Appendix II

QHSE - Checklist: Warehouses for BCS Products – Extension Quart de Poblet

Requirements Results

1. Site and Infrastructure

Site
 no residential areas, hospitals, schools in the immediate neighbourhood
 surfaced road to the warehouse site
 2 different routes of access for emergency services
 no undesirable influences/actions from the neighbourhood
 no danger of flooding by surface or storm water
 no danger of landslide
Infrastructure
 local fire brigade, familiar with the site (incl. products), appropriately equipped,
desirable reaction time < 15 minutes.
 Reliable water supply
Site Security
 controlled access during and outside working hours
 control of incoming and outgoing goods and vehicles
 24 h security guard system
 locking procedure, registered key holders
 communication line to the police and the fire brigade
 substantial external walls, fence (2.5 m high),
 external lighting
 intruder alarm if necessary, additional measures in particular for types of goods
(high value, very toxic)
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2. Separation of the warehouse form other activities
Fire-resistant separation or 10 m safety distance of the warehouse compartment
from:
 manufacturing, formulation, filling, packaging
 shrink-wrapping with quarantine area
 workshop, forklift-maintenance
 administration
Open handling of chemicals within the warehouse area:
 only for cleaning up leaks
 sampling in separate designated areas with appropriate equipment only
Battery charging in well ventilated zone
 in separate room with sufficient ventilation or
 in areas with permanent and sufficient roof ventilation and minimum distance of
5 m to any combustible material
Outside floor areas along front of warehouse:
 Not used to deposit goods, empty pallets, packaging or other combustible
materials to such an extent that in case of an “outside fire” access to the
warehouse would be difficult or that the outside fire could spread to the inside.
 Safety distance to next building still observed.

3. Construction
Construction and materials
 non combustible construction materials
 supporting structure at least 30 minutes fire resistant
 warehouse subdivided into fire compartments by fire resistant walls (90 minutes
resistance, wall 1 m above roof) and doors (90-minute resistance) with
automatic closure, load-bearing steel protected by insulation
 ductworks passing fire walls to have (automatic) fire dampers fitted
 smoke and heat vents (operated from outside) about 2% of floor surface or roof
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 covering that will fail in the event of fire or as approved by the responsible fire
brigade
 maximum allowable load of racks to be posted
 racks to be protected from damage by FLT and vehicles
Size of fire compartments :
 Table 1 limits to be checked
 floor areas should be subdivided where flammable liquids are stored
Floors
 smooth, impervious to liquids, sealed joints
 no drains which open to sewer
 roof drains inside building protected from mechanical and thermal damage
Installation, storage concept,
 preferable: pallet racks fitted with sprinklers , sufficient and reliable water supply
 blocks 2 pallets wide, 3 p high (or according to the specific packaging
specification) 8 p long, 2 double rows with corridor of 0,8 m in-between, then
normal passageway suitable for forklift truck, 0,8 m inspection gap along the
wall
 block rows clearly marked and numbered
Aisles and Passageways
 floor markings for storage zones and passage ways
 aisles for pedestrians at least 0.80 m wide
 passageways for trucks and pedestrians: 1 m wider than widest vehicle
Retention :
 retention for liquids in case of leakage or shipping damage and for fire
water contaminated with chemicals to avoid environmental consequences

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Escape routes
 at least 2 emergency exits per room (to be opened in the escape direction)
 maximum escape distance 50 m
 exits properly marked, illuminated or luminescent
 Should not be locked at all times
 Access to all emergency exits and safety related equipment must be
unobstructed at all times

Ventilation
 effective natural ventilation (roof and wall vents)
 forced ventilation to be monitored and air exchange rate to be measured
verified regularly
 0,4 air changes p.h. and flammable liquids: explosion hazard 1,5 m from bottom
 2 air changes p.h. to prevent no explosive atmosphere (flam. liquids storage)
Heating
 no direct heating
 avoid heating the products above the ambient temperature, keep at least 0,5 m
distance between the heating devices and the stored goods
 safety barriers to be provided for surface temperatures > 70°C, to avoid direct
skin or goods contact

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4. Electrical installations
Electrical installations
 have to meet the requirements of local electrical codes
 have to be protected against water spray (IP5/ IP6 ) in sprinklered rooms
 installation has to be checked regularly by a qualified electrician
 explosion proof installation necessary where legally required or for flammable
gas storage, or for flammable liquids (1,5 m above floor) stored at temperature
near flash
 where explosion proof installation is required, forklift trucks and other vehicles
must also meet these requirements
 lights must not heat up stored goods , minimum distance 1 m

Lightning protection:
 in line with local standards and codes,
 annually inspected by a qualified company
Electrostatics for areas with explosion hazards :
 floors < 108 
 racks earthed

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5. Product segregation and separation
Product segregation
 no foodstuffs, animal feed or other material (consumer products) such as
clothing, cosmetics, etc.
 spontaneously combustible substances, substances that are igniting or self-
heating in contact with air
 flammable gas, aerosol cans , unless adequately fire-protected
 flammable liquids (flash point < 55°C) in significant quantities, unless
adequately fire-protected
 substances developing flammable, corrosive or toxic gases, or reacting violently
in contact with water
 oxidising substances
 quarantine products for 24 h (substances just ground, dried, still “thermally
active”), goods shrink-wrapped by means of flame-heated equipment
 substantial quantities of readily combustible packaging materials (e.g. paper)
 where legally required, toxic / very toxic non-combustible products to be
separated from combustible products
 incompatible products ( products that when storage together may result in
undue hazards in the case of fire, leakage and spill
Segregation of products should be achieved so that:
 dangerous interactions (reactions, packaging damage in case of leakage)
cannot occur
 same or compatible extinguishing media can be used
 safety / emergency measures are appropriate for the category with the highest
risk

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6. Organisation, Management System
Permits
Building and environmental permits or notifications as required by local laws have
to be available, permit restrictions to be followed
Responsibilities:
Designated and documented responsibilities for warehouse operation, receipt and
dispatch of goods, emergencies
Training:
Staff adequately trained concerning: product hazards, SOPs, emergencies, use of
fire extinguisher, first aid, forklift trucks
Documentation
to be accessible at any time at a safe location outside the warehouse:
 emergency contact numbers: fire brigade, police, warehouse management,
medical service
 layout of the warehouse, type of products and maximum quantities in each fire
compartment
 full detailed inventory (not older than 1 week), quantity and location of goods
 material safety data sheets of all products
 emergency instructions for coping with spills, fire, and for personal protection
Operating Procedures :
 SOP: Regular operation, materials stored, dealing with spills and damaged
packages, PPE specification
 Stock control system (obsolete stocks)
 Hot work permit system
 Prohibition of smoking in the warehouse
 Arrangements and plans for inspection and maintenance of devices with safety
functions.

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Emergency management:
 adsorbent material and sewer protection to be available
 emergency plan in place for spillage, intruders, injuries, fire and regular training
provided
 information provided to public emergency services on contents of warehouse,
available equipment, availability of competent personnel
 action plans to warn and protect neighbours
 communication line to Bayer CropScience
 regular (annual) emergency drills
Housekeeping
 Clean floors and racks, no product spillage
 Passage ways and emergency exits kept clear
Labelling
 All stored goods are appropriately labelled , according to national requirements
(hazard symbols, dangerous goods or transport codes)
 Goods stored in appropriate compartment

7. Hygiene and personal safety

 PPE for regular operations, at least work clothes and appropriate gloves to be
worn
 additional PPE for dealing with spills to be available
 first aid kits must be provided
 trained first aiders must be always available
 amenities should be in good condition
 FLT drivers to be trained and authorised

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8. Fire detection
 push button/telephone to alert nearest fire brigade and permanent surveillance
as a minimum request
 automatic fire detection (smoke detection) is generally recommended
 fire detection without an automatic extinguishing system requires immediate
alert and short reaction time (< 15 minutes) of a fire brigade
 automatic transmission of alarm on activation of an automatic extinguishing
system to a permanently manned place.
9. Fire fighting
 at least 3 persons trained in handling leaks and fighting fires, re-training at least
yearly
 1-2 12 kg powder or water based fire extinguishers per 100 m², placed next to
the exits
 2 powder extinguishers of 50 or 100 kg available for bigger (1000-2000 m²) fire
compartments with 5 tonnes of solvents or more
 6 kg CO2 fire extinguisher for switch rooms
 every point within the range of hose lines from 2 sides
 larger warehouses should be equipped with pallet racks fitted with sprinklers,
one sprinkler level per two rack rows
 block storage: efficient sprinkler1 – 2 m above the block , blocks maximum two
pallets high
 foam extinguishing system (addition of foam concentrate to extinguishing water)
for flammable liquids storage
 deluge systems for manual operation only where site/works fire brigade is
available
 gas detectors, floor foaming, aspiration, where indicated (particularly for highly
flammable goods, aerosols)
 Installation of special extinguishing systems (e.g. with nitrogen or Inergen ®) to
be approved by IOP GF and QHSE.

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Water requirements for fire fighting
 Smaller (100m²) warehouses: 0,8 m³/min, for 1 hour
 Warehouses from 500 m² on: 2-3 m3/min; for at least 90 min, for 8-10 hose 1)
lines, 150 –200 mm water supply pipe, 3 bar at hose connection point
 Sprinklers: 3-6 m3/ min for up to 90 minutes;
 Objects with appropriate sprinkler protection: total quantity up to 700 m3.
 2 pumps system (electric and diesel), regularly (at least weekly) checked and
regularly (at least annually) maintained by a qualified mechanic
 reservoir water level to be checked (at least weekly)
Retention of fire fighting water
 storage zones, marshalling/receiving/dispatching areas included in retention
volume
 no drains to public sewer system or surface waters
 retention volume availability to be checked regularly
 contaminated rainwater is collected
 retention capacity for fire fighting water according to Table 2.

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