CPC A/S

Cement Plant Consultants

Site Safety Manual

Nyumba Ya Akiba SA site
FLS order no. 13-45327

Bas Congo province

DR Congo

Written by: Torben Pedersen

Version: 2
Date: 21.11.2015

Received,

Date:________________

Site Safety Manual: Rev. 2

Supervisor/Spec: ____________________

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 2 of 29

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Contents
1. Introduction ............................................................................................................................... 3
2. Safety organisation ..................................................................................................................... 4
3. Emergency plans ........................................................................................................................ 4
3.1. At site ................................................................................................................................. 5
3.2. In the client KCZ guest house ............................................................................................... 6
4. Site safety regulations (summary) ............................................................................................... 7
4.1. Client KCZ regulations .......................................................................................................... 7
5. Workplace hazards ..................................................................................................................... 7
6. Accident prevention .................................................................................................................... 8
6.1. Work at heights ................................................................................................................... 8
6.2. Confined spaces ................................................................................................................... 9
6.3. Electrical safety.................................................................................................................. 10
6.4. Lockout/tag out ................................................................................................................. 11
6.5. Housekeeping .................................................................................................................... 12
7. Personal Protection Equipment (PPE) .......................................................................................... 12
8. Transportation safety ................................................................................................................ 15
9. When the accident occurs .......................................................................................................... 16
10. Health & Hygiene .................................................................................................................... 17
10.1. Heat stress ...................................................................................................................... 18
10.2. Work in cold climate ......................................................................................................... 18
10.3. Severe weather conditions ................................................................................................ 20
11. Personal security .................................................................................................................... 22
12. Safety administration .............................................................................................................. 22
12.1. Bulletin boards & signs ...................................................................................................... 22
12.2. Regular safety meetings .................................................................................................... 22
12.3. Introduction courses ......................................................................................................... 22
13. Safety reporting ..................................................................................................................... 23
13.1. Regular reports ................................................................................................................ 23
13.2. Incident reports ............................................................................................................... 23
14. Hazard Analysis and Risk Management...................................................................................... 24
Appendix 1: Contacts on site ......................................................................................................... 27
Appendix 2: External contacts ....................................................................................................... 27
Appendix 3: Incident Report form .................................................................................................. 29
Appendix 4: Template for safety risk assessment............................................................................. 30

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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1. Introduction
Nobody goes to work to get hurt. Accidents unfortunately do happen far too
frequently, and therefore preventive measures must be taken.
It is important to understand that almost all accidents are preventable. They are
caused by people and the mistakes of people.
FLSmidth and CPC A/S has a policy which states that the goal for any project site is
zero ( 0 ) accidents. This may sound difficult to achieve, but in fact we can get very
close if everybody on site is made fully aware of the risks of accidents and how to
prevent them. Discipline, awareness and attention are required no matter where or
when.
The following manual serves as an introduction to safety at the Nyumba Ya Akiba SA
Cement Plant site, and must be studied carefully by all employees who are to work at
this site.
At Nyumba Ya Akiba SA Cement Plant we have a so-called Supply Contract ( EP ),
where the client will carry out all work on site, construction, installation, etc.
The contractor(s):
INDEC ( Kiln to Packing plant ) and Al Razi ( RM feed to Pre Heater ) perform the
actual work for the client. The role of the FLSmidth and CPC A/S representatives at
site is accordingly only advisory, and we do not have direct influence on the health &
safety behaviour of the other parties.
Any issue identified must be relayed by the CPC Site Management through the official
communication channels to the client. On the other hand, the FLSmidth / CPC
Supervisors are still responsible for their own safety and must follow the guidelines
below.
In case e.g. a location is not safe to enter, the Supervisor / Specialist must refuse to
do so, and report the issue to the Site Management and Site Safety manager
immediately.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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2. Safety organisation
CPC DRC safety organisation diagram:

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

CPC DRC Safety Manager / Coordinator: ( Torben Pedersen ) Xxxxxx Xxxxxxxxxx
Client Nyumba Ya Akiba SA - Safety Coordinator: Jack Tshibangu
Mob. +243 81 615 2626, email: jtshibangu@nya-cement.com
Contractors Safety coordinator: Mr. Shakeel Ur Rehman on behalf of Nyumba.
Mob +243 81 049 5711, e-mail: srehman@nya-cement.com

3. Emergency plans
The following emergency plans will briefly describe the actions to be taken in case of
an accident, fire, earth quake or similar.
No two incidents will be similar, and the initial action to be taken depends on the
circumstances. See section 9 for some general guidelines.
If an evacuation alarm sounds everyone must immediately leave their present location
and move towards the evacuation meeting point(s), see below. If possible, and
without any increase of the danger, lights and electrical appliances should be switched
off, machines stopped and doors and windows in buildings closed. Nobody should
carry any items along, this will impede the movement.
A serious effort must be made to check that everybody is alerted and evacuating.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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3.1. At plant construction site

In case of an emergency, the following persons should be contacted:
CPC DRC (FLSmidth):
FLSmidth A/S:
Outside ( FLS Safety):

Torben Pedersen, CPC Site manager, +243 81 949 9349

Bo Allan Josefsen, Project manager, +45 36 18 29 90
Sergey Avramenko, Site safety manager, +7 926 356 9284

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

In case of an evacuation the following signal will be given: Xxxx ( Sirene )
The evacuation meeting points (red circles) are shown at the following site map:

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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

In case of an emergency, the following persons should be contacted:
CPC DRC (FLSmidth):
FLSmidth A/S:
Outside (FLS Safety):

Torben Pedersen, CPC Site manager, +243 81 949 9349

Bo Allan Josefsen, Project manager, +45 36 18 29 90
Sergey Avramenko, Site safety manager, +7 926 356 9284

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

In case of an evacuation the following signal will be given: SIRENE
The meeting point is shown at the following map of Yuku camp:

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 7 of 29

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4. Site safety regulations (summary)

FLS Safety Handbook most be observed with special attention to the 10 safety rules.
Further please pay attention to the below highlighted issues.

Everybody must attend the Site Safety Briefing prior to doing any work on site.
Hard hat, safety shoes & safety visual vest must be worn at all times on site.
Safety goggles (glasses) & hearing protection to be carried everywhere on site,
ready to wear when needed.
Working at heights is only allowed if proper railings are in place, otherwise
safety harness and line must be used, please refer to FLS Site Safety rules.
Other items of Personal Protection Equipment to be used whenever indicated by
signage ( boards ) or Site Management instructions.
Never enter dangerous locations (e.g. confined spaces) alone.
Strictly comply with safety measures around energized machinery and
equipment, including items with a potential for being energized (e.g.
lockout/tag out).
Restrictions on smoking and use of open fire to be strictly obeyed.
Everybody must act on evacuation alarms / sirenes without any delay.
All unsafe behaviour and installations observed to be reported.

4.1. Client regulations

N/A

5. Workplace hazards
The following list contains examples of typical hazards that can be encountered on a
cement plant site:

Falling objects
Falls from heights
Hot activities, e.g. welding, gas cutting & grinding
Electric shocks
Impact from transportation / lifting of heavy equipment / earth moving
Toxic or corrosive chemicals
Fire or explosions
Radiation, e.g. from material test equipment
Heat stroke from working in a hot ambient climate

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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6. Accident prevention
6.1. Work at heights
Falls
Fatalities from construction workers falling from heights are all too common all around
the world. Falls are basically prevented in two ways:

Stairs, walkways and platform or deck edges are furnished with proper
guardrails. Guardrails should be set up with a kick plate at the bottom, a knee
rail half way up and a handrail at a height around 1100 mm.

Anyone working in an elevated location without guardrails must be equipped

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

Scaffolding and ladders must be of good and approved quality, well maintained and
properly set up and secured. Floors of walkways & steps of stairs must be strongly
made and no holes or openings are to be accepted. Guardrails must be continuous,
with no gaps left open.
Tools or materials are not to be carried by hand while climbing up or down scaffolding
or ladders. Shoulder bags, backpacks or tool belts must be used for this purpose.
Dropped items
Items brought up in elevated heights may for a lot of reasons fall down, with the
potential of injuring people below.

Construction or installation workers may accidentally drop something they are

holding in their hands.
Items left on an elevated platform or deck may fall down due to not being
secured properly, or left too close to the edge. Strong wind may have an
influence here. Guardrails will provide considerable protection against such
occurrences.
Items may be dropped from cranes or other lifting equipment, due to
inadequate fastening or poor-quality equipment.
Parts under installation are often initially fastened temporarily, e.g. by tackwelding. The fastening, if not properly done, may fail and the part may fall
down.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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

placing items, temporarily or permanently. Crane operators and - loaders must ensure
that items are properly fastened and that hooks, chains, wires or belts are in good
condition.
Finally, people on the ground should consider where they are. It should be avoided to
stand right below areas where activities above are ongoing. If close to a building
under construction, it is more safe to stay below a deck than just outside.
6.2. Confined spaces
Working in a confined space may be a required regular part of the job or it may be a
one-time emergency. Confined spaces must always be considered dangerous.
Confined spaces have few or very small openings. They are not meant for workers to
stay in. Ventilation is usually poor. While working inside a shell, silos, tunnels,
cyclones etc. focus must be kept on the available openings and ventilation.
There are four main dangers in confined spaces.
1. There may not be enough oxygen to breathe. Rust, sewage, or chemicals can
use it up. Even if there is enough oxygen when the person enters, it can be
used up by his/her presence and the work more quickly than expected.
2. Chemicals and gases can explode suddenly, from cigarettes, static electricity,
sparks, or heat. Fire and explosions can cause immediate death or serious
injury. But even if they do not, they may use up oxygen quickly enough to
prevent escape and cause death within minutes.
3. In confined spaces there is the danger of poisonous and toxic elements in the
air. They can harm the breathing and nervous system. Often, a human being
cannot see or smell them. Some gases, vapours and dusts can burn or poison
the person quickly. Others may have a more long-term health impact.
4. There are physical dangers such as loud noise, intense heat, and falls. These
can be very hazardous in confined spaces.
Preparations
Before entering a confined space, careful preparations must always be made, no
matter how great an emergency it is. The right Personal Protective Equipment must
be at hand, and needed ventilation must work. All equipment must be tested and
grounded.

Gas, power, steam or water lines into the confined space must be disconnected.
A sign stating that people are inside must be set up in a conspicuous place.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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

machine - the power supply should be interrupted in the substation, following
the lockout/tag out system (see section 6.4).
If in any doubt concerning the oxygen level, either a control measurement must
be arranged or a fresh-air supply must be worn.
It must be ensured that the entrance stays open by use of a chain or similar.
At least one colleague must remain outside, in visual or audible contact.
Anyone working inside a confined space must stay alert and refrain from
smoking or eating inside.
If there is any risk of poisoning or other harm when climbing down into a tank,
the employee must wear a safety harness and have the line attached to a winch
or hoist above, so the colleague posted outside can pull the person out in case
of loss of consciousness.

6.3. Electrical safety

Site Supervision must give special attention to the electrical safety. It is very
important for the persons who are involved on the job as well as for the equipment.
The following important rules for electric safety must be followed:

Electrical equipment, machinery and work areas must be kept clean. Oil, dust,
waste and water can be fire hazards around electricity.
Access to panels and junction boxes must be kept clear.
Machine energy supplies (in the substation) must be disconnected before doing
any work, following the lock-out/tag out procedure (see below).
Appliances must be unplugged before cleaning, inspecting, repairing or
removing anything from them.
Unauthorized & incompetent persons should not work on electrical equipment.
The location of fuses and circuit breakers must be well known. If a fuse blows,
the reason must be found before it is replaced. If a machine blows its fuses
repeatedly it is never a solution just to install bigger fuses. Also, electrical
circuit should not be installed with fuses that carry more amperage than the
rating of the wiring of the circuit.
All electrical equipment must be properly grounded.
A check with the local utility Co. and the necessary permission in writing are
required before any digging or work is done near suspended/ routed power
lines.
If someone has received an electric shock, the victim must be separated from
the source of current before any first aid is done. If the electricity cannot be
turned off easily, a rope, wood or some other insulator must be used to pull the
victim away.
Employees, who are not trained to work in high voltage areas, are not to enter
them, even in an emergency.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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

equipment area.
As far as possible, the employees working with electrical equipment should
avoid having contact with metal or wet surfaces.
All electrical rooms are to be kept closed to avoid unauthorized entry and for
the safety of the equipment.
The necessary log book system must be implemented in all electrical
substations.
Safety circuits, fuses and programs are not to be by-passed.
No electrical panels / switchboards may be left open without proper protection,
warning sign boards etc.
Keep flammable materials away from electric heat sources and lights.

Reporting of unsafe conditions

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

Electric equipment & machinery giving electric shocks, sparks, smoke or which
is overheating.
Corroded outlets, switches and junction boxes
Exposed wiring; broken plugs, outlets, missing box covers or faceplates
Improper wiring/ installation of any equipment
Unauthorized / unskilled operation
Persons working with improper tools/PPE etc
Improper/unsafe maintenance of electrical equipments

6.4. Lock out / Tag out

"Lock-out/Tag-out "(LOTO) refers to specific practices and procedures to safeguard
employees from the unwanted energizing or startup of machinery and equipment, or
the release of hazardous energy during service or maintenance activities.
Before any machine or equipment is entered, or before any inspection /maintenance
activities, all the emergency switches must be closed and the connected electrical
breaker must be pulled out and locked with a safety padlock by the person who enters
/ works on the equipment. Also, a lockout/tag-out permission sheet shall be signed off
before entering or working on any equipment.
Supervision should make sure that the equipment is thoroughly inspected, the doors
are closed and safety devices are in place before giving permission for the (re-)
starting of the equipment.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 12 of 29

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6.5. Housekeeping
Good housekeeping is an essential part of the tools to prevent accidents. Besides, it
will improve the working efficiency and minimize the number of mistakes made.
Good housekeeping consists of the following elements:
Keeping the working environment cleared of all unnecessary waste and
materials.
Organizing the storage (& temporary location) of tools, building material and
parts so they are easily accessible and do not block other activities.
Keeping lanes and roads for traffic and emergency use clear at all times.
Keeping machines, installations, operating panels & displays clean for easy
access and handling.
Maintaining an overall state of cleanliness of the whole plant.
All FLSmidth / CPC DRC supervisors and specialists should facilitate/recommend
proper housekeeping in their working area in coordination with the client and
contractor(s).

7. Personal Protection Equipment (PPE)

PPE are important tools to protect the employees against work-related hazards, which
may endanger their health & safety. All supervisors must bring and maintain their own
PPE unless otherwise agreed with FLSmidth / CPC DRC site management prior to their
travel. All FLSmidth / CPC DRC employees must use PPE wherever required according
to the site regulations.
All PPE must be carefully maintained and kept clean. Any defective items are to be
replaced without delay.
Basic Personal Protective Equipment (PPE)
Basic and minimum PPE requirements are defined as:

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

be in good condition, no cracks or other damage.
Safety footwear with steel toe and sole protection manufactured in compliance
with standard. The construction and sole materials shall be chosen in
accordance with the activity and must be adequate for the place of work.
Safety vest in a conspicuous color, to make the supervisor more visible.
Safety glasses & hearing protection. To be carried but maybe only worn when
needed.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 13 of 29

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The basic PPE must be worn at all times all over the plant site, from the time of the
initial excavation until completion of commissioning.
The only exception is when the employee is indoors with a ceiling height below 2.5
meters - or indoors in completed buildings where no more construction or installation
work is done.
Hard hats are to be worn according to local regulations in warehouse buildings with
racks higher than 3 meters.
Eye and face protection
Face/head protection scarves are only allowed if specially designed and worn in such a
way that there is no impairment of the wearers vision, and no danger of scarves
getting caught in moving machinery.
Suitable protective goggles, face shield or screens shall be worn by personnel involved
in, assisting with or adjacent to any activity where there may be a danger of flying
debris, dust, sparks or other particles; corrosive fluids or mists; excessive heat, light
or other harmful radiation. Such work situations include, but are not limited to:

Working with rotating equipment such as grinders, drills, lathes

Cutting and welding
Chipping, chiselling or caulking
Using powder bolt driving tools & nail guns
Spraying with abrasives (sand blasting) or high-pressure water
Working with chemicals, e.g. mixing drilling fluids
Working with paints, disinfectant, pesticides or other toxic or hazardous fluids
Working with strong sources of light, e.g. welding (darkened eye protection)
Working in the open with winds blowing sand
Safety sun glasses should be worn in strong sun glare to reduce eye strain and
fatigue.

Respiratory protection
Respiratory protective equipment must be used by anyone entering areas where there
is a possibility of the atmosphere being (or becoming) deficient in oxygen or
containing any harmful substance, whether particles (dust), toxic vapour or gas.
Basically, 3 types of protection exist:

Dust mask
Gas (solvent) mask
Fresh-air mask

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 14 of 29

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It is important always to use the correct type of mask for the situation in hand. If
there is enough oxygen in the ambient air, then either the dust mask or the gas mask
should be used. The dust mask will only protect against particles in the air; it is of no
use against toxic gases. The dust mask is used e.g. where powder materials (including
cement) are handled; stones, ceramics or concrete are cut, blasted or ground; or
during grinding of metal parts.
The gas mask is equipped with a filter (often based on active carbon) which will
absorb the gas. It is important to choose the correct gas mask for the given chemical
risk and the user must be aware that the lifetime of the filter is limited, it will become
saturated, and thereafter the mask provides no protection. The gas mask is used
where the ambient air is polluted by poisonous gases, organic vapours (e.g. from
painting) or liquid aerosols. Using a gas mask puts strain on the lungs, and the use
should be limited to maximum 2 hours per day.
The fresh-air mask is connected to a compressed-air container and will provide clean
air with enough oxygen to the user. A fresh-air mask would be used e.g. in confined
spaces short of oxygen or in areas with suspected very heavy pollution by toxic gases.
Hearing protection
Hearing protection should be used by all supervisors exposed to noise levels of 85 dB
(A) or above. The selection of type of protection shall be in accordance with the type
of noise hazard and the work being performed.
Hand and arm protection
Adequate hand and arm protection should be used wherever required. The
type of protection to be selected depends on the actual hazard, e.g.:

Impacts, cuts, abrasions and infections

Extreme temperatures
Chemical, toxic, corrosive and other hazardous substances.

Typically, gloves will be used. For abrasive work heavy protective gloves are best,
whereas for high temperatures, special heat insulating ones should be chosen.
For chemicals, like solvents, special gloves made of polymers are to be used, it should
be noticed that ordinary rubber or cloth gloves provide absolutely no protection
against chemicals. The specification on the polymer glove should be checked to
confirm that it does protect against the chemical to be handled.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 15 of 29

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

replaced.
Harnesses and lifelines
Harnesses and lifelines shall be provided, worn and properly secured in all locations
where any of the following dangers exist:

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

Succumbing to toxic atmospheres or oxygen deficiency

Such situations include, but are not limited to:

Working on scaffolding with incomplete rail protection

Work on any high structure
Work over (deep) water
Work in confined spaces

When working at height the lifeline system must be fastened with care, so there is no
risk of it loosening itself in case of a fall. Also, it should be considered that the
maximum fall height before being caught by the line should not be more than 1.2
meters. Accordingly, the employee should never be attached to a long free line,
which would result in a drop of several meters before the fall is arrested.

8. Transportation safety
Road safety is an important issue while considering safety. Public roads in many
countries are prone to accidents due to mixed traffic, traffic violations & speeding.
FLSmidth and CPC DRC employees must strictly follow the below-mentioned
instructions:
Supervisors driving themselves are not allowed, only local Congolese drivers:

Only authorized and competent local Congolese drivers are permitted to drive
CPC transport vehicles on public roads as well as on site.
All road safety rules & speed regulations must be strictly followed while driving
a vehicle, regardless of whether on public road or on site.
Safety belts must be used at all time while travelling.
Loads shall be within the safe weight limit for the vehicle and shall not project
beyond the vehicle body in such a manner as to present a hazard to other
vehicles, pedestrians or adjacent structures.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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Passengers shall not be carried unless a proper seat for each person is available.
Parking signs & regulations must be followed.

The use of drivers

The qualifications of local Congolese hired drivers has been ascertained by client
transport management and skills confirmed to the CPC Site Management, and the
drivers have at least have a rudimentary knowledge of English.
The local Congolese drivers is expected to:

Take full responsibility for the vehicle, the load and passengers being carried.
Check of the vehicle prior to the start of a (longer) journey.
Always wear a seat belt.
Inform the manager in charge of site transport at the destination to notify about
the arrival of the car and passenger/goods.
Refrain from picking up unauthorized persons (e.g. hitch hikers).

If an FLSmidth / CPC A/S supervisor or specialist feels uncomfortable with the driver's
performance (reckless or careless driving), the supervisor / specialist must report the
issue to the CPC DRC Site Manager, who then will have to find an effective solution. In
very bad cases, the supervisor / specialist may resort to asking the driver to stop
immediately, and then contact the CPC DRC Site Manager for alternative transport on
the spot.

9. When the accident occurs

Whenever an accident, incident or fire occurs, the first few minutes may be crucial for
the ultimate outcome. Loss of life and major loss of property may be avoided by doing
the right things from the start.
The first employee arriving at the location of the incident (or already present, but
unhurt) will have to make the initial decisions on the course of action. The very first
thing to do is always to get an overview of the situation:
Is anyone hurt and how badly (life-threatening)?
Can the victims stay where they are, or are they threatened (e.g. by a fire or
risk of falling items)?
Is there any danger to others in the vicinity or on site in general?
What is the most important thing to do initially
Immediate first-aid / moving of victim
Fire-fighting or removal/neutralizing of dangerous objects?

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 17 of 29

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

Sound an alarm for evacuation (fire or explosion risk)
Anyone nearby who can help?
Spend no more than 10-20 seconds on the overview and then take action in the order
deemed most efficient. The CPC DRC and Nyumba Site Management must be alerted,
the victim(s) tended to and if outside assistance (medical, fire brigade) is required, it
must be alerted without too much delay.
A representative from CPC DRC Site Management must take charge as soon as he or
she arrives and ensure that all the acute actions are completed.
Once the initial actions have been taken, and e.g. the victims have been removed,
the more long-term actions must be considered:
Eliminating immediate dangers
Preventive measures against recurrence
Handling the staff and outsiders like client, contractor, local authorities, the
media etc.
Reporting the incident (see below).

10. Health & Hygiene

FLSmidth / CPC DDRC employees must take good care of their health during their
assignment. It is very important to have a healthy mind and constitution to deliver
our obligations effectively. CPC DRC Site Management will set up an arrangement with
a doctor & a dentist to be available to handle any minor health issues. The site office
must maintain a first-aid box for any minor first aids. The site offices should include
clean toilets & washing facilities. To maintain good health, the following directions
shall be followed.
Before travelling to site, all FLSmidth / CPC A/S employees are advised to have a
detailed medical checkup with report to document that they are fit to undertake the
assigned responsibilities.
If any known medical issues exist, the CPC DRC Site Manager and FLSmidth Project
manager must be informed prior to the employee's arrival at site. It must be ensured
that all necessary medicines are available on site.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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Follow good health and hygiene practices.

As far as possible, get some physical exercise every day.
Consumption of alcohol to be done with prudence.
It is strictly prohibited to be under influence of alcohol during work time.
Make sure to eat sufficient, varied and nutritious food.
Use only bottled drinking water and drink enough water.
While working in the sun use sun glasses and protective clothes.

10.1. Heat stress

Heat stress is usually the result of work being performed at elevated temperatures. If
the bodys physiological processes fail to maintain a normal body temperature
because of excessive heat, a number of physical reactions can occur, ranging from
mild to fatal. Heat stress is one of the most common and potentially serious illnesses
that afflict construction workers. In areas where high temperatures are normally
encountered, regular monitoring and other preventative measures are vital.
Any occurrence of the below-mentioned conditions must be reported to the CPC DRC
Site Manager and treated as soon as possible.
Heat stroke
In heat stroke the body temperature rises so high that brain damage and death will
result if the person is not cooled quickly.

Symptoms
Red, hot, dry skin, although the person may have been sweating earlier;
nausea; dizziness; confusion; extremely high blood pressure; rapid respiratory
and pulse rate; unconsciousness or coma.
Actions
Casualty must be cooled down and medical aid sought immediately with the
person transported to the site medical facilities.

Heat exhaustion & heat cramps

Heat exhaustion and heat cramps are both caused by excessive sweating, not
compensated by drinking enough water, leading to a loss of fluids in the body.
Heat exhaustion is a state of serious weakness or exhaustion. Both heat exhaustion
and heat cramps are much less dangerous than heat strokes, but must be treated
early on to prevent progressing to heat stroke.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

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Heat exhaustion symptoms

Pale, clammy, moist skin, profuse perspiration, and extreme weakness. Body
temperature is normal, pulse is weak and rapid, and breathing is shallow. The
person may have a headache, may vomit, and may be dizzy.
Heat cramp symptoms
Acute painful spasms of various muscles; e.g., abdomen and extremities.

Heat rash
Heat rash is caused by continuous exposure to heat and humid air and is aggravated
by chafing clothes. The condition decreases ability to tolerate heat.

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

10.2. Work in a cold climate

n/a

10.3. Severe Weather Conditions

Early notification about severe weather conditions may become necessary to provide
safety and welfare to our employees and to prevent or reduce damage or loss to
project property.

Definitions (Severe Weather)

Lightning - All large-scale, high tension, natural, electrical discharge in the

atmosphere; the visible flash of light accompanying such discharge.
High Winds and Rain - When the winds or rain become a hazard to the work
force or the work being performed. Wind approximately 30 mph (50 kph) and rain
limiting visibility or footing.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 20 of 29

CPC A/S

Clients site Safety Department Responsibilities

Site Safety Officers of each construction site are responsible to prepare a procedure
indicating
how to obtain information about severe weather conditions from their local
weather bureau in a timely manner
ways of distributing information
measures to be taken in case of anticipated severe weather conditions
Site Safety Officers should keep CPC DRC Site Manager updated as to location and
intensity of a storm on a routine basis.
Severe Weather Actions

Lightning

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

members, pipe racks, roof tops, process columns, antennas, etc.
Make sure that personnel do not group together and/or huddle under or
near tall structures.
Avoid a depression with standing or running water or a stream.
Have all crane booms lowered to the ground or retracted to the shortest
boom length.
All cranes, derricks, gin poles, and erection rigs unable to be boomed
down must be grounded from their booms to the ground.

High Winds and/or Rain

When high wind creates a hazard to craftsmen or work being performed, i.e.,
instability in elevated areas,limited visibility due to dust or particles in the air,
unmanageable materials, etc. Supervision will stop work activities, re-assign work and
area, properly store and secure material which might blow away, injure or damage,
lower/tie down crane booms and obtain further instruction from CPC Site
Management.
When rain creates a hazard to craftsmen on work being performed, i.e., unstable
footing conditions due to slippery structural steel, muddy and flooded work
environments, unstable trenches or excavations, poor visibility due to rain or eye
protection, supervision will stop specific work due to hazard, re-assign work duties
and/or areas, and obtain further instructions from Project Management.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 21 of 29

CPC A/S

11. Personal security

Personal safety & security for FLSmidth and CPC DRC personnel is of paramount
importance to the Management. All employees (and family members) at site should
use their common sense to assess their safety, no matter where they are.
The CPC DRC Site Management will evaluate the situation regularly in coordination
with FLSmidth Travel Security Department and the client.
n/a [Site specific information must be entered here. Points may be added to or
deleted from the general list below]
The following general guidelines are in all cases recommendable:

Follow directions from Safety/Security department.

Obtain knowledge & understanding regarding local law, traditions & habits.
Consider personal behavior while dealing with other nationalities/locals.
Follow & respect local law & regulations.
Do not discuss religion & politics with any other nationalities.
Do not wear clothes which can attract public attention or which may offend.
Avoid all religious symbols & practices which could expose to public attention.
Try to be unnoticed in the local society.
Avoid ethnic gatherings in public.
Assess the safety situation around you and inform the Site Manager if you find
anything suspicious.
Evaluate the safety & security in your weekly meeting.
Pass important information quickly to FLSmidth / CPC A/S Site Management
Stay updated with local news/ incidents /events
Keep all important emergency contact details in case they are required.
Keep contact with your National Embassy in coordination with Site
Management.
Do not allow unknown /unauthorized people to enter your residence / office /
vehicle etc.
Keep all your valuable belongings locked away in a safe place only known to
you and be aware, that Site Management will not be responsible for any
loss/damage.

Entrances and boundaries

All FLSmidth / CPC DRC employees at site should have a detailed understanding about
the plant entrance & boundaries. FLSmidth / CPC DRC personnel should not leave the
site without informing the CPC A/S Site Management.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 22 of 29

CPC A/S

12. Safety administration

The FLSmidth / CPC DRC site organisation is not alone on the plant. The client and
contractor(s) have numerous employees and a tremendous amount of activities on
site. They may engage in a lot of unsafe practices, which the FLSmidth / CPC DRC Site
Management will require to be stopped.
[For Supply Contracts, any health & safety complaint may have to go through the
client (management), typically at site meetings.]
Safety violations are to be taken seriously, and sanctions will be imposed. Blatant or
repeated disregard of well-known safety regulations can result in dismissal from site;
any FLSmidth / CPC DRC employee will in such cases be sent home, and the parent
department will decide on further actions to be taken.
12.1. Bulletin boards & signs
The CPC DRC Site Health & Safety Coordinator shall maintain a bulletin board and
display at a prominent location within the site office for the awareness about health &
safety, news and actions taken.
FLSmidth / CPC DRC supervisors and specialists should inform the client /contractor if
any awareness signboards are required in any part of their working area.
12.2. Regular safety meetings
Internal health & safety site meetings should be conducted on a weekly basis chaired
by the CPC Site Manager. The FLSmidth / CPC DRC team members should participate
effectively to evaluate and improve the health & safety conditions at site. This
meeting should be recorded and the Minutes of Meeting sent to CPC, FLSmidth & the
FLS Project Manager.
12.3. Introduction courses
Every FLSmidth / CPC A/S employee arriving at site must be given a safety briefing by
the CPC DRC Site Safety Manager (or Coordinator). The contents of the briefing
should roughly follow the contents of this manual, with special emphasis on the
particular local conditions to be aware of.
The briefing must include instructions in the emergency response procedures (alarms,
meeting points, etc.) and mandatory use of Personal Protection Equipment.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 23 of 29

CPC A/S

All FLSmidth / CPC DRC employees who are to work with construction, installation or
commissioning at site, are to receive a copy of this manual with instructions to read it
without delay.

13. Safety reporting

13.1. Regular reports
All Supervisors, Specialsits, Department Managers & the CPC A/S Site Manager should
report on health & safety conditions at site in their monthly report.
If any situations need to be addressed in between, the CPC A/S Site manager/Safety
Coordinator should be informed in writing. Also the same information must be brought
up at the site weekly safety meeting. At any time, the site safety organisation must,
besides the reporting to the line organisation, also report directly to FLSmidth Safety
& Health Manager regarding any extraordinary safety issues like accidents and near
miss accidents at the site.
13.2. Incident reports
Accidents are unexpected, unplanned and undesirable. However, it is important that
whatever experience may be gained from their occurrence is made available to
everyone concerned.
Hence, accident investigation and reporting are the first steps towards avoiding future
injuries and financial losses.
The investigation determines what, why and how the accident happened. Its purpose
is not to blame someone. A good investigation looks at how a system makes it
possible for accidents to take place. Often, the investigation will reveal that many
similar incidents (small, less serious accidents) have happened before.
The reporting may put spotlight on e.g. dangerous conditions and careless attitudes,
which apart from the accident risk also in general may lead to decreased performance
and productivity.
Incident Reporting

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

FLSmidth / CPC DRC Site Manager/Safety Coordinator who will communicate the
incident to the relevant authorities.

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 24 of 29

CPC A/S

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

relevant, must be collected and handed over to the FLSmidth / CPC DRC Site
Manager/Safety Coordinator.
Any accident involving staff under the control of FLSmidth / CPC DRC must be
reported to the FLSmidth Management within 2 days by the Site Management.
FLSmidth / CPC DRC Site Manager/ Safety Coordinator should prepare a detailed
FIR if the issue is related to FLSmidth / CPC DRC in any manner.

Any near miss accident with a potential high risk must be reported - at least internally
on site, for example:

Big parts falling down in an uncontrolled manner where staff under the control
of FLSmidth / CPC DRC might have been injured.
Traffic accidents at site where staff under the control of FLSmidth / CPC DRC
might have been injured.
Any other known conditions that might have resulted in a dangerous situation
for staff under the control of FLSmidth / CPC DRC.

Use the form in Appendix 3 when reporting accidents and near miss accidents to the
CPC DRC Site Manager and the FLSmidth Project Management. If more than one
person was injured, a separate report should be issued for each victim.
All reports must be sent to the FLSmidth Project Manager without delay.

14. Hazard Analysis and Risk Management

In some cases the local authorities or the client may request that hazard analyses are
being carried out by the FLSmidth / CPC DRC safety organisation. Often the format of
the analysis will be specified by the requester.
In other circumstances the FLSmidth / CPC DRC Management may deem it desirable
to carry out the hazard analysis for primarily internal use.
In Appendix 4 is a suggested template for a simple hazard analysis, where different
aspects of the site safety may be selected and evaluated more closely. Any item found
to be unsatisfactory must be taken up with the party responsible in order to have the
risk reduced.
Possible areas of focus are listed below:
Above-ground potential hazards:
Overhead power lines, list kV rating

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 25 of 29

CPC A/S

Micro wave / communication towers

Electrical wires
Fuel / chemical / pressure vessels and systems
Roadways & Ditches
Obstruction & unstable soil
Fences/walls & traffic flow
Adverse weather conditions
Hazards from nearby operations, etc.

Underground potential hazards:

Buried utilities
High water table & underground water waste
Building foundations
Chemical / trash dump area
Underground fuel / chemical / pressure systems and vessels
Safety management issues:
Existing emergency evacuation procedures
Emergency communication system
Traffic flow
Special personnel
Protective equipment requirements
Hazardous waste disposal
Flammable liquid / chemical / compressed-gas storage
Gas release into proposed area

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 26 of 29

CPC A/S

Appendix 1: Contacts on site

Company

Function

Name

CPC DRC
Supervision
team

Site Safety
Manager

Nyumba Ya
Akiba SA
Cement Plant

e-mail

Torben Pedersen

Telephone /
mobile
+243819499349

Site Manager

Torben Pedersen

+243819499349

torben.pedersen@sitemail.dk

Camp Manager
Nyumba

Christian Ngoy

+243816139388

cngoy@nya-cement.com

Plant Manager

Tanveer Ahmad

+243827358702

tahmad@nya-cement.com

Safety Manager

Jack Thsibangu

+243816152626

jtshibangu@nya-cement.com

Site Manager

Xxxxxx Xxxxxxxx

+243xxxxxxxx

xxxxxxxxxxxxxxxxxxxxxx

Safety Manager

Xxxxxxxx Xxxxxxx

+243xxxxxxxx

xxxxxxxxxxxxxxxxxxxxxx

Site Manager

Xxxxxx Xxxxxxx

+243xxxxxxxx

xxxxxxxxxxxxxxxxxxx

Safety Manager

Xxxxx Xxxxxxxxxx

+243xxxxxxxx

xxxxxxxxxxxxxxxxxxxx

torben.pedersen@sitemail.dk

Contractor 1:
INDEC

Contractor 2:
Al Razhi

Xxxx Xxxxx

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 27 of 29

CPC A/S

Appendix 2: External contacts

Institution

Address

Contact person / title

Telephone No.

FLSmidth office

Valby, etc.

Travel Security
Manager

+4530931111
+4530181111

Control Risk 24 h
Global Security

+44
2079398590

Project manager
Bo Allan Josefsen

+4536182990

Denis Bariat

+24382926686

Jean de Dieu
Luwembi

+243819013035

Local Police
At Nyumba site

Security
Manager

E-mail address

dbariat@nyacement.com

Local Hospital

Kimpese
Hospital

Kimpese Central
Hospital

+ 7484466026

[address]

Doctor

Nyumba Ya
Akiba SA Site
clinic

Dr. [name]

[phone No.(s)]

[address]

Dentist

To be found in
Kinshasa or
Matadi

[name]

[phone No.(s)]

[address]

Danish Embassy/
Consulate

Pretoria, South
Africa

Royal Danish
Embassy South Africa

..

[address]

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 28 of 29

CPC A/S

Appendix 3: Incident Report form

FLSmidth / CPC A/S - Site Incident Report

Name of victim:

Site name:

Date of incident:

Department name & No.

Location of accident:

Type of accident (mark with X):

Accident:

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

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

Type of injury (if any):

What caused the incident?

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

Immediate action taken:

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

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

Report prepared by:

Report date:

Near miss:

Site Safety Manual

Plant name: Nyumba Ya Akiba SA - Cement Plant
Prepared by: Torben Pedersen
Edition: 1
Date:

21-11-2015

Page 29 of 29

Appendix 4: Template for safety risk assessment

Date: _____________________________
Plant: _Nyumba Ya Akiba SA____________
Department: ________________________
Green
Yellow
Red

Problems and Actions

Housekeeping:
Access roads:
Traffic control:
Safety situation in
department:
Scaffolds
Stairs
Railing
Control of: Gas, Oil, Coal
Fire fighting prevention and
protection:
Electrical issues:
Confined spaces:
Safety situation at heights:
Lockout/tag out procedures:
Other:
Action plan:

Green:
Yellow:

The conditions are acceptable.

The conditions are not acceptable.
Corrections need to be made within 3 days.
Red: The conditions are not acceptable.
All access is prohibited until corrections are completed.

CPC A/S