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002

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Global Technical Specifications
GENERAL SPECIFICATION Version: 1.0

Date: 11/10/2018
3B – CIVIL SAFETY REQUIREMENTS

DOCUMENT CONTENT

1.0 OBJECTIVE........................................................................................................................................... ..2

2.0 INTRODUCTION .................................................................................................................................... 2
3.0 DEFINITIONS ......................................................................................................................................... 2
4.0 BUILDING SAFETY ................................................................................................................................. 2
4.1 OCCUPANCY.......................................................................................................................................... 2
4.2 REQUIREMENTS FOR WALKWAYS ....................................................................................................... 3
4.3 LIGHTING .............................................................................................................................................. 3
4.4 WORKING PLATFORMS ......................................................................................................................... 3
4.5 EMERGENCY ROADS ............................................................................................................................. 4
5.0 OUTSIDE AREAS REQUIREMENTS ......................................................................................................... 5
5.1 SAFETY SIGNALIZATION CIVIL SCOPE.................................................................................................... 5
6.0 CRITICAL AREAS .................................................................................................................................... 5
6.1 HAZARDOUS CHEMICALS STORAGE .................................................................................................... 5
6.2 BOILER ROOMS CIVIL ELEMENTS.......................................................................................................... 6
6.2.1 GENERAL REQUIREMENTS (BOILER) ..................................................................................................... 6
6.2.2 ACCESS (BOILER) ................................................................................................................................... 6
6.2.3 EQUIPMENT GUARDING AND PROTECTION(BOILER) ........................................................................... 7
6.2.4 ADDITIONAL REQUIREMENTS (BOILER)................................................................................................ 7
6.3 AMMONIA ROOMS CIVIL ELEMENTS .................................................................................................. 7
6.3.1 GENERAL REQUIREMENTS (AMMONIA) ............................................................................................... 7
6.3.2 ACCESS (AMMONIA) ............................................................................................................................. 7
6.3.3 EQUIPMENT GUARDING AND PROTECTION (AMMONIA) .................................................................... 8
6.3.4 ADDITIONAL REQUIREMENTS (AMMONIA).......................................................................................... 8
6.4 GENERATOR ROOMS ............................................................................................................................ 8
6.5 COLD ROOMS ....................................................................................................................................... 9
6.6 CELLAR AREAS ....................................................................................................................................... 9
6.7 LIQUID OXYGEN BULK STORAGE ......................................................................................................... 9
6.7.1 LOCATION (LIQUID OXYGEN) ............................................................................................................... 9
6.7.2 ACCESS (LIQUID OXYGEN) .................................................................................................................... 9
6.7.3 CONTAINMENT (LIQUID OXYGEN) ....................................................................................................... 9
6.7.4 EQUIPMENT PROTECTION & IDENTIFICATION ................................................................................. ..10
6.8 LABORATORIES ................................................................................................................................. ..10
7.0 ROOF REQUIREMENTS ..................................................................................................................... ..11
8.0 FIRE SAFETY REQUIREMENTS ........................................................................................................... ..11
9.0 GENERAL SAFETY REQUIREMENTS ................................................................................................... ..11
10.0 HISTORY & REVISIONS ...................................................................................................................... ..14
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1 OBJECTIVE
This document describes the minimum technical safety requirements for construction of buildings and
related constructions as an addition to other existing GTS documents. If there are more stringent local
legal requirements, they must be applied.
2 INTRODUCTION
Every civil construction in any ABI facility must follow all guidelines of this specification in order to
provide the safest possible condition for workers during all phases including but not limited to; design,
installation, operation, tests and start-up phases of all CaPex projects.
3 DEFINITIONS
Exit - That portion of an exit route that is generally separated from other areas to provide a protected
way of travel to the exit discharge.
Emergency Exit- Exit in a structure is a special exit for emergencies such as a fire the combined use
of regular and special exits allows for faster evacuation while it also provides an alternative if the route
to the regular exit is blocked by fire etc. It is usually a strategically located outward opening door with a
crash bar on it and with exit signs leading to it
Exit discharge - The part of the exit route that leads directly outside or to a street, walkway, refuge
area, public way, or open space with access to the outside.
Exit route - A continuous and unobstructed path of exit travel from any point within a workplace to a
place of safety (including refuge areas). An exit route consists of three parts: The exit access; the exit;
and, the exit discharge. (An exit route includes all vertical and horizontal areas along the route.)
Occupant load - The total number of persons that may occupy a workplace or portion of a workplace
at any one time.
Accessibility - refers to the accommodation of physically challenged people in structures
Traffic route - a route for pedestrian traffic, vehicles or both and includes any stairs, staircase, fixed
ladder, doorway, gateway, loading bay or ramp;
Class 3 Material – Materials that react explosively with water without requiring heat or confinement
High Voltage – see Local legislation. If no legislation exists: high voltage: > 1000 V. (usually 13kv)
Low voltage - see Local legislation. If no legislation exists: low voltage: < 1000 V. (usually 110 / 220 /
380 / 400 V)
MEC – Minimum explosion concentration
4 BUILDING SAFETY
The building safety section of this document is designed to establish the minimum technical
requirements that must be observed in all ABI buildings to ensure the construction of the safest possible
work environment.
During the design phase of any building the ZBS Safety must be involved in the final approval of the
architectural version of the building along with ABI support group (GRC) Global Risk Consultant to
ensure all major safety requirements are covered such as railing systems, access to critical areas for
cleaning, maintaining and operating the place. For this process the ABI Safety engineer responsible for
the validation shall perform the evaluation based upon local building codes to ensure the basic
requirements are in place before the project starts.
4.1 Occupancy
Every building or structure on an ABI facility designed to be permanently occupied needs to have a
certificate of occupancy issued by the local authorities (fire department and/or other local authorities
responsible for validating the building occupancy through a formal process before being permanently
occupied)
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Note: Exceptions need to be reviewed with ZBS in cases where this is not a legal requirement in the
country, state or city where the building or structure is being built.
4.2 Requirements for building walkways
In areas where machinery and equipment is installed, circulation areas must be properly marked to
indicate pathways to pedestrians away from machines.
The main pedestrian traffic routes in the work places and those leading to the exits must be at least
(1.2m / 48in) wide. Specific requirements for emergency exits are covered on (GTS.CIV.GEN.GSP -
General Specification, Building: Fire Safety)
A safety minimum distance between machines must ensure safety of workers during operation,
maintenance, adjustment, cleaning and inspection respecting a minimum distance between them of
(0.8m / 2.6ft).
Walkways must be clearly marked by means of two yellow solid lines on both sides.

4.3 Lighting
The design, installation and required light levels must comply with the requirements of
(GTS.CIV.GEN.GSP.003 - 3B General Specification, Building: Electrical)
Where possible natural light is preferable.
Lighting fixtures must be easily accessible for maintenance via a mobile platform. If not possible a
system must be in place to lower the fixture to ground level.

For lighting in hazardous area see – (GTS.CIV.GEN.GSP.003 – 3B Building Electrical)

4.4 Working Platforms
All elevated from the ground level fixed working platforms, permanently attached to the building
structure or to equipment need to be protected with guardrail system in all sides.
The working platforms must be designed and installed in compliance with the requirements presented
in the (GTS.CIV.STR.GSP.003 - 3B General Specification, Structural - Miscellaneous Metals,
Handrails, Stairs and Platforms)
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• Elevated working platform must be designed with the accessing stairs system parallel to the
platform in order to eliminate the risk of the worker falling into the stairs while working on it.

• All handrails installed in the facility must be identified at least in one side of the rail with the
information of mandatory to use the handrail while walking up or downstairs.

• The first and last step of every fixed stairs and/or staircases leading into an equipment or building
in the production areas must be clearly marked in a different color from the stairs background, it is
recommended to use zebra striping painting yellow and black to achieve the contrast.
• Stair nosing shall be installed to ensure anti-slippery conditions in all stairs.

• If the worker can be exposed to the risk of falling from a platform, mezzanine or an elevated area
leading into a ladder / stairs a self-closing gate must be installed. Chains are not allowed.

• Mezzanines or platforms for storage of goods marked with signs informing the maximum load
capacity allowable.

• Equipped with a movable pivoting railing system which allows the pallet to be stored without
exposing the worker to the open gap.
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4.5 Emergency Roads

The roads to be constructed around the facility shall be designed to be accessed by heavy emergency
vehicles.
• Be at least (6m/20ft) wide
• Support emergency vehicles with at least (25tons/55K lbs)
• High clearance (4.5m/15ft)

5 OUTSIDE AREA REQUIREMENTS

5.1 Safety Signalization in the scope of civil.
• Roads must be marked with traffic signalization in accordance to the local traffic requirements.
• Signs need to be based of pictograms defined on the local traffic laws, respecting size and color.
• The signs must be in the official language of where the project is located.
• Any additional safety signage required by ABI can be found in the (GTS.GSS.SFT.GSP.009 – 3B
Safety Logistics)

• In addition to workplace transport safety signs, all entrance of departments must be marked with
the hazards present in each area and the required personal protective equipment which must be
used upon entering the area.
6 CRITICAL AREAS
Special consideration must be given to all the specific critical areas covered by this section.
In addition to the requirements in this document, all relevant national and local regulations and
applicable industry standards shall be followed for the items presented in this section 6.
6.1 Hazardous chemicals storage
All Storage, dispensing, handling and use of solid, liquid and gaseous hazardous materials shall be
designed based on the result of a detailed Risk Analyses to be performed at the design phase with the
direct assistance and approval of the Zone ES team upon defining the substances to be stored in each
area.
The Risk Analyses must include but not be limited to:
• Compatibility of products and materials such as chemical reactivity hazards.
• Food grade requirements, flammability and also pumps, pipes, joints, sewers.
• Define required ventilation and exhaustion systems for the storage area.
• Type of secondary containment for the area
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• Access control and signalization of the storage area.

• Hazardous storage buildings, areas and rooms shall also be designed and built in accordance to
the requirements on (GTS.CIV.SCH.DSH.001 – Buildings: Room and Finish schedule.)
• Fire safety requirements: In some cases are required to be protected by an approved automatic
sprinkler system. Comply with (GTS.CIV.GEN.GSP - General Specification, Building: Fire Safety)
Un-loading points
• The bulk Un-loading points for hazardous substances must be lockable while not in use.
• The connecting point must be protected against impact from vehicles with physical barriers.
• The connecting points must be labelled to avoid any accidental mixing of chemicals.

• The unloading points to be constructed rigid, with supporting frames to protect integrity of the pipes.
• Wheel chucks shall be installed in the area to prevent the truck from moving during unloading.
6.2 Boiler rooms civil elements
6.2.1 General requirements
The boiler rooms shall be designed and constructed under the supervision and validation of an ABI
utilities specialist. (GRC) Global Risk Consulting shall always be used for guidance in the design of
these areas.
The installation of boiler and construction of the rooms and components for steam, warm and hot water
boiler systems shall comply with relevant national, local regulations and applicable industry standards.
• Boiler rooms must always be built on ground floor level, never below or above ground level.
• Clear intakes and exhaust vents must available in the building.
• The aeration openings should ideally be located at the back of the boiler. If this is not possible, for
structural reasons, deflector plates or metal ducts must be installed within the boiler installation
room to divert the intake air.
• Fresh air intake must be directly from outdoors.
• When planning the aeration openings, the position of system components that are sensitive to frost
(e.g. water treatment systems) must be taken into account.
• Chimney or gas vent must terminate a minimum of 2' above parapet walls.
• Ducted combustion air supply must have a fire damper or have fire proof covering to outdoors.
6.2.2 Access
• Two exit access doorways are required in boiler and furnace rooms where the area is over (500ft2
/ 46 m2) and any fuel-fired equipment exceeds (400,000 British thermal units-Btu / 422.000KJ) input
capacity.
• Where two exit access doorways are required, one is permitted to be a fixed ladder.
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• The design of the Boiler room and the placement of the equipment must have:

gangways of minimum (0.8m / 2.6ft) width,

equipment (valves, gauges,…) easily accessible

emergency evacuation routing clearly marked

emergency lighting

• Boilers rooms must be physically separated from Ammonia systems.

6.2.3 Equipment guarding and protection
• Guarding/ fencing around the Steam boiler equipment with limited number of access doors (but
reckoning with safe emergency evacuation and safe access for maintenance and inspection).
• The Boiler room and all the Steam equipment (such as condensers and piping on roofs and fuel
supply and storage) need to be equipped with adequate lightning protection.
6.2.4 Additional Requirements
All fire related requirements are available in the (GTS.CIV.GEN.GSP - General Specification, Building:
Fire Safety).
All specific Safety requirements related to the Boiler System other than civil engineering aspects are
available in the (GTS.GEN.SFT.GSP.008 – 3B Safety Utilities)
6.3 Ammonia rooms civil elements
6.3.1 General requirements
The Ammonia rooms shall be designed and constructed under the supervision and validation of an ABI
utilities specialist. (GRC) Global Risk Consulting shall always be used for guidance in the design of
these areas.
• Ammonia rooms must always be built on ground floor level, never below or above ground level.
• Provided with spill containment so that a spillage of liquid ammonia cannot spread beyond the room.
• Rooms shall be designed in such a way that all parts of the equipment in the room are easily
accessible for service, maintenance, and operation.
6.3.2 Access
• Machinery rooms larger than (1,000ft2 / 93m2) shall have at least two exits or exit access doorways.
Where two exit access doorways are required, one is permitted to be served by a fixed ladder.
• All portions of machinery rooms shall be within (150ft / 45m) of an exit or exit access doorway where
such rooms are not protected by an approved automatic sprinkler system.
• Doors shall swing in the direction of egress travel, regardless of the occupant load served.
• Install doors that open wide and tall enough to accommodate removing, replacing, or adding
equipment.
• Access to machinery room shall be limited to ensure good control of authorized personnel only.
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• The design of the Boiler room and the placement of the equipment must have:

gangways of minimum (0.8m / 2.6ft) width,

equipment (valves, gauges,…) easily accessible

emergency evacuation routing clearly marked

emergency lighting
• The discharge of the air shall be to the outdoors, exhaust from mechanical ventilation systems shall
be discharged not less than (20ft / 6m) from a property line or openings into buildings.
6.3.3 Equipment guarding and protection
• The machinery room and all the ammonia refrigeration equipment (such as condensers on roofs)
needs to be equipped with adequate lightning protection.
• Physical barriers protecting the refrigeration equipment shall be install (e.g., unloading points, pipes,
valves, evaporator coils, tanks, vessels, etc.) everywhere it is likely to be damaged by a driving by
motorized vehicle or equipment.

6.3.4 Additional Requirements

• For fire related requirements see (GTS.CIV.GEN.GSP - General Specification, Building: Fire
Safety).
• For specific ventilation and civil engineering aspects see (GTS.CIV.GEN.GSP.002 General
Specification, Building: HVAC Systems)
• For required signalization in the room see (GTS.GEN.SFT.GSP.008 – 3B Safety Utilities)
6.4 Generator rooms
• Walls, floors and ceilings of rooms containing emergency generators must resist to one hour of fire.
• The only openings allowed are for the purposes of access, ventilation of combustion gases.
• Doors must have fire resistance of at least 1 hour. They must close automatically.
• Combustion gases must be evacuated directly towards the exterior by means of pipes lined with
fire-resistant material offering at least one hour's protection,
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• If the oil tank is located in the same room as the emergency generator, it must have double walls
to ensure that it is leak-proof.
• The fuel infeed pipeline shall be located outside the wall and infeed valve must be lockable.
6.5 Cold rooms
• Refrigerated storage rooms where fork trucks are to be used for storing pallets the walls shall be
protected with metal plates.

• The doors of the refrigerated storage rooms shall be equipped with a device to ensure the possibility
to open the door from inside

.
6.6 Cellar area
Measures to reduce or eliminate CO2 accumulation in the Cellar areas shall be in place either through
natural or forced ventilation.
In Outdoor tank cellars (tank cone areas) natural ventilation can be achieved by screening section
“louvers” installed on the higher part of the wall allowing air exchange with the external area through
the screened panels.

6.7 Liquid Oxygen Bulk Storage

6.7.1 Location
• The oxygen system shall be located above ground level.
The location selected shall be:
• (15m / 50ft) away from any electric power lines, flammable or combustible liquid lines, or flammable
gas lines and combustible structures
• (7.5m / 25ft) from congested areas such as offices, lunchrooms, locker rooms, time clock areas,
and similar locations where people congregate.
6.7.2 Access
• The system shall be readily accessible to mobile supply equipment at ground level.
• Access must allow control to authorized personnel only
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6.7.3 Containment

• Oxygen stored as liquid, need to be in contained non-combustible surfacing. For purposes of this
paragraph, asphaltic or bituminous paving is considered to be combustible.
• The containment to have drains equipped with lockable valve.
6.7.4 Equipment protection and identification
• The installation should be clearly marked – WARNING – Liquid Oxygen, authorized personnel only.
• If installed outside a chain link fence enclosure and physical barrier to be provided for protection.
• The area around it (7m/25ft) in all directions should be posted “No Smoking” / “No Storage” area.

6.8 Laboratories
• Office area shall be built separated from analytical area within the laboratories.
• The sink for washing lab glass shall have a faucet with a minimum of (30cm/12in) high pipe to
prevent breaking glasses in the edge of the sink countertop.

Countertops
All work surfaces, bench tops, counters shall be:
• Impervious to the chemicals.
• Designed To be easily cleaned.
• Made of a seamless one-piece to prevent contamination.
• Penetrations for electrical, plumbing, etc. to be completely and permanently sealed.
• If the bench top abuts a wall, it needs to be covered or have a backsplash against the wall.
Exhaust hoods:
• Combined general and fume hood exhaust systems are preferred where their application can
provide reduced cost and energy use without compromising safety or system integrity.
• Use 316 stainless steel duct material except for general exhaust branch upstream of combined duct
• Use pressure independent air terminal units for balancing as needed
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• Located at least 3 feet from obstructions such as large equipment or columns

• At least 4 feet from adjacent doorways and main traffic aisles
• At least 5 feet between fume hoods that face each other
• Locate controls for hood utilities outside the hood

• Hood lighting and other fixed electrical equipment within the hood shall be explosion proof.
7 ROOF REQUIREMENTS
For any new roof see (GTS.CIV.GEN.GSP.007- General Specification, Building Envelope, Metal Siding
and Roofing).
Any low roof or canopy built less than (4m/13ft) high can be revised by the Global team and an exception
granted to eliminate the necessity of a railing system be installed around the roof if the design and civil
group consider it necessary. Any exception will need to be formalized and the alternative method of fall
protection defined during the approval implemented as an alternative (Ex: Life line installation)
Note: All new roof construction shall have the anchorage points for installations of safety nets designed
to become permanently part of the roof and left in place as part of the structure for future use.
8 FIRE SAFETY REQUIREMENTS
See - (GTS.CIV.GEN.GSP - General Specification, Building: Fire Safety).
9 GENERAL SAFETY REQUIREMENTS
Floors
• The dry floor concept must be followed in all areas, every drain in and out of production areas must
attend the requirements presented in the (GTS.CIV.GEN.GSP.001 - Process Drains)
• Any floor conditions that create an additional risk of slips and trips the area must be identified by
painting preferable yellow to make it visible for pedestrians.

• Every location where necessary uneven floors / gaps are created, the potential drops on the sides
such as slopes, access ramps, docks and other similar situation need to be physically guarder to
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prevent any exposure to the vehicles to this uneven obstacles, these areas need to be equipped
with bars to guide the wheel to prevent the equipment / vehicle from falling into it.
Pipelines
• Pipes, conduits equipment parts running above head at a height lower than (2.2m 7fts) shall be
clearly marked.
• Caution signs and soft edge protection area recommended to be installed in these areas.
• Pipe beds used to accommodate hot liquids or steam lines subject to pipe hammer effects need to
be supported considering the flexibility without dropping down.

Lifting Devices
• Every known area for having operation or maintenance reasons to lift parts of equipment to be
provided with a lifting equipment structure composed of a lifting beam and hoist device.
• Technical documentation must be delivered with the equipment signed by Engineer responsible.
• The lifting beam need to be painted yellow and clearly identified with load capacity.
• The entire system need to be designed matching the weight it is intended to be used

Hose Stations
• Any type of hose required to be available in the production area need to be installed with the
auxiliary of a retracting system to ensure the hoses are stored

Eyewash Stations
General requirements
• The travel distance from potential exposure sites to the showers to be approximately (15m / 50ft)
• The pathway to the shower station need to be free from obstructions.
• Locating showers in the hallway has the advantage of serving multiple areas as long as the
requirements of traveling distance are met.
• Avoid installing telephones, thermostats, or power receptacles within six feet of the shower.
Locations
• Located near each central storage of hazardous substances
• Near each bulk unloading area of liquid hazardous substances
• Near each major lab
• Near CIP installations, crate washers and bottle washers
• Near main battery loading stations
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• Near unloading points, pipelines and storage tanks of LPG stations, bulk hazardous chemicals such
as ammonia, caustic, CO2, Freon, ethanol, fuel.
Construction requirements
• These stations shall be constructed as follow:
• Permanently connected to a continual source of potable water
• Self-contain its own flushing fluid
• Easily accessible, area free from obstructions
• Preferably located in the most obvious escape route.
• Protected against frost when located outside (where applicable).
• The lever of the valve on the water supply piping to the emergency shower must be lockable.
• Flow rate equal to 20 gallons per minute (GPM) for a min of 15 min at 30lb/in2 - PSI
• The valves must activate in one second or less, stay-open and remains on until shut it off.
• Physical barriers, barricades shall be installed in all areas where the risk of impact from any type of
motorized vehicle.

Segregation of production areas outside Logistics.

• In Production area any pedestrian doors shall be built separately from vehicle access doors never
use common entrance for both.
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• The door designed to be used for vehicle access shall be protect with physical barriers on the sides
and top to prevent damages to the structure of the entrance.

Gas Cylinder
• A compressed gas storage area(s) meeting the requirements of applicable codes and standards for
fire separation, ventilation, restraint and separation of incompatibles shall be provided preferably in
an appropriate outdoor location to provide sufficient back up supply and empty cylinder storage for
users. Separate space for full and empty cylinders.
• Storage areas shall be secured against unauthorized entry.
• Approved storage racks shall be provided that adequately secure gas cylinders by chains, metal
straps, or other approved materials, to prevent cylinders from falling or being knocked over.
• Chains are preferable to straps. Straps shall be non-combustible.
• Gas-cylinder securing systems shall be anchored to a permanent building member or fixture.
• All necessary signs must be available in the local language in the area.

10 HYSTORY OF REVISIONS
Revision Date Responsible Approval Comments
00 11/05/18 Rodrigo Pontello Peter Copermans Initial Release