UC RUSAL Sustainability report 2016



The unchanged priority of UC RUSAL is the work safety of its employees, industrial and fire safety of production processes and operations. G4-EMS, HKEx Appendix 27 KPI В2

In accordance with the ethical principles and UC RUSAL standards in health, industrial and fire safety, every employee of the Company, from specialists to supervisor, must:

       be aware of personal responsibility for his/her life and health, and for the life and health of others;

       know the risks accompanying his/her activities;

       by personal example encourage the safe conduct of his/her colleagues and contractors.

The work of UC RUSAL in the area of work safety is carried out in accordance with the laws of the country of operation, as well as corporate regulations and procedures, which stipulate the requirements for safe working conditions and for the reduction of occupational diseases and injuries.

In the Russian Federation, UC RUSAL focuses primarily on the following work safety instruments:

       Labour Code of the Russian Federation;

       Federal Law No 116-FZ On industrial safety of hazardous production sites dated July 21, 1997;

       Federal Law No 426-FZ On special assessment of working conditions dated December 28, 2013;

       federal rules and regulations in the area of industrial safety;

       Industry tariff agreement for the mining metallurgical complex of the Russian Federation for 2014-2016.

In 2016, 241 audits were carried out at the Company's production facilities by the supervisory authorities. The results of the audits confirm compliance with the requirements of the legislation in the areas of health, industrial and fire safety and sanitary and epidemiological welfare.

UC RUSAL continuously monitors changes in HSE legislation. In order for UC RUSAL professionals to meet the new professional standards of HSE specialist, the relevant training is planned for 2016-2017.

The Company is also actively involved in the assessment of the regulatory impact of draft regulations, the holding of round tables and meetings on HSE issues and the preparation of necessary amendments.

Since 2014, the activity in the area HSE at the production facilities of the Company is defined by UC RUSAL Policy Statement in the area of health, industrial and fire safety, taking into account the changed requirements of the Russian law in this area. The document had not been amended in 2016.

In the reporting year, a number of new documents was adopted in the area of HSE management, including an internal order On the organization of audits of management systems for compliance with international standards ISO 9001, ISO/TS 16949, ISO 14001, OHSAS 18001 and FSSC 22000 in 2016.

In the context of compliance with HSE requirements, the Company is guided by the following purposes and principles.


       The life and health of a human being are more important than production output or economic performance;

       Full integration of the health and safety management system into the overall business management and production activities;

       All accidents are preventable;

       Compliance with law is a necessary and required condition of UC RUSAL business;

       Competency and responsibility of the employees is the foundation for safe work;

       Safe behaviour of employees must be encouraged and promoted;

       Mutually beneficial relations with suppliers and contractors;

       Monitoring and measuring performance indicators in the area of occupational health, industrial and fire safety.


       To strive to eliminate injuries and risk of emergency situations and fire;

       To ensure compliance of equipment and production processes with legal and regulatory requirements of occupational health, industrial and fire safety;

       To ensure personnel safety and health in the workplace and improve workplace environment on an ongoing basis in order to increase the level of safety;

       To prevent the development of occupational diseases.

Training HKEx Appendix 27 KPI В3

Training in HSE is provided for all employees, and a set of industrial safety briefings is also carried out on a mandatory basis (induction, primary, repeated, target and unscheduled). Those employees who operate, service and control hazardous production facilities undergo compulsory HSE training. Periodic knowledge checks are conducted to verify staff qualification: once a year, on occupational health, every three years, on industrial safety.

Mentoring is used at the Company's production facilities to allow workers to develop and acquire the necessary skills. The newly employed worker is assigned to an experienced professional, who not only controls his/her actions in the HSE area, but also helps the worker develop a culture of safe conduct.

In the framework of training of future line managers, including on HSE issues, UC RUSAL has implemented the Talent Pool project.

The Company continues to operate a distance learning system containing 12 training courses and programmes in the HSE area.

UC RUSAL Corporate University has developed a computerised environmental education programme that takes into account the peculiarities of operation of various business units and production facilities of the Company. The training program is divided into four modules. The trainees are acquainted with environmental law, with the factors of aluminium production influencing environment and with the factors influencing climate change. Special attention is paid to the ways of reducing of the environmental impact of industrial facilities and public relations. As a result of the training, four self-checks and the final exam must be completed. The managers and professionals are trained in the workplace; workers are trained in computer classes of the production facilities.

Training is also available in the classroom form: the workers of the Middle Timan bauxite mine completed the course of Environmental education in UC RUSAL.

Training and knowledge check in the area of HSE are carried out in strict compliance with the legislation of the countries of operation the Company's production facilities. The relevant requirements are also regulated by the internal documents of UC RUSAL production facilities.

Special safety programmes

As part of the training aimed at raising the awareness of occupational safety in the workplace, UC RUSAL implements various topic-based programmes. They aim both at the improvement of the culture of compliance with HSE rules and the addressing of specific risks.

The project to improve the quality of training of crane operators at the Sayanogorsk aluminium smelter

In order to improve the quality of the training of crane operators and to reduce the risk of accidents during loading and unloading operations, the project to improve the quality of the training of crane operators has been developed and implemented. As part of the implementation of the project, there were assigned production training foremen who completed a special programme on 'Trainings, mentoring', 'Safety in the operation of the lifting mechanisms', 'Accident and injury experience at the lifting mechanisms'. Two simulators of special pot tending cranes have been installed to provide practical skills in isolation from the actual production of the production facility.

The project was successfully continued in the reporting year: there were no incidents in the operation of the lifting machinery (4 incidents in 2015).

The project of safety in the use of loading machines

In order to reduce the risk of injury in the performance of the works with the use of loading machines, NGZ has developed a project of safety in the use of loading machines. The project included a questionnaire for the employees to evaluate working conditions through queries and developed a number of proactive measures. According to the first results, the project promotes the improvement of the conditions and safety of work at the production facility, the prevention of injuries and health of workers, and the preservation of the main production assets. As a result of the measures undertaken, the risks of dangerous situations with loading machines are minimised. In 2016, there were no injuries or accidents in the use of the loading machines.

At the Bratsk and Krasnoyarsk aluminium smelters specialised sites were created that fully imitate the potroom of the smelter, where the operators of intrashop floor equipment develop their professional skills.

Within the framework of the Safe Potroom project, a new reflective floor marking has been applied in the potrooms No 5-6 of the Krasnoyarsk aluminium smelter. New reflective elements have also been added to the loading equipment and to the helmets of the workers. Reflective floor lines have already proved their efficacy on the Khakass aluminium smelter.

'Prevention of Falls' and 'Safe Mine' projects at the Severouralsky bauxite mine

As a large share of all injuries occur in the production of raw materials and in the production of alumina, as well as in work at high altitude, the Company undertakes special measures to reduce the level of industrial injuries caused by movement and work at heights.

In particular, the ongoing project 'Prevention of Falls' provides for the identification of causes and dangerous factors causing falls in the movement in mine openings, identification of potential hazards that may lead to a fall, survey of movement in horizontal, vertical and incline working and training of employees with the analysis of specific injuries. The 'Prevention of Falls' project has reduced the risk of injury by 10%.

The 'Safe Mine' project provides for the training in risk assessment for managers and professionals, identification and determination of risk values across all work areas and their evaluation, development and implementation of the activities for risk minimisation and reduction of occupational diseases, and development of practical measures to reduce manual labour at the mine. The effectiveness of the project was demonstrated by the reduction of the risk of injury by 25% compared to 2015.

“Business Unit Safety Passport” project at the Volgograd aluminium smelter

In 2014, the production facility started implementation of a long-term project of “Business Unit Safety Passport”. The project aims at a comprehensive assessment of the work of the business unit in the area of HSE, using a number of objective indicators. Each of them is assigned a numerical score that allows determining the overall level of safety of the business unit.

Activities in the framework of this project allow to rectify the number of violations of the employee in the area of occupational health during his/her work at the production facility, to determine the contribution of the individual employee in the HSE area, to evaluate the work of a particular business unit, the level of security at the level of directorates. The goal of the project is achieved: the injury rate at the production facility in 2015 dropped to zero, and in 2016 there were no industrial injuries.

The project of 'Safety of Third Parties on Guinean Railways' at the Compagnie des Bauxites de Kindia

An analysis of the injuries of third parties on the sections of the railway of UC RUSAL production facilities in Guinea revealed the key problem – unauthorised access to railways upon the passing of trains and the use of roads by the local population as transient traffic flows. In order to reduce the risk of injury, since 2007 the Company has been building awareness, undertaking measures to organise crossings and protect the railways, working with the national police. The implementation of this project has resulted in an orderly reduction in the level of injuries on the railway. Its importance has increased with the conclusion in 2015 of a multilateral agreement involving UC RUSAL on the use of the existing railway infrastructure in the province of Boke in the framework of the Dian-Dian investment project and plans to resume the work of the Friguia complex in 2017.

The facilities of the Compagnie des Bauxites de Kindia also recorded numerous road traffic accidents due to the fatigue of truck drivers; now the drivers do not go on a trip without the Antison device.

The bauxite alumina complex of Windalco (Jamaica) is implementing an educational project to prevent personnel hand injuries. In addition to the sessions and trainings, injury-risk equipment is replaced, in particular level handles of locking accessories are replaced with hand wheels.

Collective bargain agreements

The Company has a collective bargain agreement with the employees of most production facilities, which establishes in a separate section health and safety (labour protection) issues, which allows improving the HSE management system. The content of collective bargain agreements is subject to mandatory approval by trade unions.

Through their representatives in trade unions, workers are also involved in the solution of work safety issues. Each production facility has a representative from the trade union organisations in charge with HSE, which participates in the relevant activities. On a parity basis with the representatives of the administration, they are part of the HSE committees (commissions). G4-LA5, G4-LA8

Emergency situations

The Company continues to undertake active actions for the prevention, response and mitigation of emergencies.

UC RUSAL is aware of the risk of emergencies. The Company has a well-functioning alert and information system about emergencies, assesses the risk of an emergency, prepares action plans to prevent emergencies, and develops plans for emergency recovery. The Company has a Regulation on notification of the leadership about emergencies and supports high readiness of employees and technical means for rescue works. Some production facilities of the Company operate their own fire and rescue business units staffed with trained personnel and equipped with appropriate equipment. In other cases, contracts are concluded with public and private entities to provide emergency response and fire safety services.

Production facilities also prepare for emergency response, especially in the fire hazardous spring period. The specialists verify the readiness of the fire extinguishing equipment as well as the operation of automatic fire fighting and signalling equipment and conduct fire drills. Training in countering terrorism acts involves the personnel and rescue services of the production facility, staff of security providers and security agencies. In total, 64 joint exercises were carried out at the Company's production facilities in conjunction with the EMERCOM units in 2015.

In order to prevent the occurrence of the emergency, hazardous situations are monitored at the Company's production facilities. Monthly reports of identified situations, indicating the dynamics of the effectiveness of corrective actions, are being prepared.