Corporate Health and Safety ArcelorMittal

1. RS# 5 Maintenance Draft date: Oct 5, 2011 Rev 1 Corporate Health and Safety ArcelorMittal

2. Summary • General subjects regarding Maintenance • Definitions and terms • FPA Questions • Maintenance tasks on or near Railways • Maintenance tasks on Rail Equipment

3. General subjects regardingMaintenance • Maintenance tasks (both on rails and vehicles) have a high level of risk. • When operating with heavy vehicles moving heavy loads, accidents do not give a second opportunity. • Besides, most of the maintenance task on rail devices may be affected by risks other critical risks: • Isolation (Golden Rule 3) • Working at height (Golden Rule 2) • Confined spaces, when working in maintenance pits, rail scales (Golden Rule 4) • Lifting equipment (Golden Rule 5)

4. Definitions and terms • Lineside You are on the lineside if: • you are between the railway boundary fence and the area called on or near the line, and • you can be seen by the driver of an approaching train. You are not on the lineside if: • you are on a platform (loading bay, station,..). • You are not on or near the line if you are crossing the line at a level crossing. • On or near the lineYou are on or near the line if you are: • within 3 meters (10 feet) of a line and there is no permanent fence or structure between you and the line • on the line itself. You are not on or near the line if: • you are on a platform unless you are carrying out engineering or technical work within 1.25 meters (4 feet) of the platform edge.

5. Definitions and terms • Isolation • Physical process to block the possibility of a rolling stock to enter a certain part of the railway track. • Train Approach Warning (TWA) • The form of track protection that a watchman/lookout provides, for warning track workers when a train is approaching • Individual Train Detection (ITD) • The form of track protection that can be performed when there´s and only worker performing basic tasks. • Derailment • A derailment is an accident on a railway in which a rail vehicle, or part or all of a train, leaves the tracks on which it is travelling, with consequent damage and in many cases injury and/or death.

6. FPA questions - Maintenance • Level 3 – Question 1 [L3 - Q1]Are all the legally required periodical verifications identified? Are they performed by trained and authorized people? Are the results of those controlsformalized?2. Does the plant know and understand the ArcelorMittal standard for Rail Safety and distributed the information to the personnel concerned? Recommendations and good examples ! • Braking system Maintenance regulations change among countries, and its application is not compulsory for internal traffic. Anyway, the Legal requirements could be a good starting point in order to establish a safe Maintenance system • Air tanks should be inspected and certified regularly.

7. FPA questions - Maintenance • Level 3 – Question 2 [L3 - Q2]Is the responsible person for rail activities always informed prior any work when isolation is necessary by the supervisor or his designee? Is a HIRA always performed before starting any work? Is a safety plan defined on the basis of the HIRA including the necessary safety actions to protect workers from rail traffic movements? Are formalized audits regularly performed to check compliance with the safety plan (particularly concerning the isolation procedure respect)? 3. Recommendations and good examples ! • A Work permission, job briefing and a safety coordinator for every maintenance task performed on/near the rail will reduce risk ALARP.

8. Maintenance Tasks on Railways • People accreditation and PPE´s • Track Protection 2.1 Working Limits isolation 2.2 TAW – Train Approaching Warning 2.3 ITD – Individual Train Detection • Job Briefing • Communication • Maintenance and Equipment inspections

9. 1. People Accreditation & PPE´s AM Standard Rail Safety 004 • They must be trained and competent • They must know and follow Standard Operation – AM Safety 004 – Rail Safety • They must use approved protection equipment for the respective job

10. 1. People Acreditation & PPE´sPersonal Protective Equipment; L1Q13 • The used PPE may vary and must be the outcome of a HIRA. • Approved protection equipment must be used for the respective jobs. • Requirements are e.g.; • Safety boots (high ankle boots where necessary!) • Safety glasses • Hard hat / helmet • High visibility clothing’s • Gloves • Hearing protection • The means of communication

11. 2. Track Protection (L1Q8, L1Q9) • By track protection, there are two different situation: • Working/going on the lineside (>3 m of a line). • Track protection (<3 m of a line; on or near de line). There may be three possibilities to prevent workers from being struck by a moving equipment (explained later on). • Level 1 – Question 8 Have safety rules been written for situations when duties require people to go on the lineside? The lineside within the area between the rail boundary fencing and the point that is called “on or near the line”. Have those rules been written on the basis of a HIRA? Do those rules ensure the concerned people are protected from rail movements? • Level 1 – Question 9Is it forbidden to walk on tracks? Have safety rules been written for situations when duties require people to go on or near the line (on or within 3 meters / 10 feet of a railway track)? Have those rules been written on the basis of a HIRA? Do those rules ensure the concerned people are protected from rail movements by track isolation using derail or switch locks? Recommendations and good examples !

12. 2. Track Protection Working on the lineside (> 3m of a line) L1Q8, L1Q9 • Going on the lineside (> 3m of a line); • You must wear the correct high-visibility clothing issued to you by your employer. • You must use an authorized access point, if provided, to get onto the operational railway. • You must use authorized walking routes if they are provided. • You must raise one arm above your head to acknowledge the driver of any approaching train who sounds the warning horn. • Keep in mind when on or about tracks is to expect movement in either direction on any track at any time! • You must have a min. distance of 3 m/ 10 feet from standing cars or other equipment when you cross any track. • Working on the lineside; • Any work done on the lineside must not affect or go within the area called on or near the line. • Using a road vehicle on the lineside; • If you are using a road vehicle, you must not allow it to enter the area called on or near the line unless it’s isolated.

13. 2. Track Protection Working on or near the Line (< 3m of a line; L1Q8, L1Q9) • Prior to beginning work where railroad track isolation is necessary, or to prevent unwanted car movement into an area, the supervisor, or designee, must notify those responsible for rail operations to alert them of the work to be performed.

14. 2. Track Protection Working on or near the Line (< 3m of a line; L1Q8, L1Q9) • Track protection is a way to prevent roadway workers from being struck by a moving train or other equipment. Track protection works in two ways, either by keeping: • Trains away from roadway workers • Roadway workers away from trains • The employee-in-charge has established boundaries for a section of track for a specified period of time and trains can move through these boundaries only with permission from the employee-in-charge. • Track within the Working Limits is made inaccessible by use of switches, derails, or other devices used to prevent traffic.L1Q9 TAW (where isolation is not possible) requires that certain conditions be met and that there is a qualified watchman/lookout available. ITD (temporary access, routine inspections, minor corrections) and TAW ; allows a track worker to gain temporary access to tracks where Working Limits have not been established. It can be used only when a number of conditions have been met.

15. 2.1 Isolation of the track; L1Q8, L1Q9Trains away from roadway/ track workers • Working Limits; Track within the Working Limits is made inaccessible by use of switches, derails, or other devices used to prevent traffic. • Unless specifically allowed within your company instructions, you must consider the following as types of work that will affect the safety of the line (Work that needs the line to be isolated!): • Carrying heavy or awkward equipment or materials across or along the line. • Work that will affect the condition of the track. • Digging a hole or stacking material or equipment close to the line or near the edge of a platform. • Placing a hand trolley on the line. • Using plant within 3 meters/10 feet of the line. • Using a road vehicle within 3 meters/10 feet of the line. • Using a crane or other lifting equipment that will foul the line. • Attaching anything to a railway structure, such as a bridge, a station roof or building, a signal post or gantry, or electrical equipment. • Using a ladder, unless secured so that it cannot fall towards the line. • Using scaffolding or a climbing tower, unless secured so that it cannot fall or move towards the line. • Felling or trimming trees.

16. 2.1 Isolation of the track; L1Q8, L1Q9Trains away from roadway/ track workers • May there be any equipment (locomotive, wagon, or any other rolling stock) inside the protected area, do not forget to wedge properly!

17. 2.2. Train Approaching Warning (TAW); Roadway workers away from trains • The form of track protection that a watchman/lookout provides is called Train Approach Warning. It relies on the watchman/lookout being able to see and/or hear trains. It may be used when isolation of the track is not possible • Identification; You must wear the correct high-visibility clothing issued to you by your employer.Lookouts and site-wardens must wear visual recognizable defined clothing's e.g. armlets, badges or an specific color helmet. • To act as a Watchman/Lookout or a site warden you must be trained and competent. • You must: • make sure your mobile phone is switched off • stay alert and carefully watch the group • not leave your post • You must not: • take part in the actual work • carry out any other duties • allow yourself to be distracted • act as a lookout site warden if you cannot stay alert.

18. 2.2 TAW - Watchman/Lookout; L2Q2 • Train Approach Warning can be used only when all of the following conditions are met: • Isolation of a line is not possible • Person has been qualified as a watchman/lookout by successfully completing this training and has knowledge of the area’s physical characteristics and train operations. • Roadway/ track workers are performing routine inspections or minor repairs that do not affect the safe movement of trains. • No equipment is fouling the track. • Person is able to see the approach of a train, engine, or other railroad equipment approaching at maximum speedauthorized and can move to and be in PREDETERMINED place of safety not less than 15 seconds before the train, engine, or other railroad equipment would arrive.

19. 2.2 TAW Watchman/lookout duties; L2Q2 • Watch for approaching trains or on-track equipment. • Provide sufficient warning to employees that a train or other moving equipment is approaching. • When you see a train approaching on any of the lines concerned, you must wave your chequered flag above your head as a warning. If there is more than one site lookout, each must acknowledge your warning. • You must give the warning using one of the following methods: • Whistle or air horn • Flags or lantern or fusee / touch depending of the visibility • Identify a place of safety that workers can reach at least 15 seconds before a train moving at maximum speed authorized can reach the worker’s location. • You must stop any work, acknowledge the warning and move to the position of safety immediately the lookout gives the warning. • If someone does not acknowledge or move to the position of safety when the lookout gives the warning, the lookout will give an urgent warning. This urgent warning is a series of short sharp blasts on the whistle or horn. • You must not leave the position of safety until all workers are in position of safety. • Lookout must never be distracted. Do not wear anything that makes you less able to see or hear approaching trains.

20. 2.3 ITD and individual working alone;Roadway workers away from trains • The only occasion when you can go on or near the line not isolated without a watchman/lookout, is when you are walking alone. • You must wear the correct high-visibility clothing issued to you by your employer. • Make sure you have a suitable lamp with you if you will be on or near the line during darkness, poor visibility or if you are to enter a tunnel. • Before you go on or near the line alone, consider: • the maximum speed • the direction from which trains normally approach • the location of any area where you must not go while • trains are running any location with limited clearances. • Patrolling, examining or inspecting • You can patrol, examine or inspect an open line if you are sure you will be able to look up often enough (at least every 5 seconds) to see any train approaching

21. 2.3 ITD and individual working alone • Lone worker MUST conduct job briefings with their supervisor and then the person responsible for train activities MUST be informed. • Individual Train Detection, or ITD, can be used only if all the following six conditions are met: • Person must be trained and competent. • Person is performing routine inspections or minor repairs and not fouling the track with work equipment. • Person is working on a track outside control points, interlocking, or hump yard facility. • Person is able to see the approach of a train, engine, or other railroad equipment approaching at maximum speed authorized and can move to and be in predetermined place of safety not less than 15 seconds before the train, engine, or other railroad equipment would arrive. • No power-operated tools or roadway maintenance machines are being used that impair the hearing of the lone worker. • No other physical conditions (light, fog, noise, etc.) exist that impair the vision or hearing of the lone worker.

22. 2.3 ITD and individual working alone • While walking alone • Any items you carry while walking must not affect your ability to walk safely or to see or hear and acknowledge approaching trains. • You must use authorised walking routes if they are provided. • Do not wear anything that makes you less able to see or hear approaching trains. • Do not allow yourself to be distracted by anyone or anything. • If you have to cross the line, you must not step on rails or sleepers or between movable parts of points. • Keep a good lookout for approaching trains. Make sure you look up at least every 5 seconds so that you can reach a position of safety and be in it no less than 15 seconds before an approaching train arrives. • When a train approaches • When a train approaches you must immediately move to a position of safety or, if already in a position of safety, stay there. • If the driver sounds the warning horn, raise one arm above your head to show you have heard the warning. • You must stay in your position of safety until the train has passed clear or you are certain you will not be put in danger by that train or any other train.

23. 3. Job Briefing • Job Briefing is a communication tool required before any on-track safety job or task begins and any time the works conditions changes. A risk assessment should be performed before this job briefing by the employee-in-charge. Repetitive works should have safe work instructions. Job briefing should have a documental support, with written duties and responsibilities Job briefing should be done BEFORE starting the job from a safe location It should be done under safe conditions

24. 3. Job Briefing • Identifies the employee-in-charge of on-track safety. Discusses the job and the sequence of the steps required. • Points out the potential hazards. Explains the type of track protection that has boon established for jobs that foul the track (HIRA). • Directs participants to check the equipment and tools to be used. • Reviews the protective equipment required. • Makes sure everyone, at a minimum, can answer questions applicable to the job, such as: • Who is the employee-in-charge of on-track safety? What type of track protection do I have on the track I’m working? Is this type of track protection appropriate for the work I’m doing? Will I foul the track with personnel? With machinery? If using a lookout, what is the sight distance? Is it sufficient? • Will other machines or people be involved? How? • What type of track protection do I have, if any, on adjacent tracks? How will I be warned when trains pass on adjacent tracks? Can I continue to work when trains are passing on adjacent tracks? • When clearing the track, where is my “place of safety”? • What are the track limits of my track protection? • What is the time limit, if any, of my track protection? Do I have the correct time now? • Do I understand everything and feel confident that I’m adequately protected against trains and on-track requirement? • Follows up as necessary to ensure compliance.

25. 3. Job Briefing • On any job that includes work equipment, make sure job briefing includes discussion of on-track safety, such as: • Reminder about the blind spots of the equipment. A good rule of thumb is that if the roadway worker cannot see the eyes of the operator, the operator cannot see him. • Discussion of the danger (red) zone around any equipment. • Roadway workers must not enter a machine’s red zone without first communicating with the operator.  • Conversely, an operator must not allow the machine to approach workers closer than e.g. 3 meters/10 feet without first communicating with them. • Review of the spacing requirements between machines and between the machine and workers. • Reminder of the signal used for reverse movement of equipment or any other special movement and the designated employee to give these signals to the operator. • Review of any factor, such as weather, visibility, or track condition, that might impact stopping capabilities of the work equipment. • Review whether track protection exists on adjacent tracks in situations where booms or arms can foul adjacent tracks. • Review of engine numbers of scheduled trains passing through or by Working Limits.

26. 4. Communication • You must not use communications equipment if it may cause a distraction or affect safety. • Make sure you are in a position of safety before using mobile communications equipment. • Before beginning work, the method of communication between each operator and other roadway workers must be established. • Whether radios or hand signals are used depends on work site circumstances, but communications must be clear. • Employees involved in the movement of rail equipment must follow AM Standard on mobile phones (AM ST 301).

27. 5. Maintenance and equipment inspections L2Q6 • Are all the lines, points, level-crossings, signalling and rolling stock listed? Is there a planning for regular inspections and maintenance on lines, points, ballasts, level-crossings, signalling and rolling stock? Is the planning followed? Are the results of those inspections formalized? Recommendations and good examples ! • Rail equipment including track, switches and trestles must be maintained in a safe condition. • Identify inspections steps and develop inspection process for the following: • identify and apply the steps to be taken in inspecting the equipment • develop and implement a plan for equipment inspection appropriate for the equipment being used

28. 5. Maintenance and equipment inspections; L2Q6 • Derailments can be caused by poor housekeeping, weather conditions, poor track maintenance, worn train car wheels, damaged switch, going too fast or careless train operation. Pay attention to winter/extreme conditions, when maintenance task on switches (and other critical parts) should be increased

29. 5. Maintenance and equipment inspections; L3Q1 • Level 3 – Question 1 Are all the legally required periodical verifications identified? Are they performed by trained and authorized people? Are the results of those controlsformalized?2. Does the plant know and understand the ArcelorMittal standard for Rail Safety and distributed the information to the personnel concerned? Recommendations and good examples ! • There must be a program of regular legally required- and other inspection and preventive maintenance to ensure equipment is in good working order, in order o ensure that people and assets are properly preserved. Legal requirements should be taken into account (despite there may not apply to internal traffic) and could be a good reference to establish the Maintenance plans • Authorized persons conducting audits, observations, being trained, or trouble shooting for maintenance may be permitted to ride on the equipment after receiving permission from the competent operator. No unauthorized person is allowed to ride on cars or locomotives.

30. Maintenance Tasks on Rail Equipment • People acreditation & PPE´s • Maintenance Tasks on the general purpose railway • Maintenance Tasks in the Workshop • Wedging • Workshop track protection • Lifting equipment • Working in pits • Maintenance Plans • Maintenance Derailment & Re Railing • Derailments • Re-railing

31. 1. People Acreditation & PPE´s AM Standard Rail Safety 004 • They must be trained and competent • They must know and follow Standard Operation – AM Safety 004 – Rail Safety • They must use approved protection equipment for the respective job

32. 1. People Acreditation & PPE´sPersonal Protective Equipment; L1Q13 • The used PPE may vary and must be the outcome of a HIRA. • Approved protection equipment must be used for the respective jobs. • Requirements are e.g.; • Safety boots (high ankle boots where necessary!) • Safety glasses • Hard hat / helmet • High visibility clothing’s • Gloves • Hearing protection • The means of communication

33. 2. Maintenance Tasks on the general purpose railway • When any maintenance task is needed on equipment, the priority should be to have this task done in the workshop, due to the fact that this environment is better known by workers, all tools and needed equipments are in the same area • Nevertheless, when it is not possible (e.g. due to a major breakdown), maintenance task must be done on the railway out of the workshop. In this case, the same conditions as railway maintenance tasks apply: • Job briefing • Track protection. • Wedging of both maintained & near equipment

34. 3. Maintenance Tasks in Workshops • Maintenance works in the vehicles workshop are affected by many others risks, being the ones with the AM Standards the most dangerous: • Confined spaces (Golden Rule 4) • Lifting equipment (Golden Rule 5) • Isolation (Golden Rule 3) • Working at height (Golden Rule 2) • Hot work (cutting and welding) • People performing maintenance in the workshop, must be then trained and competent on all these topics. • Service tracks who enter a workshop will depend on the responsibility of the department others external service tracks fall under the responsibility of the railway service. • Entering / Exiting workshop; • Crews pulling or setting cars in and out of a building must come to a stop before entering. • A crew member must enter the workshop ahead of the train to see that track is clear of obstructions and personnel in or near cars are warned of the trains approach.

35. 3.1 Wedging in Workshops • May there be any equipment (locomotive, wagon, or any other rolling stock) inside the protected area, do not forget to wedge it properly • Locomotives • Wagons • Mounted axes

36. 3.2 Workshops Track Protection • Changes driving to workshops must be isolated according to internal instructions, in order to avoid other vehicles to enter the maintenance tasks zone without notice. • Isolation must be performed by people in-charge of the workshop.

37. 3.3 Lifting equipment • Slings, chains, hooks, lifting devices, and every other device hanging/suporting a load are to be considered under this Standard (AMS 007) and Golden Rule (Number 5) • Lifting equipment should be in good condition, and checked: • before each use • Monthly, keeping a register • yearly by a specialized service (internal or external)

38. 3.4 Working in pits • Maintenance pits should meet legal requirements (current voltage, lights, number of exits, air renewal, etc) • In some cases, it can even be considered as a confined space! • Pits must also have a protection agains falling from heights, by means of railings, life lines, coverings etc.

39. 4. Maintenance Plans • AM Standard Rail Safety 004 • There must be a procedure for inspections to establish that equipment is in good working order before operating. This inspection must encompass all equipment highlighted in a risk assessment.

40. 5.1 Maintenance - derailment • There are several main causes of derailment: broken or misaligned rails, excessive speed, faults in the train and its wheels, and collisions with obstructions on the track. Derailment can also occur as a secondary effect in the aftermath of a collision between two or more trains. Trap points protect main lines from runaway vehicles by deliberately derailing them to bring them to a stop. Flangeless wheels make it easier for a locomotive to negotiate curves, but make them more prone to derailment. Rerailing a train after it has derailed is not an easy task, and often requires the use of large rail-mounted cranes. • Rail breakages • Rail breaks at rail joints • Manufacturing defects in rail • Wheel burn-related rail breaks • Wheelflat-related rail breaks • Cold weather-related rail breaks • Cold weather and switch points • Misaligned railroad tracks • Excessive speed derailments • Slow speed derailments • Uneven loading • Train "stringlining" on sharp reverse curves • Poor train handling • Rolling stock design • Obstacles • Housekeeping

41. 5.2 Maintenance – re-railing • Re-railing Is the process used to place wagons or engines back on the tracks and repair damage from the incident. Since engines and wagons are quite heavy, up to 300 tons, even a slight derailment can be difficult to rectify. Serious derailments where the cars are completely removed from the normal track alignment will likely incur track damage, and vehicles may have to be removed by rail mounted cranes. Contracting companies specializing in derailment recovery exists some countries, and railroads often rely on external contractors for disaster recovery. • If rolling stock rolls down an embankment as a result of a derailment, a locomotive and cable can sometimes be used to haul those vehicles back to the top again. • Special precautions must be taken to avoid overhead power lines, utilities and underground lines and gas pipes • Special precautions must be taken when using jacks, cranes complete with lifting plans and HIRA