Karara Mining Limited

KARARA MINING LTD

Karara Mining Limited Steel Erection and Rigging Standard

Document ID: CORP-HS-STD-1012 Revision ID; 2 Revision Date: 23-June-15

©2012 by Karara Mining Limited

This document contains proprietary information of Karara Mining Limited. Any use of this document without

express, prior, written permission from Karara Mining Limited and/or its affiliates Is prohibited.

KARARA MINING LTD

KARARA MINING LIMITED STEEL ERECTION AND RIGGING STANDARD

"This document has been prepared by Karara Mining Limited for exclusive use on the Karara Iron Ore Project ("the Purpose"). Use of this document other than for the Purpose is not permitted."

APPROVAL DATE DESCRIPTION ORIG REVIEW REV

sw N/A 4-Jun-09 Issued for use DT A D Tancred J Lee

28-Jul-09 Re-issused for use 1 B S Campbell J Lee McLernon

J Q/iggs G Duke Re-issused for use 23-June-15 2

rian rcjf

CORP-HS-STD-1012 Page 2

Rev 2 Re-issused for use

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CONTENTS PURPOSE 4

SCOPE 5

DEFINITIONS 3. 6

ROLES AND RESPONSIBILITIES /| 7

PROCEDURES 5. 8

5.1 Planning

5.2 Training

5.3 Personal Protective Equipment (PPE)

5.4 Adverse Weather

9

12

13

14

5.5 Lifting Equipment

5.5.1 Certification Procedures

14

14

REFERENCES 16

6.1 Associated Documents 16

6.2 Specific Situations Requiring Barricades 16

REFERENCES 17

7.1 Supporting Documents 17

Appendices

APPENDIX 1- LIFTING EQUIPMENT REGISTER (SAMPLE)

Page 3 CORP-HS-STD-1012


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PURPOSE

This procedure outlines the design, planning, preparation and work practice requirements for the safe installation of plant, equipment and the erection of structural steelwork.



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SCOPE 2.

This Standard shall be applied to all Karara Mining Limited (KML) personnel, contractors and their subcontractors. Contractors may, however, when agreed through the engagement processes, utilise their own standards and procedures in so far as the requirements of their procedures are at least equivalent to those of this Procedure, and those of applicable Australian and Western Australian regulations which should be read and complied with in conjunction with this Procedure.

In relation to forms/formats and reporting requirements Contractors shall adopt KML applicable forms/formats and reporting time lines.

AS/NZS 3828 - 1998 Guidelines for the erection of building steelwork shall be used as a guide and complied with where it does not conflict with this document or any other KML requirements.

The requirements of the Karara Mining Limited Crane Management Procedure (Ref. Doc No CORP-HS-PRO-1007) shall also apply.



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DEFINITIONS

A person who has, to the satisfaction of the Registered Manager, acquired, through a combination of training, education and experience, sufficient knowledge and skill to enable him or her to perform specific tasks safely and correctly.

Competent Person

Contractor Include subcontractors.

Means the engineer responsible for the structural design. Design Engineer

Is the maximum permissible combined weight of a cargo container GROSS Weight (or mass) and its contents, i.e. GROSS WEIGHT = TARE WEIGHT + NETT WEIGHT.

Karara Mining Limited KML

Weight of actual product also called actual net weight. NETT Weight

Means operations which generally include welding, drilling, bolting, painting, and other tasks of a similar nature.

Other work

Means a person who holds an appropriate high risk work licence to carry out the appropriate level of "rigging" work and who has experience in the erection of structural steel.

Rigger

means - moving, placing or securing a load (such as plant, equipment or members of a building or structure) using mechanical load shifting equipment but does not include operation of the mechanical load shifting equipment; or erecting or dismantling cranes or hoists.

Rigging

Is a horizontal or substantially horizontal line to which a lanyard may be attached and which is designed to arrest a free fall.

Static line

Means the party responsible for the fabrication of the steel work. Steel fabricator

Safe Work Load. SWL

Working Load Limit. The maximum gross load which may be applied to the crane, hoist or lifting attachment, while in a particular working configuration and under a particular condition of use. Also called Rated Capacity.

WWL



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ROLES AND RESPONSIBILITIES

KML Registered Manager

• Ensures full compliance with the requirements of this Procedure.

Line Manager/s

• implements controls in accordance with the requirements of this Procedure.

• Arranges training as required by this Procedure.

Supervisor/s

• Conducts workplace inspections and enforces compliance with the requirements of this Procedure.

Employee/s

• Comply with the requirements of this Procedure.

KML Safety Superintendent

• Audits and Monitors for compliance with this Procedure.

• Identifies remedial corrective actions required to meet the requirements of this Procedure



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PROCEDURES 5 •

The Contractor shall ensure that the direction of all cranes is undertaken by a licensed dogman or rigger, as the case may require.

Safety harness with shock absorbing lanyards or inertia reels shall be worn and used where there is a potential fall risk. Personnel working at height involved in erection of structural steel shall also comply with the Karara Mining Limited Working at Height Procedure.

Walking of steel is prohibited as per the Project Working at Heights Procedure; Ref. Doc. No. CORP-HS-PRO-1004.

Climbing up or down columns is prohibited as a means of access or egress.

Loads hoisted shall be provided with a tag line(s) for control.

Loads shall not be lifted over the heads of personnel.

Employees shall not work below areas where steel work is being erected or bolted up.

Rigging/hoisting equipment shall not be released from structural members unless they have at least been 'two-bolted' at each connection and drawn-up tight with a spanner.

The erection area shall be secured with a rigid barricade, and "Danger Men Working Overhead" signs shall be posted.

Tag lines shall be used during the loading/unloading of any load and during the erecting of structural steel.

Ladders shall be used to ascend or descend trucks and trailers.

All structural steel shall be placed on substantial cribbing (i.e. gluts, dunnage, etc.) and secured in a manner to prevent rolling or shifting of the load.

Employees are to be made aware of (by the Contractor) and avoid potential pinch point locations such as between the truck and steel or crane and steel.

Gloves shall be worn while handling any material.

The use of a crane to "forcibly" pull a connection into place shall not be allowed.



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All two-bolt columns shall have steel wedges forced in under the base plates until the tie-in steel is erected.

All columns shall be tied-in at the end of each shift.

Personnel shall use ladders, scaffolds, EWP's or stairs to access or egress elevated areas.

Bolts, nuts, washers and any other items that could fall are not to be left on beams or the structure in an unsecured state at any time.

All connections shall have a minimum of two bolts, with nuts that secure the connection with full thread protruding past the end of the nut before the load is released from the crane.

Softeners/packing shall be used on all rope lines used to plumb up structures.

All bolts and small items will be put in a bolt bag to be hoisted by hand. The throwing of bolts will not be allowed.

Bolt-up personnel shall raise and lower impact wrenches with a rope or other appropriate device/equipment. Impact wrenches should be relocated lowering them to the ground then hoisting them back up at the new location. Personnel shall avoid physically carrying impact tools to a new location.

Where permanent stairways cannot be installed for access, Contractors shall install access towers with stairways for the safe access and egress of erection personnel where possible.

5.1 Planning

Contractors shall plan their erection method to ensure that fall prevention and not fall arrest is the priority risk management process. Where fall arrest systems are to be used, those must be of an approved type, inspected and tagged by a competent person and installed by a licensed Rigger trained and competent in the erection, inspection and maintenance of fall prevention equipment and approved by the KML Registered Manager (or their nominated delegate). This shall be in compliance with AS/NZS 1891.3 Industrial Fall-Arrest Systems and Devices: Fall-Arrest Devices and AS/NZS 1891.4 Industrial Fall-Arrest Systems and Devices; Selection, Use and Maintenance.

Contractors shall ensure that no person works in an elevated position without:

• A JHA detailing the hazard and control methods.

• Approved means of access.

• Approved guard railing as the first priority.



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• Approved fall protection (full body harness with shock absorbing lanyard).

Only persons with an appropriate High Risk Work Licence (See Occupational Health and Safety Regulation, 1996; Division 2 and 3.55(5)) as a Rigger shall directly supervise rigging work and shall not supervise more than one (1) unlicensed person at any one time.

Contractors shall submit a Lift Plan, completed by a competent person, for all Non-Standard lifts to the KML Registered Manager (or their nominated delegate) for review and acceptance at least two (2) days prior to the lift taking place, and a Lift Plan and a Crane Study for all Critical Lifts for review and acceptance at least five (5) days prior to the lift taking place.

Following review and acceptance of the lift study, all persons involved in the lift (i.e. riggers, crane operators, engineers, etc) shall attend a JHA sessions where all aspects of the proposed lift will be disseminated by the Contractor.

The Contractor shall ensure that structural steel members typically designed for the support of cable trays are not used as anchor points for the use of chain blocks, snatch blocks, tirfors or anchorage of winches or any other lifting medium. The use of 'pad eyes' or other similar devices that will be placed under load will require Project approval and NDT destructive testing prior to use.

All rigging equipment, chain blocks, tirfors, and pullers shall be identified by a numbered system and be colour coded to readily identify that testing requirements have been carried out for the current period (quarterly). Colour coding shall be carried out in the same periodic fashion as electrical tagging. Refer to OSH Regulation (1996) Section 3.51, AS 1891 and Code of Practice: Prevention of Falls at Workplaces (2004).

A Register (Refer to Attachment 7.1 - Lifting Equipment Register) shall be kept of all rigging equipment with details of the different types of equipment, the unique number of the item, the date of any testing and inspection carried out, the type of testing or inspection carried out (i.e. visual, load, NDT, annual, periodic, etc) and the name of the qualified person carrying out the inspection (rigger, manufacturer or supplier).

Contractors shall ensure that all rigging personnel are aware that the only approved methods for lifting steel plate are as follows:

• Approved plate clamps - must be position locking and inspected before use.

• Approved plate shackles.

• Approved collared eye bolts.

• Approved 'D' or bow type shackles.

• Complies with the AS/NZS 1891 series and/or the manufacturer's recommendations.


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The use of chain sling hooks hooked onto the edge of the plate (point loading of the hook) is prohibited.

All loads lifted or moved by cranes shall have a tag line{s) attached to control the movement of the load.

Contractors shall provide a detailed Risk Assessment for the loading and unloading of piping, structural steel, temporary buildings, reinforcing mesh, steel and plant equipment and machinery from truck trailers, in accordance with the Project Material Transportation Standard (Ref. Doc. No. CORP-HS-STD-1011). This shall include but not be limited to the following:

• Safe access and egress to the trailer/load,

• Specific details on falls prevention to be provided,

• Contingency plans for the safe removal of loads moved or displaced during transport.

The use of flat synthetic web slings on the project is prohibited.

Contractors shall ensure that all riggers understand and comply with the following Project requirements for chain blocks, chain pullers and tirfors;

• Back-hooking of load chains or ropes onto chain blocks, chain pullers, tirfors, etc. is prohibited.

• Load chains or wire ropes shall not be loaded when they pass over edges or obstacles.

• Point loading of hooks is prohibited.

• Chain blocks are not to be used in the horizontal position. They are designed for vertical lifts only.

• Where loads are to be lifted or drifted at angle, the necessary deductions must be made to the SWL of the lifting device.

• Using extensions to lever handles, or introducing a mechanical means to assisting the operation of, or using more than one person on chain block to pull on the chains is prohibited.

• Chain blocks and chain pullers must not be directly attached to any structure where the hooks or safety catches may be damaged.

The throwing or dropping of gear etc. is prohibited.

Contractors shall provide wrist lanyards or other restraints for tools, equipment where there is any possibility that the tools or equipment may be dropped to a lower level. Where there is a disagreement on whether the tools or equipment may be dropped, the Contractor shall meet with the KML Registered Manager (or nominee) and KML Safety Superintendent to discuss and reach an



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agreed outcome. If an agreed outcome cannot be reached, the matter shall be referred to the KML Project Safety Manager.

• Contractors shall ensure that no loose material, nuts, bolts, tools, etc. are left on any structure where they may be displaced and fall to lower levels (Refer to AS 3828—1998: Guidelines for the Erections of Building Steel). In compliance with sound housekeeping (Refer to the Project Housekeeping Procedure; Ref. Doc. No. CORP-HS-PRO-1011) and hazard prevention practices, such items shall be kept in containers and otherwise secured from falling.

Contractor shall not use eye bolts for lifting without a Risk Assessment being completed and approved by the KML Registered Manager (or their nominated delegate).

5.2 Training

All persons working with steel shall be appropriately trained and competent to carry out the work, or be in training under the direct supervision of a competent person.

Training needs can be split into induction and more specific task related training and may be met by a mixture of on-the-job and off-the-job training. All information, instruction and training provided shall be in a language and form which employees will understand.

Competent personnel approved by the KML Registered Manager (or nominated) and HSE Training Superintendent shall be used to carry out the training function.

Training and competency assessments shall be carried out in accordance with the Project HSE Training and Induction Procedure (Ref. Doc. No. CORP-HS-PRO-1001).

Where there is a risk of falling, all riggers shall be trained in the use, care, selection and maintenance of fall protection equipment, must a wear safety harness and be attached to a secure anchorage at all times when working above grade level where other forms of fall protection have not been provided.

Contractors shall train and competently assess all personnel required to undertake any work involving winches (erection, cable pulling, etc).

Where a fall injury prevention system is used, the instruction and training given should include at least:

• What each individual piece of equipment is intended for and how it works.

• The correct selection, fitting, use, care, inspection, maintenance and storage of individual fall-arrest and restraint equipment (in accordance with the manufacturer's instructions and Australian/New Zealand Standard, AS/NZS 1891.4), their strengths and weaknesses and the siting of temporary fall-arrest systems.



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• The method to be used in carrying out a specified work task, including the access and attachment method.

• Maintenance of evidence of training undertaken

• Emergency rescue procedures.

Contractors shall provide the KML Registered Manager (or their nominated delegate), the name of all licensed riggers and copies of their National Licenses prior to the employee/s to mobilisation to site.

In addition, Contractors shall provide verification that the rigger has successfully completed a competency assessment in the following:

• Safe slinging techniques.

• Correct and safe use of lifting/rigging equipment.

• Correct and safe use of falls prevention equipment.

• The safety and health responsibilities of a Rigger.

• The safety requirements of this Procedure.

These assessments shall be conducted not more than one month prior to site mobilisation

Contractors shall ensure that all erection personnel are trained and knowledgeable in the procedural requirements applicable to the scope of work being undertaken and contained in the Project Safety Procedures/Procedures, site rules and legislative requirements.

Contractors shall establish a process where Supervisors are assessed on their knowledge of the relevant Safety Procedures/Procedures. Documentation of these assessments are to be maintained and made available to the KML Registered Manager (or their nominated delegate) upon request.

Also refer to:

• CORP-HS-PRO-1001: HSE Training and Induction Procedure.

• CORP-HS-PRO-1054: Language and Literacy Procedure.

• Occupational Health and Safety Regulation (1996).

• AS 3828—1998: Guidelines for the Erections of Building Steel.

5.3 Personal Protective Equipment (PPE)

Contractors shall provide the following PPE which is to be worn at all times by erection crews and riggers:



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• Safety helmet with chin strap.

Note: The reversing of the helmet is not permitted.

• Safety glasses with side shields.

• Steel capped safety footwear.

• Leather riggers gloves (when handling steel).

Refer to:

• CORP-HS-PRO-1037: Personal Protective Equipment Procedure.

5.4 Adverse Weather

Contractors shall as part of the hazard analysis, within their scope of work, provide the management strategies and controls to be implemented to ensure the safety and health of employees engaged in erection and rigging activities during periods of adverse weather conditions (includes lightning);

• Hot weather.

• Wet weather.

• Windy weather.

5.5 Lifting Equipment

Lifting equipment shall comply with the requirements of the relevant Australian Procedure (e.g. AS 2550.1 - 2002 - Attachments).

Lifting equipment shall be certified prior to being brought to site.

Lifting equipment certification shall be conducted by a National Association of Testing Authorities (NATA) approved testing authority.

Contractors shall verify that the following Certification requirements are complied with prior to mobilising lifting equipment to site.

Contractors shall have evidence of lifting equipment certification on site available for audit or review upon request by the KML Registered Manager (or their nominated delegate).

5.5.1 Certif ication Procedures

• Conduct visual inspections on lifted equipment, checking design conformance, structural condition of lifted equipment.



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• Conduct pre-load test magnetic particle inspections of welds (e.g. pad-eyes, etc).

• Conduct proof load tests.

• Conduct post load test visual inspections ensuring no permanent distortion of structural members or other damage that may affect safe operation.

• Conduct post-proof load test magnetic particle inspections of the same welds after the load test.

• Ensure the Number, SWL (WLL) TARE, NETT, GROSS data are legible.

• Fit compliance plate to equipment.



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REFERENCES 6.

• AS 2550.1 - 2002 Cranes, hoists and winches - Safe use - Part 1 - General requirements

• AS 3828 - 1998 Guidelines for the erection of building steelwork

• AS 3828—1998: Guidelines for the Erections of Building Steel.

• AS/NZS 1891.3 Industrial Fall-Arrest Systems and Devices: Fall-Arrest Devices

• AS/NZS 1891.4 Industrial Fall-Arrest Systems and Devices: Selection, Use and Maintenance

• Code of Practice: Prevention of Falls at Workplaces (2004).

• Manufacturers Recommendations.

6.1 Associated Documents

6.2 Specific Situations Requiring Barricades

• CORP-HS-PRO-1001: HSE Training and Induction Procedure.

• CORP-HS-PRO-1054: Language and Literacy Procedure.

• CORP-HS-PRO-1004: Working at Heights Procedure.

• CORP-HS-PRO-1011: Housekeeping and Waste Disposal Procedure.

• CORP-HS-FRM-1122: Lifting Equipment Register.



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REFERENCES

• AS 1319; Safety signs for the occupational environment

• AS/NZS 4576 Guidelines for scaffolding

• Occupational Safety and Health Act (1984)

• Occupational Safety and Health Regulations (1996)

• WorkSafe WA Code of Practice: Excavations (2005)

7.1 Supporting Documents

• CORP-EN-PRO-1004; KML Approvals Requests and Ground Disturbance Procedure

• CORP-HS-FRM-1062: KML Job Hazard Analysis Form

• CORP-HS-PLN-1001: KML Occupational Health and Safety Management Plan

• CORP-HS-PRO-1020: KML Job Hazard Analysis Procedure



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Appendix 1- Lifting Equipment Register (Sample)

CORP-HS-STD-1012 Appendix

Rev 2 Re-lssused for use

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