7 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of brake failure. Such measures must include ensuring: Regulation Off the Road TMM On the Road TMM

8.10.7.1 that trackless mobile machines are operated with adequate and effective braking systems;

ISO 3450 Specification National Road Traffic Act, Compliance Specification

8.10.7.2 all braking systems are adequately and routinely tested for intended functionality;

Pre-use Check using Brake Test Ramp

Pre-use Check using Level Road &/or Brake Test Ramp

8.10.7.3 all braking systems are regularly maintained; and

500 hr. Service & Simret Test

Service Interval brake inspection and service

8.10.7.4 that where a combined braking system is used, the design of the braking system is such that it complies with the requirements for the separate systems and that it fails to safe.

ISO 3450 On site Verification

Local Municipality Road Worthy certificate

Audit : Data : Braking Systems : ISO 3450 Verification

14

Verification test procedure:

Do Simret brake test, ensure brake efficiency is better than 29% x gravity Load truck as close as possible to 120% payload Go over brake test ramp and verify brakes Brake test:

Drive truck down slope of 8% Accelerate to speed of approximately 50km/h Apply service brakes at pre – determined point Mark and measure stopping distance Truck should comply to ISO3450 standard

Repeat above and stop using service and park brakes for references purposes History – All EH3500 ACII – Failed On site verification Hitachi & GG upgraded brake pads Adjusted brake pressures and re-did tests All trucks now comply


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines






• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier (Onsite Trials)





Restricted operator visibility. Y

TMM COP 8.8. Most TMMs have visibility charts. These charts have been incorporated into operator training. GG induction illustrates this restriction to make pedestrians and other TMM operators ware of this restriction. Haul Trucks are the highest risk with regard to restricted vision and have thus been fitted with camera systems to augment visibility

Update TMM COP with outstanding visibility charts of remaining TMM and contractor TMMs

31-Aug-15

Fatigue while operating a trackless mobile machine. Y

Procedure (GG OPI B01-031 REPORTING IN CASE OF SICKNESS, TIREDNESS AND SLEEPINESS) to manage fatigue but relies on operator feedback

Investigate Safe mine Fatigue Monitoring system 15-Dec-15

Battery charging facilities N

Pit TMM Battery charging facility complies but ventilation can be improved. SCM and Pool Workshop Battery charging Facility does does not have an effective provisions to treat persons in the event of acid spillage; Pool WS does not have adequate Lighting. SCM does not have adequate ventilation

Implement an effective provisions to treat persons in the event of acid spillage and a ventilation scheme to comply with 0,5m/s and adequate lighting

31-Aug-15

Diesel refuelling facilities Y

Total diesel and lubricant Facility is an open air installation fitted with fire fighting equipment and designed to comply with SANS 10089-1,2,3.

Audit : Data : Restricted operator visibility 17

EH3500 Haul Truck Visibility Chart

EH3500 Haul Truck Visibility Chart with Camera Assist

8.10.8 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of restricted operator visibility.

Audit : Data : Fatigue while operating a trackless mobile machine

18

8.10.9 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of fatigue of operators. GG OPI B01-031 REPORTING IN CASE OF SICKNESS, TIREDNESS AND SLEEPINESS The above procedure encourage TMM operators to book tired is they feel they are unable to operate safely. The procedure allows for a rest period to combat fatigue. SAFEMINE FATIGUE MONITORING to be investigated as part of PDS Roll Out

Online Fatigue Monitoring Investigation 19

Integrate with SM CAS technology: Driving performance: harsh braking,

swerving, cornering

Interaction with vehicles: alarms, reaction time, dangerous behavior

Measure development over time, driver specific

Audit : Data : Pit TMM Battery charging facilities 20

8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facilities are ergonomically designed, constructed and equipped with the following: i) Adequate through

ventilation; ii) Adequate fire

suppression equipment; iii) Effective provisions to

treat persons in the event of acid spillage; and

iv) Appropriate and adequate lighting.

0 – 3.9m/s vs 0.5m/s

192 lux vs 100 lux

Audit : Data : SCM Battery charging facilities 21






0m/s vs 0.5m/s

498 lux vs 100lux

No effective provisions to treat persons in the event of acid spillage. No eye wash or emergency shower

Audit : Data : Pool Workshop Battery charging facilities

22






No effective provisions to treat persons in the event of acid spillage. No eye wash or emergency shower

3,7 ; 3,4 vs 0.5m/s

104 lux vs 100 lux

26 lux vs 100 lux

Audit : Summary : Battery charging facilities 23

Recommendations Implement an effective

provisions to treat persons in the event of acid spillage and a ventilation scheme to

comply with 0,5m/s and adequate lighting

Action Responsible Due date Comment CompletionDesign, procure and construct an effective provisions to treat

persons in the event of acid spil lage at SCM & Pool

Workshop

Heinrich Bornman 31-Aug-15 0%

Design, procure and construct a ventilation scheme to comply to

0,5m/s in SCMHeinrich Bornman 31-Aug-15 0%

Install additional l ighting in Pool W/S

Heinrich Bornman 31-Jul-15 0%

Install additional vent in Pit Facil ity

Heinrich Bornman 31-Jul-15 0%

Regulation Audit Finding8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facil ities are

ergonomically designed, constructed and equipped with the following: i) Adequate through ventilation; i i) Adequate fire

suppression equipment; i i i) Effective provisions to treat persons in the event of acid spil lage; and iv) Appropriate and adequate

l ighting.

Pit TMM Battery charging facil ity complies but ventilation can be improved. SCM and Pool Workshop Battery charging Facil ity

does does not have an effective provisions to treat persons in the event of acid spil lage; Pool WS does not have adequate

Lighting. SCM does not have adequate ventilation

Action Plan

Audit : Data : Diesel refuelling facilities 24

8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: i) Adequate through ventilation;

Open Air Surface Facility ii) Adequate fire suppression equipment;


8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: iii) Effective provisions to cater for oil and diesel spillages; and


8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: iv) Appropriate and adequate lighting.


8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: v) Surface diesel refueling facilities are in accordance with:

a. SANS 10089-1 (2008): The petroleum industry Part 1: Storage and distribution of petroleum products in above-ground bulk installations.

Spill Slab and Fall Protection Units are designed according to SANS 10089-1 (2008)


8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: v) Surface diesel refueling facilities are in accordance with: b. SANS 10089-2 (2007): The petroleum industry Part 2: Electrical and other installations in the distribution and marketing sector.


8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: v) Surface diesel refueling facilities are in accordance with: c. SANS 10089-3 (2010): The petroleum industry Part 3: The installation, modification, and decommissioning of underground storage tanks, pumps/dispensers and pipe work at service stations and consumer installations.


8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following: i. Adequate through ventilation; Comply ii) Adequate fire suppression equipment; Comply iii) Effective provisions to cater for oil and diesel spillages; and Comply iv) Appropriate and adequate lighting. Comply v) Surface diesel refueling facilities are in accordance with: Comply a. SANS 10089-1 (2008): The petroleum industry Part 1: Storage and distribution of petroleum products in above-ground bulk installations. b. SANS 10089-2 (2007): The petroleum industry Part 2: Electrical and other installations in the distribution and marketing sector. c. SANS 10089-3 (2010): The petroleum industry Part 3: The installation, modification, and decommissioning of underground storage tanks, pumps/dispensers and pipe work at service stations and consumer installations.


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines






• Licencing of TMM Operators • MOSH Risk Assessment • PDS Supplier





Wheels, tyres and rims Y

TMM COP 8.10.4 & 8.10.5 Procedures for changing wheels, Changes and maintenance of tyres on equipment and the associated risks are addressed in BPI GG/I01.078 BPI and GG/I02.056

Access of persons to and from the trackless mobile machines

Y

TMM COP 8.5.1 All TMMs are provided with safe access facilities to theoperator’s cabin. All relevant personnel are trained regarding the associateddangers and correct procedures to follow regarding boarding onto, alightingfrom, riding on or working on top of TMM’s.

Visibility of trackless mobile machines, skid mounted machinery and trailers to persons. Y

TMM COP 8.10.2. & 8.18. All TMMs have reflective strips, reverse hooters and directional hooters where applicable and rotating strobe lights which also form part of the TMMs pre-use checklist

Unauthorised access to or operation of trackless mobile machines. Y

TMM COP 8.12.6 Key control procedure (GG/SPI/J00.100), proxy system on primary GG owned TMMs is implemented to prevent unauthorized access or operation

Audit : Data : Access of persons to and from the trackless mobile machines

33

Audit : Data : Visibility of trackless mobile machines, skid mounted machinery and trailers to persons.

34


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines











Isolation and lock-out of trackless mobile machines Y

TMM COP 8.10.6 All primary TMM have specific lockout procedures and isolations points on TMMs, Haul Trucks and Shovels have IRB (Isolation Record Book). Procedures BPI/I01.075, BPI/I01.076 and BPI/01.077 are examples of machine specific lock out procedures

Operating procedures Y

TMM COP 8.15 details operating procedures. SPI GG/B00.004, BPI/B01.001, BPI/B01.007,BPI/B01.009,etc..

Maintenance standards and procedures Y

TMM COP 8.10. Maintenance of all machines is scheduled in accordance with maintenance schedules as per the OEM’s manuals and guidelines. Maintenance Schedules are registered in the SAP system as per BPI.I04.032. Regular inspections are carried out by persons appointed by the AME and to assist him in enforcing the regulations andsafe working procedures.

Remote and remotely controlled trackless mobile machines

NGG uses an MMD Atlas Transporter to move IPCC and Backfill systems which is a RC TMM. No SANS 61000 certification

Engage MMD (OEM) to get transporter certified

31-Aug-15

Audit : Data : Isolation and lock-out of trackless mobile machines : TMM Specific Lock Out Code

37

Identify TMM Type / group

Identify all Energy Sources

Apply isolation and lockout

guideline A to H

Identify Tasks that require lock-out of

TMM

Develop Task vs Lockout

Matrix

Procedure Decription

BPI GG I01.077 Isolation and Swithching procedure for Mechanical and Electrical Equipment at Auxilliary Equipment Rev.1

OPI GG I01 075 GENERAL ISOLATION AND SWITCH - ON PROCEDURE FOR MINING MAINTENANCE SHOVELS AND POWER DISTRIBUTION REV 4

OPI GG I01.076 GENERAL ISOLATION AND SWITCHING ON FOR PRIMARY TRUCKS REV 3

Audit : Data : Operating procedures 38

OPI GG B02 001 DRILLING Rev3 OPI GG B01.045 HYDRAULIC SHOVELS REV.1

OPI GG B01 049 Stripping of top soil Rev 1 OPI GG B01 048 - Operating a cable reel machine REV1

OPI GG B01 032 HANDLING OF DEFECTIVE MINING EQUIPMENT REV3 OPI GG B01 001 PH SHOVELS AND LOADING REV6

GG OPI B01.050 OPERATION OF LOWBED REV1 GG OPI B01.044 RUBBERWHEEL DOZER REV1 docx

GG OPI B01.043 HAUL TRUCK CAT 777 GG OPI B01.006 Operation of Water truck

GG OPI B01 018 Waste Rock Dumps Revision 7 GG OPI B01 002 OPERATING OF HAUL TRUCKS Rev9

BPI GG BPI B01.003 Graders BPI GG B01.047 OPERATING A BACK ACTOR REV2

BPI GG B01.004 TRACK DOZERS BPI GG B01 053 FRONT END LOADER_992, 928 966_ REV 1

BPI GG B01 051 Operation of RUBBERWHEEL DOZER 824 at shovels Rev 1 BPI GG B01 046- OPERATING A ROAD COMPACTOR REV1

BPI GG B01 028 FRONT END LOADER _994_ Rev 3

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/OPI GG B02 001 DRILLING Rev3.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/OPI GG B01.045 HYDRAULIC SHOVELS REV.1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/OPI GG B01 049 Stripping of top soil Rev 1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/OPI GG B01 048 - Operating a cable reel machine REV1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/OPI GG B01 032 HANDLING OF DEFECTIVE MINING EQUIPMENT REV3.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/OPI GG B01 001 PH SHOVELS AND LOADING REV6.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/GG OPI B01.050 OPERATION OF LOWBED REV1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/GG OPI B01.044 RUBBERWHEEL DOZER REV1 docx.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/GG OPI B01.006 Operation of Water truck.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/GG OPI B01 018 Waste Rock Dumps Revision 7.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG BPI B01.003 Graders.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG B01.047 OPERATING A BACK ACTOR REV2.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG B01.004 TRACK DOZERS.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG B01 053 FRONT END LOADER_992, 928 966_ REV 1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG B01 051 Operation of RUBBERWHEEL DOZER 824 at shovels Rev 1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG B01 046- OPERATING A ROAD COMPACTOR REV1.pdf

http://grootegeluk/Controlled Documents/BPI/Mining (B)/Documents/BPI GG B01 028 FRONT END LOADER _994_ Rev 3.pdf

Audit : Data : Remote and remotely controlled trackless mobile

39

8.10.19 The employer must take reasonably practicable measures to ensure that remote control devices for trackless mobile machines using a wireless remote control device comply a) SANS 61000-4-2 (IEC 61000-4-2) b) SANS 61000-4-3 (IEC 61000-4-3) c) SANS

61000-4-4 (IEC 61000-4-4) d) SANS 61000-4-5 (IEC 61000-4-5) e) SANS 61000-4-6 (IEC 61000-4-6) f) SANS 61000-4-8 (IEC 61000-4-8) g) SANS 61000-4-11 (IEC 61000-4-11)

b)No Certification however crawler remote is designed to SANS 61000-4-3. Crawler relies on

remote control serial number encryption


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines











Trailers Y

No Trailers are manufactured on site. Trailers are specified and purchased from various OEMs. 8.6.2 Procedure for coupling / decoupling.

Towing and recovery of trackless mobile machines Y SPI GG/J02.008 stipulates procedure for towing.

Roadway conditions Y

SPI/GG/B00.004 7.4, 7.5 & 7.6 stipulates road design parameters. The width of haul roads is stipulated at a minimum of 2.5xMaximum width of TMM. Road demarcations and barricades are also stipulated. Daily inspection are conducted on Bench roads and weekly site servility surveys on permanent roads. Plant roads are also maintained and tarred roads are resurfaced every 7 years and refurbished every 20 to 25 years.

Selection, training, appointment and licensing of trackless mobile machine operators N

Operators of trackless mobile machines are not authorized in writing by their supervisor. Current License do not display operators photograph and the issue date of the license

Update TMM operator authorization procedure in line with MHSA regulation 8.10.23

30-Nov-15

Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators

42

Selection, training, appointment and licensing of trackless mobile machine operators

Finding Compliance Action Date

8.10.23.1 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the selection, training, appointment and licensing of trackless mobile machine operators, which procedures must include:

8.10.23.1 physical and psychological pre-selection criteria;Physical Ability Assessment (PAA) is conducted as part of selection criteria. Dover Testing is done as part of psycholigal criteria.

Y

8.10.23.2 a training programme for trackless mobile machine operators, covering:

i) theoretical training in a training Centre;Each TMM has a training manual linked to the operating procedure of the TMM

Y

ii) practical training; andEach TMM has a practical training component inked to the operating procedure of the TMM and assessed by way of a PTO

Y

iii) on the job training.Each TMM has on the job training which is assessed by a training instructor

Y

8.10.23.3 assessment of the trainee, on successful completion of the training programme, by a competent person;

GG/OPI/B01.017 7.2 stipulates what the competency declaration must include and who must conduct it

Y

8.10.23.4 that only operators, assessed to be competent are authorised in writing by the responsible engineer to operate trackless mobile machines;

GG/OPI/B01.017 7.3 stipulates authorization by the AME (Responsible engineer)

Y

8.10.23.5 that operators of trackless mobile machines are authorized in writing by their supervisor to operate trackless mobile machines. Such authorization must detail their duties, responsibilities, limitations and areas of operation.

NUpdate procedure to include authorization letter by supervisor

31-Jul-15

8.10.23.6 when an operator has not operated a trackless mobile machine for a period of two years, such operator is re-assessed to be competent by a competent person prior to being issued with a new license.

GG/OPI/B01.017 7.4.4 stipulate retesting is conducted once a year

Y

Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators – Physical Criteria

43

FAT % 6% of Index Rating

Aerobic Capacity

Step Test

Flexibility

Shoulder

Sit and reach

Muscle Strength

Back strength

Leg strength

Arm strength

Grip strength

Endurance

Abdominal

Shoulder

Leg

Test Battery - Physical Ability Testing

26% of Index Rating

Physical work capacity (PWC) = 29%23% of Index Rating

17% of Index Rating Functional Testing = 71%

28% of Index Rating

Profession Rating /5 Profession Rating /5 Profession Rating /5 Profession Rating /5Artisan aid 4 Admin assistant 0 Foreman 2 0

High Risk Low Risk Medium Risk Low RiskBoilermaker 4 Blaster 2 General Worker 4 3

High Risk Medium Risk High Risk Medium RiskDiesel Mechanic 3 Blasting assistant 4 Loco driver 3 3

Medium Risk High Risk Medium Risk Medium RiskElectrician 4 Controller 1 Maintenance operator 3 2

High Risk Low Risk (Screen repairs) Medium Risk Medium RiskFitter 3 Coordinator 1 Operator 3 2

Medium Risk Low Risk Medium Risk Medium RiskForeman 3 Drill operator 3 Process controller 3 0

Medium Risk Medium Risk Medium Risk Low RiskHelper 2 Drilling helper 3 Senior Process controller 2 3

Medium Risk Medium Risk Medium Risk Medium RiskMaintenance operator/hel 4 Foreman 3 Shunted 3 4

High Risk Medium Risk Medium Risk High RiskMillwright 5 General worker 4 Yard master 3 1

High Risk High Risk Medium Risk Low RiskPainter 3 Geologist 3 2

Medium Risk Medium Risk Medium RiskPlanner 0 Geology assistant 2 5

Low Risk Medium Risk High RiskPlanning Clerk 1 Helper 2 3

Low Risk Medium Risk Medium Risk

Electrician/Master

Engineer

Foreman

Fitter/Master

General worker

Diesel mech

Summary Risk ProfileEngineering Summary Mining Summary Plant Summary Waterberg Summary

Admin/Planning assistant/ClerkArtisan aid

Assistant Surveyor

Auto electrician

Boilermaker/welder

Contract Specialist

Body fat Step Test Flexibility Sit & Reach Back Grip L Grip R Leg Arm Sit-Ups Push-Ups Squads

23 28 119 0 25 149 39 39 159 69 29 16 34


23 28 119 0 25 134 34 34 149 59 24 11 29


23 28 119 0 25 119 29 29 139 54 19 7 19

High Risk

Medium Risk

Low Risk

Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators – Psychological Criteria

44

PSYCHOMOTORIC

Vienna Test Systems (Psychomotoric Assessment)

VTS is a computer aided assessment battery for machine and equipment operators. This battery

assesses the psychomotoric alertness of such employees and came into being when low-level labour-

intensive techniques were replaced by mechanization, both in underground and surface mining.

VTS is a reliable and objective battery that assesses operators for skills required to safely operate

mining equipment.

The VTS measures the following skills;

• Eye-hand, eye-foot and auditory perception,

• Two-hand co-ordination

• Spatial perception

• Glare recovery or visual accuracy with concentration

• Speed and distance estimation

Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators – Physical Criteria

45

The skills mentioned above were identified as essential for the safe, efficient and repeated successful

operation of modern mining equipment in Trackless, Conventional, Open – cast and Dredging mining.

The benefits of using the VTS are:

• Selection decisions can be quantified through research and statistics.

• Operators who are a safety risk can be identified beforehand

• People with risk behaviour can be out selected even before entering the system

• Loss in production, damages to expensive equipment and possible injuries by identifying risk operators can be minimized

• After evaluation of an employee it can be determined why an incident took place (e.g. Under estimation of speed / distance, etc).

• Selection Criteria A – High Risk / Fast Moving Equipment; B – Medium Risk / Slow Moving Equipment; C- Not recommended.

Audit : Data : Selection, training, appointment and licensing of trackless mobile machine operators

46

Init & Surname:

Employee No:

Equipment Type Authorisat Type

Employee Signature

Authorised by Signature

Expiring date

I-Permit Operate 2019-12-07

Overhead Crane Operate 2015-06-27

Safe Lifting Practice

Operate 2015-05-23

0

0

0

0

0

0

0

0

AUTHORISATION PERMIT FOR MACHINERY/EQUIPMENT IN TERMS OF THE MINE

HEALTH AND SAFETY ACT 29 OF 1996, AS AMENDED

You are hereby authorised by the Employer to operate/maintain/clean or repair MACHINERY/EQUIPMENT as listed below in accordance to the

Mine Health and Safety Act 29 of 1996, as amended. Approval of authorisations by appointed Managers / Engineers / Superintendent

(2.13.12) in terms of delegate of Section 7(2) and 7(4) of the Act.

R.D MASIMONG20070803

Init & Surname:

Employee No:

Dated Issued

Equipment Type Authorisat Type

Employee Signature

Expiring date

777 Low Bed Operate 2016-02-25Articulated Dump Truck

Maintain 2016-02-26Excavator BELL 1023

Repair 2016-02-27

FEL Le Tourneau Operate 2016-02-28

Euclid 190 Operate 2016-02-26

Euclid 200 Repair 2016-02-26

Grader 16M Operate 2016-02-26Articulated Service Truck

Operate 2016-02-26

2014-02-25

Authorised by Signature

TRACKLESS MOBILE MACHINE LICENSE CARDYou are hereby authorised by the responsible Engineer to operate

Trackless Mobile Machines as listed below in accordance to the Mine Health and Safety Act 29 of 1996, Regulation 8.10.23.4. Approval of

authorisations by appointed Engineers (2.13.1 or 2.2.13.3.1) in terms of delegation of authority as per Section 7(2) and 7(4) of the Act.

Photo

W HOFFMANN6176420

Regulation Applicable



8.10.23.7 that every operator of trackless mobile machines is issued with a license containing at least the following: i) a photograph to

positively identify the operator;

ii) ii) the trackless mobile machine types which the operator may operate;

iii) date of issue and expiry date; and

iv) the operator's company identification number.

Current License Card

Proposed License Card

Audit : Summary : Selection, training, appointment and licensing of trackless mobile machine operators

47

Recommendations

Update TMM operator authorization procedure in line with MHSA regulation

8.10.23

Action Responsible Due date Comment Completion

Update procedure to include authorization letter by

supervisorWillem Hoffmann 31-Jul-15 Procedure to be sent out for

revision0%

Workshop new license card in l ine with new regulation on

MineWillem Hoffmann 31-Mar-15

Sessions held with SHEC, AME's and Supts and layout was

finalised100%

Gain buy in from Snr Machinery Inspector Limpopo n proposed

layoutWayne Mulligan 15-Apr-15

Sample sent to Limpopo Snr Machinery Inspector for

comments50%

Train Training staff of new License cards Willem Hoffmann 28-May-15 Awaiting Approved License Card 0%

Implemented new license card Willem Hoffmann 30-Nov-15Issue new Licence card as operators do re-training 0%

Action Plan

Audit Finding

Operators of trackless mobile machines are not authorized in writing by their supervisor. Current License do not display

operators photograph and the issue date of the l icense

Regulation

Selection, training, appointment and l icensing of trackless mobile machine operators


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines











Pre-use inspection procedures N

TMM COP 8.10.2. & 8.10.3. 84% of all TMM types have a pre-use that was derived from a risk assessment to determine all safety devices that need to be checked before use. These pre-use also have the criteria to determine if the item is safe or unsafe for use. The rest of the TMMs are using a standard pre-use.

Complete 16% of pre-use for TMMs 31-Dec-15

Reversing over the edge of a stockpile Y

GG/OPI/B01.018 stipulates condition of dumps (stockpiles) and dumping procedures to ensure safe dumping. Dumps are sloped and berms are erected to prevent reversing over the edge

Inadvertent movement of the trackless mobile machine Y

TMM COP 8.15.1 refers to operating procedures which govern the safe parking of TMMs. Certain TMMs also use stop blocks in addition to park breaks based on a risk assessments

Mandatory carrying of license Y Current GG StandardCertain regulations not applicable Y Implemented as such

Audit : Data : Pre-use inspection procedures 50

8.10.24 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for inspecting trackless mobile machines immediately prior to use, which procedures must include: 8.10.24.1that the operator of the trackless mobile machines physically inspects and ensures that the brakes, lights and any other defined safety features and devices are functioning as intended prior to setting such trackless mobile machines in motion; 8.10.24.2 pre-use check lists that have to be completed by all operators of trackless mobile machines at the beginning of their shift. Such check lists must clearly identify all the components, features and functionalities to be inspected by the operator. For each component, feature or functionality, the check list must clearly indicate the pre-established criteria under which the trackless mobile machines may or may not be put in motion.

Pre-Use Checklist

Pre-Use Checklist Standard

Audit Comply Non-Compliance TotalPre-use Checklist 72 37 109

TMMs 993 194 1187% 84% 16%

Audit : Data : Inadvertent movement of the trackless mobile machine

51

8.10.26 The employer must take reasonably practicable measures to prevent inadvertent movement of any trackless mobile machine whilst parked.

Loading Gradient Stop Blocks Front Stop Blocks Rear Outer ResultEmpty Incline 0 1 FailedEmpty Incline 1 0 FailedEmpty Decline 2 0 PassedEmpty Incline 2 0 PassedEmpty Decline 0 2 PassedEmpty Incline 0 2 PassedLoaded Decline 2 0 FailedLoaded Incline 2 0 FailedLoaded Decline 0 2 PassedLoaded Incline 0 2 PassedLoaded Incline 2 2 PassedLoaded Decline 2 2 Passed


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines









Audit : Data : Collisions between trackless mobile machines and pedestrians and trackless mobile machines

53

Collisions between trackless mobile machines and pedestriansPrimary Mining

activites

Service and Maintenance

Contractor Employee

Private Vehicles

8.10.1 The employer must take reasonably practicable measures to ensure that pedestrian are prevented from being injured as a result of collisions between trackless mobile machines and pedestrian. At any mine where there is a significant risk of such collisions, such measures must include at least the following:

8.10.1.1 All electrically or battery powered trackless mobile machines, excluding shovels, bucket wheel excavators and overburden drills, must be provided with means to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the trackless mobile machine and the pedestrian must be warned of each other's presence by means of an effective warning. In the event where no action is taken to prevent potential collision, further means must be provided to retard the trackless mobile machine to a safe speed where after the brakes of the trackless mobile machine are automatically applied without human intervention.

N/A N/A N/A N/A

8.10.1.2 All underground diesel powered trackless mobile machines must be provided with means:8.10.1.2(a) to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the diesel powered trackless mobile machine and the pedestrian shall be warned of each other's presence by means of an effective warning; and

N/A N/A N/A N/A

8.10.1.2(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must fail to safe without human intervention.

N/A N/A N/A N/A

Audit : Data : Collisions between trackless mobile machines and pedestrians and trackless mobile machines

54

Collisions between diesel powered trackless mobile machinesPrimary Mining

activites

Service and Maintenance

Contractor Employee

Private Vehicles

8.10.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between diesel powered trackless mobile machines. At any opencast or open pit mine where there is a significant risk of such collisions, such measures must include:8.10.2.1 Every diesel powered trackless mobile machine must be provided with means to automatically detect the presence of any other diesel powered trackless mobile machine within its vicinity; and

N N N/A N/A

8.10.2.1(a) upon detecting the presence of another diesel powered trackless mobile machine, the operators of both diesel powered trackless mobile machines shall be warned of each other's presence by means of an effective warning; and

N N N/A N/A

8.10.2.1(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must "fail to safe" without human intervention.

Not Yet in Force

Not Yet in Force

N/A N/A

Collisions between trackless mobile machines and rail bound equipment8.10.2.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between trackless mobile machines and rail bound equipment. At underground operations where there ie a significant risk of such collisions, such measures must include warning the operators of the trackless mobile machine and the locomotive of each other's presence by means of an effective warning.

N/A N/A N/A N/A

Significant Risk Evaluation Process 55

TMM Type Approximate QuantityPrimary Mining activites 145

Service and Maintenance 445Contractor 74

Employee Private Vehicles 419

Area Identification Hazard Identification Risk Identification and Assessment Raw Rating Controls Residual Rating

Geographical area Hazard Activity Risk (Unwanted event) Consequences

Co

nse

qu

en

ces

Lik

eli

ho

od

Ra

w R

ati

ng

Controls

Co

nse

qu

en

ces

Lik

eli

ho

od

Re

sid

ua

l R

ati

ng

Additional controls

Mining – Haul roads

Hauling on haul roads

Unauthorized use of equipment Fatality, Major damage 5 4 24

• Key control system for all equipment

• Training • Procedures • Supervision

5 2 19

Failure to use safety belts on trucks/TMMs

Fatalities, serious injuries 5 3 22

• Training • Safety belts should be worn at

all times • Mindset of an operator while

on duty • procedures

5 2 19

Slip and fall while Ascending or descending a haul truck Serious injuries 3 3 13

• Procedure and correct PPE • Training • Make sure that there’s enough

light during the night • Use of a Three point anchor

method • Housekeeping: No Foreign

objects on the walkways

3 2 9

Driving through water of unknown depth Injury, Major damage 3 4 17

• TMM operator should communicate with foreman/pit worker when encountering water of unknown depth

• Awareness of area before drive through.

• Determine depth of water before attempting to drive through.

• Procedures.

3 2 9

Interaction between equipment and structures /

power lines

Fatality, Electric shock, major damage 5 5 25

• Inspection of roads, loading and dumping areas during shift

• Awareness of structure’s positions near roads

• Demarcation on roads to guide traffic – leads, poles, etc.

• Safety berms to be placed in high risk areas

5 3 22

226 / 1187 Require PDS

56 Risk Assessment : Geographical Environment

Open Pit (Red Permit) Area:

• Mining Activities • TMM KE < 60MJ

• Haulers 200T Class • Blasting

• Major TMM Related Incidents

Plant Areas:

• TMM KE < 12MJ

• TMM Designated Areas of Operation

• Minor TMM Related Incidents

Office Area: • LDV Traffic Area

• Designated Parking • Demarcated

Pedestrian Crossing • No TMM Incidents

Access to Green Areas Service Station

Main access shared by LDV and Coal Trucks

Slow Moving TMM Operators Relieve And others activities

Risk Assessment : Evaluation Matrix 57

1. Hazard Identification 2. Risk Identification

3. Risk Analyses 4. Consequence & Likelihood

5. Identify High Risk 6. Control Measures (1-9)

7. Residual Risk 8. Implement Control Measures

9. Significant Risks - PDS

RISK ASSESSMENT PROCESS RISK ASSESSMENT PROCESS

Significant

Risk

Risk Assessment : Past Collision Data

Safety Performance

58

Haul Truck30%

Shovel14%

ADT1%

Dril l Rig4%

Diesel Bowser1%

LDV15%

Water Bowser2%

Grader3%

FEL2%

Track Dozer

1%

Rubber wheel Dozer

4%

Man - Service trucks

3%

Busses0%

Pedestrian0%

Stationary object20%

5 year historical of TMM type involved in collision incidents in mining

Risk Assessment : Past Collision Data

Safety Performance

59

2010 2011 2012 2013 2014P_HME 6 32 21 29 18S_HME 2 6 5 8 11LDV / Busse / Services 5 3 2 10 21Pedestrians 0 0 0 0 0Stationary Objects 10 10 16 6 2

0

5

10

15

20

25

30

35

Num

ber o

f inc

iden

ts

Summary of TMM, Pedestrians & Stationary objects involved in incidents

Risk Assessment : Open Pit TMM Collisions Summary

60

Section Possible TMM Collision Pairs

Highest Inherent (Raw) Risk

Highest Residual (Post Control) Risk

Target Risk (Post action Plan)

Open Pit Area

Haul Roads 738 25 25 19

Loading Areas 516 25 22 19

Drilling Blocks 25 22 22 19

Discard 381 25 19 15

IPCC 497 25 19 15

1300/1400 382 25 19 15

Niertjie 375 25 19 15

Blasting Area 25 19 19 15

Construction & Road Maintenance 738 25 25 19

Tipping Bins 348 25 24 19

Stockpiles 375 25 22 19

Workshops 627 25 25 19

Green Area Hauling 250 25 22 19

Green Area Secondary 250 25 22 19

Explosives Magazines 12 19 19 15

Risk Assessment : Plant Area TMM Collisions Summary

61

Section Possible TMM Collision Pairs

Highest Inherent (Raw) Risk

Highest Residual (Post Control) Risk

Target Risk (Post action Plan)

Open Pit Area

Beneficiation Plant 580 23 20 13

Central 396 23 17 13

Supply Chain 147 23 17 13

Risk Assessment : Mining Red Area TMM Collisions

63

Area: Haul RoadsIn

here

nt R

isk

Haul

Truc

ks

Grad

ers

Wat

er Tr

ucks

LDVs

Trac

k Doz

er

Whe

el Do

zers

824

Whe

el Do

zers

tiger

FEL (

large

)

FEL (

small

)

Exca

vato

r

TLB

Dies

el Bo

wser

Hone

y suc

ker

ADT S

ervic

e tru

ck

Low

Bed 7

77

Low

Bed s

ervic

es

Was

te tr

uck

Tyre

hand

ler

Cable

hand

ler

Trac

tor b

room

Fork

lift

Mob

ile cr

anes

Road

com

pacto

r

Craw

ler

Titan

Pant

o Plat

form

Cher

ry pi

cker

Mot

ivato

r

MAN

Cher

rypic

ker

MAN

Serv

ice tr

uck

Buss

es

Mini

-bus

/ tro

oper

Explo

sives

truc

ks

ADT W

ater

truc

k

Bob C

at

Drill

Rig

Shov

el

Stru

cture

s/bu

lding

s

Perso

ns

Haul Trucks 25 24 24 25 18 22 9 9 22 22 22 22 22 22 18 22 19 19 22 22 22 22 22 19 19 19 22 22 22 22 25 22 22 22 9 19 25 25Graders 14 22 22 13 9 22 14 14 5 5 22 22 13 22 22 19 19 22 22 22 22 19 5 22 19 18 9 9 22 22 22 18 22 9 19 22 22Water Trucks 22 22 17 17 17 8 8 19 19 22 22 22 24 24 19 19 22 22 22 22 22 18 22 22 21 22 22 22 22 21 19 22 18 19 25 22LDVs 20 14 22 22 22 22 5 5 22 22 22 22 22 2 19 19 22 22 22 14 14 22 19 22 22 22 22 21 19 21 13 18 5 25 22Track Dozer 9 9 9 14 14 14 14 22 19 13 9 14 19 3 5 14 3 22 18 18 22 19 14 10 14 22 15 19 14 19 9 3 19 22Wheel Dozers 824 9 22 18 18 13 9 22 18 18 22 22 6 6 13 13 9 14 9 9 22 14 22 22 22 22 22 22 13 22 9 9 18 22Wheel Dozers tiger 9 13 13 22 22 22 22 18 13 13 18 18 18 22 22 22 19 6 13 19 8 8 8 22 22 22 8 22 14 3 13 22FEL (large) 5 9 22 22 22 18 18 13 13 18 18 18 22 22 22 22 6 13 15 13 13 18 22 22 22 18 22 14 3 13 22FEL (small) 13 9 9 22 9 18 19 19 14 14 14 18 22 22 13 3 14 14 19 14 14 22 22 22 18 22 9 6 13 22Excavator 9 5 22 18 18 18 18 14 14 14 13 13 18 13 8 18 14 18 18 18 22 22 22 18 22 5 5 9 22TLB 14 22 19 18 18 18 18 13 13 13 13 18 13 5 18 13 18 18 18 22 22 22 18 22 5 5 13 22Diesel Bowser 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22Honey sucker 14 18 18 18 18 18 18 2 22 22 18 3 9 9 18 18 18 22 22 22 18 22 9 9 18 22ADT Service truck 0 18 18 18 18 18 22 22 18 18 5 9 13 18 18 18 22 22 22 18 22 13 6 18 22Low Bed 777 0 18 18 13 13 22 22 18 19 5 9 18 18 18 18 22 22 22 18 22 14 6 13 22Low Bed services 18 18 13 13 22 22 18 18 5 9 18 18 18 18 22 22 22 18 22 14 6 13 22Waste truck 0 18 18 22 22 22 18 5 13 18 18 18 18 22 22 22 18 22 9 1 13 22Tyre handler 18 13 13 18 18 18 5 18 18 18 18 18 22 22 22 18 22 9 1 13 22Cable handler 13 13 18 18 18 5 18 18 18 18 18 22 22 22 18 22 9 1 13 22Tractor broom 13 13 22 13 5 13 13 18 18 18 22 22 22 18 22 9 5 13 22Forklift 13 13 13 5 22 18 18 18 18 22 22 22 18 22 9 5 13 22Mobile cranes 22 18 5 18 18 18 13 13 22 22 22 18 22 13 9 13 22Road compactor 9 5 13 18 18 13 13 22 22 22 18 18 9 5 9 22Crawler 0 6 6 6 6 6 6 6 6 6 6 6 6 6 22Titan Panto Platform 0 18 18 18 18 22 22 22 18 22 9 6 22 22Cherry picker 5 18 18 18 22 22 22 18 6 6 6 13 22Motivator 0 18 18 22 22 22 18 22 6 18 17 22MAN Cherrypicker 9 18 22 22 22 18 22 6 8 13 22MAN Service truck 22 22 22 22 22 22 13 9 13 22Busses 22 22 22 22 22 6 9 18 22Mini-bus / trooper 22 22 22 22 6 9 18 22Explosives trucks 22 22 22 22 22 22 22ADT Water truck 0 22 9 9 13 22Bob Cat 4 4 3 5 18Drill Rig 3 3 13 25Shovel 3 13 18

Resid

ual R

isk

Haul

Truc

ks

Grad

ers

Wat

er Tr

ucks

LDVs

Trac

k Doz

er

Whe

el Do

zers

824

Whe

el Do

zers

tiger

FEL (

large

)

FEL (

small

)

Exca

vato

r

TLB

Dies

el Bo

wser

Hone

y suc

ker

ADT S

ervic

e tru

ck

Low

Bed 7

77

Low

Bed s

ervic

es

Was

te tr

uck

Tyre

hand

ler

Cable

hand

ler

Trac

tor b

room

Fork

lift

Mob

ile cr

anes

Road

com

pacto

r

Craw

ler

Titan

Pant

o Plat

form

Cher

ry pi

cker

Mot

ivato

r

MAN

Cher

rypic

ker

MAN

Serv

ice tr

uck

Buss

es

Mini

-bus

/ tro

oper

Explo

sives

truc

ks

ADT W

ater

truc

k

Bob C

at

Drill

Rig

Shov

el

Stru

cture

s/bu

lding

s

Perso

ns

25 24 24 25 15 19 9 9 19 19 19 19 15 19 14 15 15 15 19 19 19 15 19 10 15 15 19 19 19 15 19 19 19 19 9 5 22 2210 15 19 9 9 15 10 10 5 5 19 15 9 15 15 15 15 15 19 15 15 15 5 15 15 14 9 9 15 15 19 14 19 9 15 19 19

15 19 13 13 13 8 8 15 15 15 15 15 19 19 15 15 19 19 19 19 19 10 15 15 18 15 19 15 19 18 15 19 18 19 25 2220 10 15 15 15 15 5 5 19 15 15 15 15 2 15 15 19 15 15 10 10 15 15 15 15 15 15 18 15 18 9 6 5 22 15

9 9 9 10 10 10 10 15 15 9 9 10 15 3 5 10 3 15 10 10 15 15 10 10 10 15 15 15 10 15 9 3 15 159 15 14 10 6 6 15 10 14 15 15 6 6 6 6 9 10 9 9 15 10 15 15 15 15 19 19 6 15 9 9 14 15

9 9 9 15 15 15 15 14 6 6 10 10 10 15 15 15 15 6 6 15 8 8 8 15 15 15 8 15 10 3 6 155 9 19 19 19 15 15 9 9 14 14 14 19 19 19 19 6 9 9 9 9 14 19 19 19 14 19 10 3 9 15

9 9 9 15 9 14 15 15 10 10 10 14 19 19 9 3 10 1 15 10 10 15 19 1 14 19 9 6 9 199 5 15 14 14 14 14 10 10 10 9 9 10 9 8 10 10 14 14 14 15 15 19 14 15 5 5 9 15

10 15 15 14 14 14 14 9 9 9 9 9 9 5 9 9 14 14 14 15 19 15 14 15 5 5 13 1519 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19

10 14 14 14 14 14 14 2 15 15 14 3 9 9 14 14 14 15 15 15 14 19 9 9 14 190 14 14 14 14 14 19 19 14 14 5 9 9 14 14 14 19 19 19 14 19 9 6 14 19

0 14 14 9 9 15 15 14 15 5 9 14 14 14 14 15 15 15 10 10 10 6 9 1914 14 9 9 15 15 14 15 5 9 14 14 14 14 15 15 15 10 10 10 6 9 19

0 10 10 15 15 15 14 5 9 10 10 10 10 15 15 15 10 10 9 1 9 1915 9 9 14 14 14 5 14 14 14 14 14 19 19 19 14 19 9 1 9 19

9 9 10 10 10 5 10 10 10 10 10 15 15 15 10 19 9 1 9 199 9 15 9 5 9 9 10 10 10 15 15 15 10 15 9 5 9 19

9 9 9 5 15 10 10 10 10 15 15 15 10 15 9 5 9 1915 10 5 10 10 10 10 10 15 15 15 10 10 9 9 9 19

9 5 9 9 9 9 9 19 19 19 15 15 9 5 9 190 6 6 6 6 6 6 6 6 6 6 6 6 6 19

0 14 14 14 14 19 19 19 18 19 9 6 19 195 14 14 14 19 19 19 14 6 6 6 13 19

0 14 14 19 19 19 14 19 6 14 13 199 14 19 19 19 14 19 6 8 9 19

19 19 19 19 19 19 9 9 9 1919 19 19 19 19 6 9 14 19

19 19 19 19 6 9 14 1919 19 19 19 19 19 19

0 19 9 9 9 194 4 3 5 14

3 3 9 193 9 10

Risk Assessment : Plant Area TMM Collisions 64

Beneficiation Plant Ra

w ris

k

LDV

/ Tra

ilors

Coal

trans

porte

rs

Tar lo

ading

Tank

ers

Mob

ile Cr

anes

Trac

k Doz

er

Whe

el Do

zers

FEL

Mob

ile br

oom

Exca

vato

r

TLB

Self p

rope

lled D

iesel

Bows

er

Hone

y suc

ker

ADT

Low

Bed

Was

te tr

uck

Ambu

lance

Fire t

ruck

Fork

lift

Horse

& Tr

ailer

Road

com

pacto

r

Man

iscop

ic

Cher

ry pi

cker

Wat

er tr

ucks

Buss

es

Mini

-bus

/ tro

oper

Tippe

r tru

cks

Bob C

at /

Skids

teer

Grad

ers

Mob

ile Sc

reen

Stac

ker /

Recla

imer

s

Train

build

ings /

struc

ture

s / ov

erhe

ad ca

bles

Anim

als

Hum

an

LDV / Trailors 23 18 15 18 15 18 21 10 15 15 15 15 15 15 18 15 15 18 15 10 18 15 15 21 21 19 21 19 10 21 18 23 23 15Coal transporters 21 15 15 10 10 18 10 0 0 18 0 18 15 15 15 15 15 15 10 15 15 15 15 15 15 15 15 10 0 15 18 10 15Tar loading Trucks 0 15 0 0 15 10 0 15 15 15 15 15 15 15 15 15 15 10 15 15 15 15 15 15 15 0 0 0 0 15 10 15Mobile Cranes 21 15 15 15 10 15 15 15 15 15 21 15 15 15 15 15 15 15 10 15 15 15 15 10 15 10 15 15 21 10 15Track Dozers 0 0 15 0 0 0 15 0 0 15 0 15 15 0 0 0 0 0 0 0 0 0 0 0 0 15 0 18 10 15Wheel Dozers 0 15 0 0 0 15 0 0 0 0 15 15 0 0 0 0 0 15 0 0 0 0 0 0 15 0 14 10 15FEL 15 15 15 15 15 15 18 15 15 15 15 15 15 15 15 15 15 15 15 18 15 15 15 18 15 21 21 15Mobile broom 0 0 15 15 15 15 15 15 15 15 15 15 0 15 10 15 15 15 15 10 15 0 0 15 15 10 15Excavator 0 0 15 0 15 15 0 15 15 0 0 0 0 0 15 0 15 15 0 15 15 0 0 18 10 15TLB 0 15 15 18 15 15 15 15 15 15 15 15 15 15 15 15 18 15 15 15 15 15 18 10 15Self propelled Diesel Bowser 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 0 15 15 10 15Honey sucker 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 0 15 18 10 15ADT 18 15 15 15 15 15 15 15 15 15 15 15 15 18 15 15 15 10 15 15 10 15Low Bed 18 15 15 15 18 18 15 18 15 15 15 15 15 15 15 15 15 15 18 10 15Waste truck 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 0 15 15 10 15Ambulance 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 10 15Fire truck 0 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 10 15Forklift 18 18 15 15 15 15 15 15 15 15 15 15 15 15 21 10 15Horse & Trailer 15 15 18 15 15 15 15 15 15 15 15 15 15 15 10 15Road compactor 0 15 15 15 15 15 15 15 15 15 0 15 15 10 15Maniscopic 15 15 15 15 15 15 15 15 15 18 15 18 10 15Cherry picker 0 15 15 15 15 15 15 15 15 15 15 10 15Water trucks 15 15 15 15 15 15 15 0 15 15 10 15Busses 15 15 15 15 15 15 0 15 15 10 15Mini-bus / trooper 18 15 15 15 15 15 15 18 10 15Tipper trucks 21 15 15 15 15 15 18 10 15Bob Cat / Skidsteer 15 15 15 15 15 17 10 15Graders 0 15 0 15 15 10 15Mobile Screen 0 0 0 2 10 15

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20 8 6 8 3 6 12 3 6 6 10 6 6 6 6 6 6 13 6 3 8 3 8 12 12 9 12 9 3 3 12 16 16 1012 3 3 3 10 10 10 0 0 10 0 13 6 6 6 6 6 6 3 6 10 6 6 6 6 6 6 10 0 6 13 3 10

0 6 0 0 6 10 0 6 10 6 6 6 6 6 6 6 6 3 6 10 6 6 6 6 6 0 0 0 0 6 3 1017 3 6 6 10 6 6 10 6 6 17 6 6 6 6 6 3 6 10 6 6 6 6 6 6 10 6 6 17 3 10

0 0 6 0 0 0 10 0 0 6 0 6 6 0 0 0 0 0 0 0 0 0 0 0 0 6 0 8 3 100 6 0 0 0 10 0 0 0 0 6 6 0 0 0 0 0 6 0 0 0 0 0 0 6 0 3 3 10

6 10 6 6 10 6 13 6 0 6 6 6 6 3 6 10 6 6 6 13 10 6 10 8 6 12 12 100 0 6 10 6 6 6 6 6 6 6 6 0 6 3 6 6 6 6 3 6 0 0 6 6 3 6

0 0 10 0 6 6 0 6 6 0 0 0 0 0 6 0 6 6 0 6 10 6 0 8 3 100 10 6 8 6 6 6 6 6 6 3 6 10 6 6 6 8 10 6 3 3 10 8 3 10

10 10 10 10 10 10 10 10 10 3 10 10 10 10 10 10 10 10 10 0 10 10 3 100 6 6 6 6 6 6 6 3 6 10 6 6 6 6 6 6 10 0 6 8 3 10

13 6 6 6 6 6 6 3 6 10 6 6 6 13 10 6 10 6 6 6 3 1013 6 6 6 13 13 3 13 10 6 6 6 6 10 6 10 6 6 13 3 10

0 6 6 6 6 3 6 10 6 6 6 6 10 6 10 0 6 6 3 100 6 6 6 3 6 10 6 6 6 6 10 6 10 6 6 6 3 10

0 6 6 3 6 10 6 6 6 6 10 6 10 6 6 6 3 1013 13 3 6 10 6 6 6 6 10 6 10 6 6 13 3 10

6 3 13 10 6 6 6 6 10 6 10 6 6 6 3 100 6 10 6 6 6 6 10 6 10 0 6 6 3 10

6 10 6 6 6 6 10 6 10 8 6 8 3 100 10 10 10 10 3 10 3 3 10 6 3 6

6 6 6 6 10 6 10 0 6 6 3 106 6 6 6 6 10 0 6 6 3 10

6 6 6 6 10 6 6 8 3 1017 10 6 10 6 6 8 3 10

3 10 3 3 10 12 3 60 10 0 6 6 3 10

0 0 0 2 3 6

65 Risk Assessment : Significant Risk Result

Open Pit (Red Permit) Area:

• PDS Required • Further action to

reduce risk

Plant Areas:

• PDS Not Required • Further action to

reduce risk

Office Area: • PDS Not required Access to Green Areas

Service Station

Main access shared by LDV and Coal Trucks

Slow Moving TMM Operators Relieve And others activities


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines









PDS Collision Risk Scenarios Addressed 67

1. 2.

3. 4.

5.

SAFE - MINE Project Scope 68

Function Detail

Traffic Awareness P_HME S_HME LDV

360∘ awareness, simple display

Safety Centre Shovel Assist

Tracking Radar Pedestrian (Only TMM will detect pedestrian)

Range up to 30m Detection of moving objects only Smart algorithm based collision Range up to 12 m Adapted to vehicle width Detection of static and moving

Geo - fencing Static Object Detection

NO – GO zones stop signs, overhead line Structures / buldings

Black Box Recording – Real Time

Continuous recording of vehicle parameters (speed, direction, braking)

Test / Sync Station, Boom Gates Testing

Assures protection and registers vehicles

Auto update of firmware and configuration

Equipment list covered in the project 69

Project Schedule Milestones 70

Task Name Duration Start Finish

PSO Setup 10 days Mon 15/05/04 Fri 15/05/15Project Planning 5 days Mon 15/05/18 Fri 15/05/22DMR Feedback Session 0 days Fri 15/05/22 Fri 15/05/22Contract Signature 0 days Mon 15/05/04 Mon 15/05/04Place Contract Orders 5 days Mon 15/06/08 Fri 15/06/12Site Establishment 33 days Fri 15/05/22 Wed 15/07/08Change Management 221 days Mon 15/05/25 Mon 16/03/28Critical Spares on Site 35 days Mon 15/05/04 Fri 15/06/19Installation Configuration Design

49.38 days Mon 15/05/25 Fri 15/07/31

Update of Procedures 90 days Fri 15/07/31 Fri 15/12/04Equipment Delivery 0 days Fri 15/07/31 Fri 15/07/31Installation 260 days Fri 15/07/31 Fri 16/07/29Activation 155 days Fri 16/01/29 Fri 16/09/02Training 160 days Fri 16/01/29 Fri 16/09/09

Audit : Summary : Collisions between trackless mobile machines and pedestrians and trackless mobile machines

71

Recommendations

Implement PDS on all TMMs operating in the red permit

area

Action Responsible Due date Comment CompletionInvolve H&S Committee to

evaluate TMM interactions according to MOSH risk assessment philosophy

Vicente Alvarado 15-May-15Sessions held with relevant H&S

committee members and risk assessment concluded.

100%

Compile Functional Specification for PDS

Henry Lefawane 15-Apr-15Sample sent to Limpopo Snr

Machinery Inspector for comments

100%

Complete Tender Process and award tender fro PDS

Johann Kruger 14-May-15Process conclude and Trysome

was awarding contract to install Safe mine PDS system

100%

Access to RBE (Spreader) in open pit is restricted but

requires PDSHenry Lefawane 09-Sep-16

Implement GEO fencing of Backfil l Spreader, CV10 and

MD100%

Implement PDS system Johann Flick 09-Sep-16 Kick-off meeting concluding site establishment in process

0%

Implement MOSH standard Adoption Change management

on PDSMadele Nelson 28-Mar-16 Scoping HR change management

project 0%

Regulation Audit Finding8.10.1 The employer must take reasonably practicable measures to ensure that pedestrian are prevented from being injured as a

result of coll isions between trackless mobile machines and pedestrian. At any mine where there is a significant risk of such

coll isions, such measures must include at least thefollowing:

226/1187 TMMs require PDS

Action Plan


H&S Committee

Vision & Purpose

Background



Summary

Comply (83%)




Diesel Refuelling




Selection










machines









Summary and Closure 73

Based on the audit conducted on the new TMM regulations Exxaro Grootegeluk believes that the non-compliances identified and the action plans initiated will ensure that Grootegeluk complies with the new TMM regulations which will assist Grootegeluk in achieving our vision.

EXXARO reaffirms its commitment to strive for Zero Harm. An injury and fatality free company.

Backup Slides

Regulations

DMR Surface Mobile Equipment Interactive Risk Incident Review

MOSH T&M: Risk Analysis and Potential Leading Practice for Open Pit/Cast Operations

DMR Yardsticks

75

TMM Regulations 8.10.1 to 8.10.1.2 76

Collisions between trackless mobile machines and pedestrians8.10.1 The employer must take reasonably practicable measures to ensure that pedestrian are prevented from being injured as a result of collisions between trackless mobile machines and pedestrian. At any mine where there is a significant risk of such collisions, such measures must include at least the following:8.10.1.1 All electrically or battery powered trackless mobile machines, excluding shovels, bucket wheel excavators and overburden drills, must be provided with means to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the trackless mobile machine and the pedestrian must be warned of each other's presence by means of an effective warning. In the event where no action is taken to prevent potential collision, further means must be provided to retard the trackless mobile machine to a safe speed where after the brakes of the trackless mobile machine are automatically applied without human intervention.8.10.1.2 All underground diesel powered trackless mobile machines must be provided with means:8.10.1.2(a) to automatically detect the presence of any pedestrian within its vicinity. Upon detecting the presence of a pedestrian, the operator of the diesel powered trackless mobile machine and the pedestrian shall be warned of each other's presence by means of an effective warning; and8.10.1.2(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must fail to safe without human intervention.

TMM Regulations 8.10.2 to 8.10.3 77

Collisions between diesel powered trackless mobile machines8.10.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between diesel powered trackless mobile machines. At any opencast or open pit mine where there is a significant risk of such collisions, such measures must include:8.10.2.1 Every diesel powered trackless mobile machine must be provided with means to automatically detect the presence of any other diesel powered trackless mobile machine within its vicinity; and8.10.2.1(a) upon detecting the presence of another diesel powered trackless mobile machine, the operators of both diesel powered trackless mobile machines shall be warned of each other's presence by means of an effective warning; and

8.10.2.1(b) in the event where no action is taken to prevent potential collision, further means shall be provided to retard the diesel powered trackless mobile machine to a safe speed where after the brakes of the diesel powered trackless mobile machine are automatically applied. The prevent potential collision system on the diesel powered trackless mobile machine must "failto safe" without human intervention.

Collisions between trackless mobile machines and rail bound equipment8.10.2.2 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of collisions between trackless mobile machines and rail bound equipment. At underground operations where there ie a significant risk of such collisions, such measures must include warning the operators of the trackless mobile machine and thelocomotive of each other's presence by means of an effective warning.Trackless mobile machines running uncontrolled8.10.3 The employer must take reasonably practicable measures to prevent trackless mobile machines running uncontrolled.


Overturning of any trackless mobile machine8.10.4 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of overturning of any trackless mobile machine. Roll overprotection structures must be fitted on trackless mobile machines if required in terms of the mine's risk assessment.Objects falling onto operators and/or passengers of trackless mobile machines8.10.5 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of objects falling onto operators and/or passengers of trackless mobile machines. Trackless mobile machines must be fitted with falling object protection structures to protect operators and passengers from falling objects if required in terms of the mine's risk assessment.Persons inadvertently falling out of or being ejected from trackless mobile machines.

8.10.6 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of operators and/or passengers inadvertently falling out of or being ejected from any trackless mobile machine in motion.

Braking systems8.10.7 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of brake failure. Such measures must include ensuring:8.10.7.1 that trackless mobile machines are operated with adequate and effective braking systems;8.10.7.2 all braking systems are adequately and routinely tested for intended functionality;8.10.7.3 all braking systems are regularly maintained; and 8.10.7.4 that where a combined braking system is used, the design of the braking system is such that it complies with the requirements for the separate systems and that it fails to safe.


Restricted operator visibility.8.10.8 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of restricted operator visibility.Fatigue while operating a trackless mobile machine.8.10.9 The employer must take reasonably practicable measures to ensure that persons are prevented from being injured as a result of fatigue of operators. Such measures must include a fatigue management procedure for operators.Battery charging facilities8.10.10 The employer must take reasonably practicable measures to ensure that battery charging facilities are ergonomically designed, constructed and equipped with the following:

i) Adequate through ventilation;ii) Adequate fire suppression equipment;iii) Effective provisions to treat persons in the event of acid spillage; andiv) Appropriate and adequate lighting.Diesel refuelling facilities8.10.11 The employer must take reasonably practicable measures to ensure that diesel refueling facilities are ergonomically designed, constructed and equipped with the following:i) Adequate through ventilation;ii) Adequate fire suppression equipment;iii) Effective provisions to cater for oil and diesel spillages; andiv) Appropriate and adequate lighting.v) Surface diesel refueling facilities are in accordance with:a. SANS 10089-1 (2008): The petroleum industry Part 1: Storage and distribution of petroleum products in above-ground bulkinstallations.

b. SANS 10089-2 (2007): The petroleum industry Part 2: Electrical and other installations in the distribution and marketing sector.

c. SANS 10089-3 (2010): The petroleum industry Part 3: The installation, modification, and decommissioning of underground storage tanks, pumps/dispensers and pipe work at service stations and consumer installations.


Wheels, tyres and rims8.10.12 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented to prevent persons from being injured as a result of the use, storage and handling of wheels, tyres and rims.Access of persons to and from the trackless mobile machines8.10.13 The employer must take reasonably practicable measures to ensure that trackless mobile machines are designed, constructed and maintained such that persons getting on and off, or working on them can do so safely.Visibility of trackless mobile machines, skid mounted machinery and trailers to persons.8.10.14 The employer must take reasonably practicable measures to ensure that trackless mobile machines, skid mounted machinery and trailers are visible to persons in their vicinity.Unauthorised access to or operation of trackless mobile machines.8.10.15 The employer must take reasonably practicable measures to ensure thatunauthorised persons do not ride on or operate trackless mobile machines.


Isolation and lock-out of trackless mobile machines8.10.16 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the safe isolation and lockout of trackless mobile machines.Operating procedures8.10.17 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the safe operation of trackless mobile machines.Maintenance standards and procedures8.10.18 The employer must take reasonably practicable measures to ensure that procedures and standards are prepared and implemented for maintaining trackless mobile machines in a safe operating condition.Remote and remotely controlled trackless mobile machines8.10.19 The employer must take reasonably practicable measures to ensure that remote control devices for trackless mobile machines using a wireless remote control device comply with:a) SANS 61000-4-2 (IEC 61000-4-2) Electrostatic immunity discharge test;b) SANS 61000-4-3 (IEC 61000-4-3) Radiated, radio frequency, electromagnetic field immunity test;.c) SANS 61000-4-4 (IEC 61000-4-4) Electrical fast transient/burst immunity test;d) SANS 61000-4-5 (IEC 61000-4-5) Surge immunity test.e) SANS 61000-4-6 (IEC 61000-4-6) Immunity to conducted disturbances, induced by radio-frequency fields;f) SANS 61000-4-8 (IEC 61000-4-8) Power frequency magnetic field immunity test; and.g) SANS 61000-4-11 (IEC 61000-4-11) Voltage dips, short interruptions and voltage variations immunity test.


Trailers8.10.20 The employer must take reasonably practicable measures to ensure that:a) the design and construction of any trailer is in accordance with specifications approved by a competent person, which specifications must take into account the intended use of the trailer;b) the design and construction of trailer coupling and uncoupling mechanisms is such that coupling and uncoupling can be done safely and that no inadvertent uncoupling of the trailer can take place; andc) procedures are prepared and implemented for the safe operation of trailers.Towing and recovery of trackless mobile machines8.10.21 The employer must take reasonably practicable measures to ensure thatprocedures are prepared and implemented for the safe recovery and towing oftrackless mobile machines.Roadway conditions8.10.22 The employer must take reasonably practicable measures to ensure that the design, construction and maintenance of roadways are appropriate for the type and category of trackless mobile machineSelection, training, appointment and licensing of trackless mobile machine operators8.10.23.1 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for the selection, training, appointment and licensing of trackless mobile machine operators, which procedures must include:8.10.23.1 physical and psychological pre-selection criteria;8.10.23.2 a training programme for trackless mobile machine operators, covering:i) theoretical training in a training Centre;ii) practical training; andiii) on the job training.8.10.23.3 assessment of the trainee, on successful completion of the training programme, by a competent person;8.10.23.4 that only operators, assessed to be competent are authorised in writing by the responsible engineer to operate trackless mobile machines;8.10.23.5 that operators of trackless mobile machines are authorized in writing by their supervisor to operate trackless mobile machines. Such authorization must detail their duties, responsibilities, limitations and areas of operation.8.10.23.6 when an operator has not operated a trackless mobile machine for a period of two years, such operator is re-assessed to be competent by a competent person prior to being issued with a new license.8.10.23.7 that every operator of trackless mobile machines is issued with a license containing at least the following:i) a photograph to positively identify the operator;ii) the trackless mobile machine types which the operator may operate;iii) date of issue and expiry date; andiv) the operator's company identification number.


Pre-use inspection procedures8.10.24 The employer must take reasonably practicable measures to ensure that procedures are prepared and implemented for inspecting trackless mobile machines immediately prior to use, which procedures must include:

8.10.24.1that the operator of the trackless mobile machines physically inspects and ensures that the brakes, lights and any other defined safety features and devices are functioning as intended prior to setting such trackless mobile machines in motion;

8.10.24.2 pre-use check lists that have to be completed by all operators of trackless mobile machines at the beginning of their shift. Such check lists must clearly identify all the components, features and functionalities to be inspected by the operator. For each component, feature or functionality, the check list must clearly indicate the pre-established criteria under which the trackless mobile machines may or may not be put in motion.Reversing over the edge of a stockpile8.10.25 The employer must take reasonably practicable measures to prevent any trackless mobile machine reversing over the edge of a stockpile or dump.Inadvertent movement of the trackless mobile machine8.10.26 The employer must take reasonably practicable measures to prevent inadvertent movement of any trackless mobile machine whilst parked. Mandatory carrying of license8.10.27 All operators of trackless mobile machines must have their originally issued license on their person whilst operating any trackless mobile machine.Certain regulations not applicable8.10.28 Regulations 8.10.23 and 8.10.27 do not apply to trackless mobile machines licensed under the National Road Transportation Act 2000 and not used for primary mining activities.

END of TMM Regulation Slides click on ? To return to presentation menu 84

END of Surface Mobile Risk Review click on ? To return to presentation menu 88

MOSH T&M: Risk Analysis and Potential Leading Practice for Open Pit/Cast Operations

MOSH T&M: Equipment Related Hazards 90

MOSH T&M: Operator Related Hazards 91

MOSH T&M: Information Related Hazards 92

MOSH T&M: Environment Related Hazards 93

MOSH T&M: Operation Related Hazards 94

END of MOSH Slides click on ? To return to Significant Risk Evaluation Slide 95

DMR YARDSTICKS 96

1. Fatigue Management 2. Pre-Use Checklists 3. Roll-Over Protection Systems (ROPS) 4. Falling Objects Protection Systems (FOPS) 5. Procurement 6. Checklist of all TMMs 7. Pedestrian Detection (PD) System 8. Anti Collision Devices 9. Brake Interlocking (Doors) 10. Contractors' Packs 11. Maintenance Systems 12. Brake Test Ramp 13. Fitness to Perform Work (Medical) 14. Fire Extinguishers 15. Fire Suppressions 16. Emergency Preparedness 17. Ergonomics Assessment 18. Illumination 19. Equipment Noise Monitoring

YARDSTICKS – Baseline HIRA 97

22 22

19

22 22

19

22

18 19

22 22

6

15

10

19 19

6

14

9 9

19 19

YARDSTICKS 98

YARDSTICKS 99

YARDSTICKS 100

YARDSTICKS 101

YARDSTICKS 102

YARDSTICKS ADDITIONAL IMPROVEMENT ACTIONS / INITIATIVES

103

YARDSTICK SPECIFIC ACTIONS TARGET STATUS

TMM RELATED 1. Random Vehicle audits to check condition and

compliance to standards. Monthly CONTINUOUS

2. CAS / PDS ????? IN PROCESS

CONTRACTOR MANAGEMENT

1. Contractor Management Department June 2014 COMPLETE

2. Contractor competence and authorizations off site Monthly CONTINUOUS

EMERGENCY PREPARDENESS AND RESPONSE

1. Investigating method to improve EPR process and outputs. March 2015 IN PROCESS

2. Realignment of Trauma and Fire Fighting team March 2015 IN PROCESS

3. Currently evaluating the EPR Instruction issued by DMR for compliance.

February 2015 IN PROCESS

HEALTH AND HYGIENE RELATED

1. TMM Illumination audits and surveys on a more frequent basis Monthly CONTINUOUS

2. Physical Ability Testing Monthly CONTINUOUS

YARDSTICKS ADDITIONAL IMPROVEMENT ACTIONS / INITIATIVES

104

YARDSTICK SPECIFIC ACTIONS TARGET STATUS

GMIRM STRATEGY Risk Management Program to support management of Yardsticks

1. GMIRM Training on all 4 levels of Management and Workforce. July 2015 IN PROCESS

2. Identify GG status on the Journey Model January 2014 COMPLETE

3. Implementation of Improvement Plans. March 2015 IN PROCESS

COMPLIANCE STRATEGY

1. Compliance actions analysis - Present August 2014 COMPLETE

2. Analyze past 2 years actions implemented for completeness.

September 2014 COMPLETE

3. Audit and rectify completeness of actions in specific areas Monthly CONTINUOUS

4. VFL sessions to evaluate behavior Weekly CONTINUOUS

5. Instructions to comply process Random CONTINUOUS

6. Internal Sec 54 / 55 process Random CONTINUOUS

END of YARDSTICKS click on ? To return to Audit Summary 105

END of Backup Slides click on ? To return to presentation menu 107