Factory and Industrial Works RAMS Guide for UK Contractors

Key Topics in a Factory Works RAMS

Lockout/Tagout (LOTO) and energy isolation

Industrial plant operates at high energy levels — high-voltage electrical, pneumatic systems at 6–10 bar, hydraulic presses, steam systems, and gravity-loaded equipment. LOTO procedures require the complete isolation and physical lockout of every energy source before any intrusive work. The RAMS must identify every energy source associated with the work scope, the isolation method for each, confirmation that stored energy has been dissipated (capacitors discharged, pressure released, elevated loads lowered), and the multi-lock procedure where multiple contractors work on the same isolation. Factory LOTO procedures are typically set by the factory's Authorised Person system — contractors must use the factory's PTW and LOTO procedure, not their own.

ATEX zones and explosive atmospheres

Factories handling flammable liquids, dusts, or gases operate ATEX zoning under the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Zone 0/20 (continuous risk), Zone 1/21 (occasional risk), and Zone 2/22 (abnormal risk) have strict requirements for tools, equipment, and PPE — only ATEX-rated intrinsically safe or explosion-proof equipment may be used. The RAMS must confirm that the contractor has received the ATEX zone drawing for the site, that all tools and equipment used in ATEX zones are appropriately rated, that no ignition sources (including mobile phones) are introduced into Zone 0 or Zone 1, and that hot works within or adjacent to ATEX zones require a formal hot works permit from the factory's safety manager.

Interface with production-critical overhead cranes

Many factories operate overhead travelling cranes (OTCs) for process purposes — these cannot always be stopped for construction works without disrupting production. The RAMS must describe the interface between OTC operations and construction activity: exclusion zones under operating cranes, the process for requesting crane suspension when works require working in the crane's travel path or lift zone, load path management for OTC lifts over the construction area, and the communication procedure between the crane driver and construction operatives. Where the OTC cannot be suspended, a specific exclusion zone and overhead protection scheme must be designed before works proceed.

Process hazard identification

Industrial processes introduce hazards that are absent from standard construction environments: chemical releases, steam, high-temperature surfaces, radioactive level gauges, laser measurement systems, and high-voltage electrical bus bars. Before works commence, the factory must provide a site-specific hazard briefing covering the process hazards in and adjacent to the work area. The RAMS must reference this briefing, confirm that operatives have attended, and describe the specific controls for each identified process hazard. If the works require partial shutdown of a production line, the shutdown procedure must be agreed and controlled by the factory's own safety and production management.