1. PURPOSE To describe the Ontario Operations standard methods for preventing serious injury resulting from fall from heights and to provide a Standard for Fall Protection to safeguard employees who work within 2 metres of a Fall Hazard. 2. SCOPE To set forth the requirements and criteria for fall protection and/or travel restraint at Vale s Ontario Operations. 3. REFERENCES Regulation 854 For Mines and Mining Plants, Sections 14, 46, 48, 60, 94 and 190 Ontario Division All Mines Standard Practice, Chapter 6, Section 1. Ontario Ministry of Labour Health and Safety Guideline R.S. 14. C.S.A. Standards Z259.16-04 & Z259.12 Vale Golden Rules Fall-Arrest Systems Practical Essentials (CSA PLUS 1156) ANSI A92.5-2006 Boom-Supported Elevating Work Platforms ANSI A92.6-2006 Self-Propelled Elevating Work Platforms Vale CED SPEC-20001 Standard Designs General Lifeline Attachment & Anchors 4. DEFINITIONS 4.1 Travel Restraint System (TRS): An assembly of components (lanyard, belt or full body harness without energy absorber) that, when properly assembled and used together, and when connected to a suitable anchor point, prevents an employee from reaching an unprotected edge or opening where a fall could occur. Do not tie off to handrails, electrical cable trays, process piping. 4.2 A Fall Arrest System consists of a full body harness, an energy absorber, a suitable connecting device, a suitable anchor point and a written rescue plan. For a single fall arrest system the anchor point should be able to with stand 5000 lbs {Fall-Arrest Systems Practical Essentials (CSA PLUS 1156)}. The reason for the 5000 lbs is because it is the minimum breaking strength of a majority of the components of a typical fall arrest system. 4.3 Fall arrest condition: An opening or unguarded edge at a work level, that is large enough that an employee could fall through it, or over it to a lower level or obstruction that is 1.8 m or more below the work level. (Reference Vale Golden Rules) A Fall Hazard begins when a person is within 2m of the opening or edge, or 2m from the point where unsafe footing or ground slope might cause a slip or fall towards the opening or edge. (Reference O. Reg 854 Section 14) 4.4 Energy absorber: A device that dissipates kinetic energy, limits deceleration forces during fall arrest, and does not return kinetic energy to the system or into the human body. Note: Kinetic energy is energy due to motion. (To ensure latest version, refer to Safety tab under Sudbury s Safety, Health & Environment Intranet Homepage) Page 1 of 5
Note: In a free fall situation the energy absorber will elongate. This additional length must be taken into account when choosing the length of the lanyard for a particular free fall situation. 4.5 Self-Retractable Lanyard (SRL): A device that performs a tethering function while allowing vertical movement (below the device) to the maximum working length of the device, which will arrest a user s fall. The SRL is designed to arrest a fall while minimizing free fall distance and impact force. Note: Not to be used when working on top of unconsolidated material, e.g. muck in ore passes, sand in sand bins. 4.5.1 Type 1 (SRL) is 1.5m (5ft) to 3m (10ft) in length. Not repairable or serviceable. 4.5.2 Type 2 (SRL) is greater then 3m (10ft) in length. Type 2 SRLs must be recertified 2 years after purchase an then annually thereafter. When a type 2 SRL has been subject to the force of a fall, it must be removed from service and recertified. 4.5.3 Type 3 (SRL) is the same as a type 2 SRL but with an integrated rescue / retrieval winch that allows a single attendant to raise or lower the individual that is suspended in arrest. Type 3 SRLs must be recertified 2 years after purchase an then annually thereafter. When a type 3 SRL has been subject to the force of a fall, it must be removed from service and recertified. 4.6 Free Fall Distance: The vertical distance from the onset of a fall to the point where the fall-arrest system begins to apply force to arrest the fall. 4.6.1 Free fall distance is regulated to a maximum of 1m (3ft) by Regulation 854 Section 14 (4)(a). 4.7 Written Rescue Plan: When ever a fall arrest system is being used a written rescue plan must be available. The rescue plan could be a section in a procedure or the completed working at heights worksheet that is attached to this SPI. Working at Heights Rescue Plan Worksheet 4.8 Suitable Anchor Point: A suitable anchor point for travel restraint and fall arrest is generally a structural member such as a beam, girder, column, floor, or wall (CSA standard). If the anchor point is a permanent anchor point, then it requires be engineered. Both for fall arrest and travel restraint. Temporary anchor points depend on the loads or forces they are subjected to but require to withstand a minimum amount of force. Please reference the Construction Regs (26.7), the Ontario Building Code, and also the CSA Standards for more specifics. Do not tie off to handrails, electrical cable trays, process piping. 4.9 Engineered Anchor Point: An anchor point that must be installed, inspected, and maintained in accordance with a Professional Engineer s Design. Reference Vale CED SPEC-20001 Standard Designs- General- Lifeline Attachment & Anchors. In this standard, it refers to various acceptable lifeline bolting installations i.e. steel, concrete or rock. (To ensure latest version, refer to Safety tab under Sudbury s Safety, Health & Environment Intranet Homepage) Page 2 of 5
5. FALL ARREST SYSTEM REQUIREMENTS 5.1 Use: A fall arrest system is to be used whenever: a) a person is exposed to the hazard of falling more than 1.8 meters. (Regulation 854 Section 14) Reference Vale Golden Rules for height b) a person (except in an underground mine) on a ladderway at an angle steeper than 70 degrees to the horizontal shall be fixed in place and be provided with: platforms at intervals not greater than 7 metres; a safety cage; or a protective device which when used will prevent a worker from falling. (Regulation 854 Section 48) c) a person is working on top of bulk material in a silo, bin, hopper, chute, etc. (Regulation 854 Section 60) d) a person is barring loose rock, or scaling, or cleaning on a face of a surface mine. (Regulation 854 Section 94) e) a person using a bosun's chair, suspended scaffold or mobile staging shall be protected by a fall arrest system, if the worker may fall more than 1.8 meters from the chair, scaffold or staging. (Regulation 854 Section 190). (Reference Vale Golden Rules for height) Note: Such fall arrest protection shall be independent from the systems used to suspend the person using the bosun s chair, suspended scaffold or mobile staging. On a standard shaft conveyance, the independent hook-up does not apply. f) While using elevated work platforms, i.e. scissor lifts, knuckle booms, etc., manufacturer recommendations in the owner s manual on the recommended fall protection should be followed. If an owner s manual only states don fall protection, then travel restraint is to be used. There are some underground exemptions to the SPI. See Exemptions to SPI-SAF-06 for current list of equipment that is exempt. g) Management may designate other activities requiring the use of a Fall Protection System that in their opinion will reduce the potential for serious injuries. Some exposures to serious injury which may apply are falling: i) into water ii) into / onto operating machinery iii) into / onto hazardous materials or objects. 6. FALL ARREST SYSTEM EQUIPMENT FOR PLANTS & MINES a) A fall arrest system consists of a full body harness, an energy absorber, a suitable connecting device, a suitable anchor point and a written rescue plan. b) All fall arrest equipment connections must be visually checked for false connections by the user. This could be done by putting the attachment onto the harness dorsal D ring prior to user installing the harness or use a dorsal D ring extension which will require adding the length of the dorsal D ring extension to the calculations for the total fall distance. (To ensure latest version, refer to Safety tab under Sudbury s Safety, Health & Environment Intranet Homepage) Page 3 of 5
c) When working in bins where the working platform is the process material in the bin, the fall arrest system must not include a Self Retractable Lanyard as this type of device will not engage unless a fall has been detected. A Vertical Lifeline and Fall arrester, or lanyard of a length specific for the application must be used. d) When used by electrical personnel and there is a hazard of an Arc Flash, the full body harness in use must be an Arc Flash harness. e) The location of the anchor point and the length of the connecting device shall be arranged so as to minimize the potential free fall distance. The Free Fall distance shall not exceed a maximum 1m. f) The equipment used in the fall arrest system must be selected and arranged so that the user cannot hit an object or level below the work level. g) The fall arrest system shall not subject a worker who falls to a peak fall arrest force greater than 6 kn (1350 lbs). (CSA Standard). 7. TRAVEL RESTRAINT SYSTEM A travel restraint system is to be used when a person s work is within 2 meters of an "open hole condition" but does not exceed the minimum distance to nearest part of the opening. The open hole condition begins from the point where unsafe footing or ground slope might cause a slip or a fall towards the opening. Note: A body belt or a full body harness connected to a lanyard and suitable anchorage is an example of a travel restraint system (CSA standard). Note: A shock absorber shall not be used in a travel restraint system. 8. FALL PROTECTION REQUIREMENTS / APPROVALS Only fall protection systems that meet or exceed current CSA standards are to be used in Vale Ontario operations. Supervisors who have employees that use fall arrest systems or travel restraint systems shall be trained in the systems used by their employees. 9. ANCHOR POINT REQUIREMENTS 9.1 Anchor points for fall arrest systems must meet the following requirements: 9.1.1 Be located so that the vertical distance from the onset of a fall to the point where the fallarrest system begins to apply force to arrest the fall is not more than 1 meter. 9.1.2 Be connected to an object that is free of sharp edges and capable of resisting the arrest force in case of a fall. If this is not possible, chafing pads or abrasion resistant straps must be used around sharp edge structures to prevent cutting action against safety lanyards or lifelines. 9.1.3 When steel slings are used as part of a fall protection system, they must be stainless steel and be a minimum of ¼ diameter and only used in the Basket Hitch Vert. set-up. If not used in the basket hitch vert. set-up, the stainless steel sling must be 3/8 or greater. The only ¼ approved stainless steel slings are: a) 3' Anchor Sling stock code 15628034 (To ensure latest version, refer to Safety tab under Sudbury s Safety, Health & Environment Intranet Homepage) Page 4 of 5
b) 5' Anchor Sling stock code 15580121 c) 6' Anchor Sling stock code 15677038 10. THE REQUIREMENTS OF THE ANCHORING HITCH ARE AS FOLLOWS A temporary anchoring hitch shall be capable of sustaining twice the force it may be subjected to and not be knotted or allow to become knotted when used or worn. (Regulation 854 section 14 guideline). An anchorage is generally a structural member such as a beam, girder, column, floor, or wall (CSA standard). Do not tie off to handrails, electrical cable trays, or process piping. 10.1 Permanent anchor points in mines and surface plants must be engineered. When a permanent anchor point has been installed for travel restraint it must be labeled as such with signage or metal tag attached stating travel restaint only. 10.2 The anchoring location for fall arrest should be selected so as to minimize the pendulum effect. 10.3 The anchoring location should be selected so that the safety line is not exposed to damage from chafing, burns or sharp edges. 11. PRE-USE INSPECTIONS Each user of fall body harness must be trained in the proper use, fit and pre-use inspection as per training manual. Each user of Personal Fall Protection Equipment or Systems must receive Equipment Training specific to the work tasks that they may perform, and the equipment they may use. 12. PROPER USE OF EQUIPMENT 12.1 The user must inspect all components of a fall protection system prior to use. This includes a visual inspection of the anchor points. 12.2 All damaged fall protection equipment or equipment that has been subjected to a fall, must be tagged and removed from service immediately. 12.3 When a body belt is used (Travel Restraint), ensure the belt is of the correct size and is worn snugly around the waist. The belt buckle tongue should fit into the 2nd grommet or greater and the belt tail must be secured in the belt keeper. The buckle must be in the front centre of the body and the "D" ring in the centre of the back. If a full body harness has a shock absorber, it shall not be used for travel restraint. When using a travel restraint system ensure that you cannot reach the open hole. (To ensure latest version, refer to Safety tab under Sudbury s Safety, Health & Environment Intranet Homepage) Page 5 of 5
12.4 Ensure that a full-body harness is of the correct size and adjusted to fit the user properly. For total mass of worker (and equipment) greater than 310 lbs, a heavy duty harness rated to 400 lbs is required. Energy absorber or energy absorbing lanyards classifications are as follows: - E4 total mass of worker: at least 45 kg (100lbs), but not more than 115 kg (254 lbs.) - E6 total mass of worker: at least 90 kg (200 lbs), but not more then 175 kg (386 lbs) 12.5 Large snap hooks and carabineers that have gate openings in excess of 19mm (0.75 in) should not be used in conjunction with fall arrest attachment points on full body harness. 12.6 Knotting of lanyards is prohibited. 12.7 When a fall arrest system must be used, there shall be a coinciding written rescue plan. 12.8 Certified personnel must complete repairs or servicing of any fall protection system component. 12.9 If a fall has occurred, then the anchor point must be: a) Replaced; or, b) Inspected by an engineer to establish the integrity of the anchor point before its next use. 13. RESOURCES Vale Working at Height Rescue Plan Work Sheet Formal Risk Assessment 14. TRAINING Renewal training will be done every 3 year and the training is to be done with an instructor. 15. REVISIONS This SPI should be reviewed as required when the referenced standards, new standards arise, or regulatory requirements change; a formal review shall be required within three years of the revision date. REVISION TRACKING (To ensure latest version, refer to Safety tab under Sudbury s Safety, Health & Environment Intranet Homepage) Page 6 of 5