Professional Documents
Culture Documents
LIGHT VEHICLES
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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CONTENTS 1 2 3 4 5 6 7 8 AIM APPLICATION DEFINITIONS REASON FOR INCLUSION REQUIREMENTS PLANT AND EQUIPMENT REQUIREMENTS SYSTEM AND PROCEDURAL REQUIREMENTS PEOPLE REQUIREMENTS
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APPENDIX A: REFERENCE DOCUMENTS APPENDIX B: IDENTIFICATION SIGNAGE SPECIFICATIONS APPENDIX C: FIRST AID KITS APPENDIX D: INSPECTION SHEET RECORD OF AMENDMENTS
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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AIM
To eliminate or minimise the risk of fatalities, injuries and incidents arising from the use of light vehicles in surface operations. This guideline refers to the implementation of the Anglo Fatal Risk Standard: Light Vehicles and should be read in conjunction with that Standard. The guidelines contained in this document are considered as "highly recommended" and deviations are to be documented and justified. Full adherence to these guidelines will not be a factor in determining compliance with the Standards, since alternative methods can be available if justified on a risk basis. In case of conflict with requirements of any other Anglo document or guideline, the following hierarchy will apply: 1. 2. 3. Anglo Safety Way Anglo Fatal Risk Standards Anglo Fatal Risk Guidelines ASW AFRS AFRG
It is important that when implementing Standards the organisation takes cognizance of, and complies with the relevant legal requirements in the country of application.
APPLICATION
This Standard applies to all light vehicles used for work-related activities and for transporting people and light loads. Examples of light vehicles covered by this Standard are passenger cars, four-wheel drives (including all-wheel drives), sports utility vehicles (SUVs), pick-ups (utilities, bakkies) and mini-buses. This Standard applies to all Anglo American Group managed businesses and operations, including contractors and visitors when involved in controlled activities. The purpose of this document is to provide guidance and clarity to enable sites to implement the requirements of the Light Vehicles Fatal Risk Standard by 4 October 2010. This should assist sites to align with each other and adopt common solutions regards to meeting the requirements. This guideline is by no means exhaustive and will be updated periodically and supported by good practice sharing. It is not intended as a template for achieving compliance. The application of the standard is mandatory when private vehicles are being used on a regular basis to undertake work related trips. The use of motorcycles (two wheeled self propelled vehicle) for work related activities should be avoided due to the high risks associated with motorcycle travel. An employee could use his motorcycle to commute to work, but not for a call-out as this is deemed for work purposes.
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This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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DEFINITIONS
A light vehicle is a vehicle which; can be licensed and registered for use on a public road has four or more wheels seats a maximum of 12 adults (including the driver) when registered, can be driven legally on a public road by a driver issued with a standard basic-level public road drivers licence does not exceed 4.5 tonnes gross vehicle mass (GVM), which is the maximum loaded mass of the motor vehicle as specified by: The vehicles manufacturer, OR An approved and accredited automotive engineer, if the vehicle has been modified to the extent that the manufacturers specification is no longer appropriate.
Any light vehicle falling outside of this group should refer to the Surface Mobile Equipment standard. Light vehicles may include the following categories of vehicles being used for workrelated activities: Anglo American owned or leased vehicles; Hire vehicles (for example Budget or Hertz rental vehicles); Contractor or supplier vehicles operating on company property; Private vehicles (personal or hired) used for work-related activities. Those where the Anglo American Group Company has the authority to determine how to manage the operation. They do not include monitored or uncontrolled activities. Those where Anglo American can exercise some influence but does not have the authority to determine how they should be managed e.g. supplier transporting goods to site; contractor transporting personnel off site. Those where Anglo American has no influence and does not supervise safety performance e.g. services provided by public Companies; activities performed at suppliers works. The work environment is defined as the establishment and other locations where one or more employees are working or are present as a condition of their employment. Injuries and illnesses that occur whilst the employee/contractor is travelling for work-related activities in the interests of the employer are classified as work related. Examples of these activities include: Driving or being driven in a vehicle for work-related purposes,
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This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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irrespective of the cause of any incident involving the vehicle. Being transported to and from customer contacts after lodging has been established and as part of work-related activity. Entertaining or being entertained to transact, discuss or promote business provided the entertainment is at the direction of the employer. Injuries sustained during an employees normal commute from a permanent residence to an office are not considered work related. Situations where the employee departs from a reasonably direct route of work related travel for personal reasons e.g. a side trip to visit a place of interest or vacation.
Risk of fatalities or injury related to vehicle accidents is high. Fatal Injury Frequency Rate international statistics due to vehicle accidents are typically 0.1 fatalities per 200 000 man-hours driving. This is 5 times higher than the current overall Anglo American Fatal Injury Frequency Rate.
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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REQUIREMENTS
Application of the Anglo Fatal Risk Standards is mandatory at all Anglo American managed businesses and operations. This mandatory nature is indicated by the use of the word shall within the Standards. In some places, the word should is used. This means that the primary intent remains, but specific circumstances may mean that implementation of the requirements is not reasonably practicable. Any deviation from the specifications set forth in these Standards should be formally approved following an exemption procedure. The exemption procedure comprises the following steps: 1. Documented and detailed description of the implementation difficulties 2. Documented and detailed risk assessment of the situation under proposed alternative control measures 3. Documented formal approval from the Divisional Head of Safety and the Divisional Chief Executive Officer that the level of risk as a result of the alternative control measures is understood, tolerable for the organisation and in line with the Anglo American Group vision of Zero Harm.
5.1
CATEGORISATION
It is advisable to start with a list of all the Light Vehicles as specified in section 1.2 of the Standard. These vehicles shall then be classified into 1 of 3 categories as defined below. Category A: Vehicles with access to the mine/site car park only. These vehicles can be private, contractors, company pool or executive vehicles and suppliers vehicles, or vehicles provided by the Company with the only purpose of transporting people from their home to the work establishment (non work-related activities). It also includes contractor or supplier vehicles driving on site to collect or drop off passengers or cargo on an infrequent basis and not interacting with the site operations. These vehicles will usually require a temporary permit issued at the security check point and they will be closely controlled (escorted) while on site. Since the access roads to the car park are usually dirt roads, the Operations shall put in place appropriate control measures when these access roads are considered hazardous (e.g. inclined, high mountain roads, muddy when raining). Measures shall include speed control, own maintenance if necessary, salt spraying, speed limit, signage, etc. Category B: Vehicles (private, third party or Company supplied) that access operational areas (plant/workshop) but do not interact at any time with heavy mobile equipment (HME). Heavy mobile equipment is defined to have tire rim size larger than 25in. The reason for specifying the rim size is that operators of equipment/vehicles with larger than 25 inch rim size have restricted visibility when interacting with light vehicles.
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This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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These vehicles may interact with other equipment/vehicles that have a tire rim size smaller than 25 inches (size of rim for articulated dump trucks). Category C: Vehicles that interact with Heavy Mobile Equipment Operational areas include roadways inside open pits, loading areas, dump areas, tip points, access to HME workshops. In underground operations these areas refer to all underground areas including decline roadways (see Underground Equipment Guideline definition of Areas). Note: Vehicles being used in work-related activities off-site shall be classified to Categories A, B and C according to the areas being accessed.
5.2
STEPS TO COMPLIANCE
It is recommended that all the safety requirements as specified under points 1, 2, 3, and 4 of the AFRS be listed against each individual vehicle that has been classified as Category C. It is suggested that this be done in a matrix format. Early interaction with the various original equipment manufacturers (OEMs) and rental firms is recommended to enable timeous fleet conversions This process will normally be done on a Divisional basis to ensure governance and coordination, and maximise cost effective outcomes. If it is identified that full compliance to the standard is not possible through replacement of vehicles reaching the end of their useful life, then a conversion program will have to be put in place. This can be achieved either with the vehicle supplier or on site with the approval of an engineer, using the Technical Guideline specifications. Sites shall then focus on safety requirements concerning the operating environments of the vehicles which include points 13, 14, and 15 of the AFRS. This process will have to be vigorously subjected to the change management process requirements as described in point 5. The change management process is also detailed in standard 2 of the Anglo Safety Way. The next task would be to identify the inspection and maintenance requirements as described in points 7 and 9 of the AFRS. It is recommended that a FMECA risk assessment technique be used to determine the maintenance requirements. This may have already been done and should possibly only be revised considering that some of the equipment will be required to be modified to comply with the standard.
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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Suitable Seat belts for all occupants Category A Mandatory Category B Mandatory Category C Mandatory
People shall only travel in dedicated seats with seat belts. A three point safety belt system for each occupant shall be fitted. Lap seat belts can be used in situations where three point safety belts are not practicable. Seat belts shall conform to SAE J140. This applies to forward and rear facing seats. Side facing seats shall not be allowed because no effective neck support can be provided to the person in the event of a collision. All seats shall be equipped with head restraints. Roll-over protection for all vehicles intended to be driven on dirt or steep roads Category A Risk Assessment for additional ROPS Category B Risk Assessment for additional ROPS Category C Additional ROPS is Mandatory
20% of fatalities and serious injuries during vehicle accidents are related to rollovers All light vehicles will have some risk of roll-over due to road conditions (e.g. dirt road), rolling down slope (e.g. steep road), as specifically mentioned in the AFRS, but also due to high speed accidents, accidents with other vehicles etc. All vehicles with cabins already have ROPS to OEM standards (no passengers shall be transported in open vehicles e.g. on the back of pick-up trucks without a canopy). The main intent of the guideline is to address the requirement for additional ROPS (over and above the cabin structure).
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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Category A and B The requirement for additional ROPS for Category A and B vehicles is to be established based on specific risk assessment. Consideration shall be given to conditions such as off-road operation, frequent driving on badly maintained or dirt roads, steep and/or winding roads, high centre of gravity (e.g. pick-up trucks, light trucks used to transport heavy equipment), or generally accident prone routes or drivers. Additional ROPS shall be mandatory for any company owned vehicle that is frequently exposed to any of the above mentioned conditions. It is not intended that additional ROPS would be applied to light vehicles other than light commercial vehicles such as pick-up trucks, minibuses and light trucks. This then implies that sedan vehicles shall not be employed where and when any of the above risk factors are prevalent. Category C Additional ROPS shall be mandatory for Category C vehicles (whether company owned or not), motivated by the fact that operational areas which include interaction with SME will mostly imply risk factors such as dirt roads, steep slopes, possible badly maintained roads, or off-road usage, etc. The additional ROPS shall be designed, tested and manufactured according to the Anglo American Specification AA Specification 264073. The Specification differentiates between two tiers of additional ROPS, namely Standard ROPS and Heavy Duty ROPS. The decision of which tier of additional ROPS shall be required for Category C vehicles, as well as Category A and B vehicles determined to require additional ROPS, shall be based on a specific risk assessment. Standard ROPS Design For normal opencast conditions (well maintained haul roads, speed regulations, berms etc.), the additional Standard ROPS shall be designed and tested according to the requirements of AA Specification 264073, which invokes the international standard ISO 3471 or equivalent. This standard is strictly speaking not applicable to light vehicles but is adapted for this purpose in the specification. Heavy-duty ROPS Design In cases where the risks of accidents involving multiple roll-overs are high, additional ROPS structures that provide higher levels of protection than achieved by ISO 3471 standard shall be used. Examples of these high risk situations include mountain passes, long distance travel on unpaved or poorly maintained off-site roads. The heavy duty ROPS must be designed and tested as prescribed in AA SPEC 264073. FOPS for Category C vehicles Although the AFRS does not specifically address the requirement for Falling Object Protection Structures (FOPS), it is required that a site based risk assessment shall also be done for Category C vehicles to determine whether FOPS must be fitted. The FOPS shall be designed in accordance to the Anglo American Specification AA SPEC 264073.
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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Cargo barriers and load restraints for all vehicles designed for carrying loads (other than passengers) or that are unable to have cargo separated from the vehicles occupant carrying space Driver-side air bag Category A Highly recommended Category B Mandatory Category C Mandatory
For all newly purchased Category A vehicles owned and operated by Anglo American Business Units, the use of driver side airbags as well as passenger airbags is mandatory. For current vehicles owned and operated by Anglo American Business Units which are being phased out a driver side airbag will suffice. If such a vehicle does not have a driver side airbag, a retro-fit airbag (see comments below) may be fitted. Anglo American employees using their private vehicles (Category A) in the pursuit of business activities as defined above are strongly recommended to purchase vehicles with driver side as well as passenger airbags. It is the responsibility of line managers to demonstrate via a documented risk assessment if private vehicles being used in the pursuit of Anglo business are safe to be used without airbags. This risk assessment shall take into consideration the nature and frequency of the journeys being taken by the employee for business purposes. Category B and Category C light vehicles including contractor vehicles must comply with the requirement of driver side airbags. Retrofit airbags that have been tested according to ISO 12097 will also be accepted on vehicles that were purchased prior to March 2008. ATD has evaluated the compliance of one retrofit airbag supplier by means of a third party inspection and is satisfied that the supplier conforms to ISO 12097. Any vehicles purchased after March 2008 must be equipped with an OEM supplied driver side airbag. Please refer to Reference Document 4 listed in Appendix A for more information on airbags in light vehicles. 2. Light Vehicle interaction with heavy mobile equipment and/or plant Light vehicles that interact with heavy mobile equipment and/or plant shall have: Systems that enable positive communication with the equipment and/or plant; High-visibility flag (e.g. a whip flag or buggy whip); Flashing, revolving or strobe light; High-visibility colour; Reflective taping.
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation. Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
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Systems that enable positive communication with the equipment and/or plant Category A Not Applicable Category B Not applicable Category C Mandatory
Two way radios are recommended especially those that are as hands-free as possible. Handheld radios with a built in microphone will be accepted so long as a radio holder is installed inside the vehicle and the radio is kept in the holder at all times (i.e. not handheld). A risk assessment must be performed to determine the best suitable position for the installation. High visibility flags e.g. a whip flag or buggy whip Category A Not Applicable Category B Not Applicable Category C Mandatory
A buggy whip shall be fitted to either the front or back of the vehicle so that the flag is at least of 3 metres from the ground level. The height of the flag must be such that operators of haul trucks can clearly see the flag from inside the haul truck cab when the light vehicle is 3m from the truck. Recommended specifications: The buggy whip shaft shall be fitted with a standard reflective sleeve. The fitment of a high visibility LED night light to the buggy whip is optional. A flashing green coloured 12 volt DC LED is recommended. The flag shall be 300mm x 250mm. triangular in shape with minimum dimensions of