MOVING THE INDUSTRY FORWARD 2006 CONTENTS PRESIDENT’S INTRODUCTION

I am pleased to introduce this report on the three award schemes run by the PAGE 3 President’s Introduction Federation for Health & Safety, Sustainability and Innovation. It shows that significant investment as well as continuing effort and imagination is being applied in the industry towards self-improvement. Cost pressures on us are intense at PAGE 5 Health & Safety Award Winner the present time, as are the impacts of legislation. Those reasons alone should be incentive enough to redouble our efforts in 2007. These awards stimulate competition and are helping to transform the industry into being safer, greener PAGE 6-7 Health & Safety Award: Joint Second Place and Highly Commended and more innovative. I urge members to continue to support all three schemes and our Concrete Targets 2010 scheme.

PAGE 8-14 Health & Safety Award: Runners Up David Szymanski President of The British PAGE 16 Sustainability Site Specific Award Winner Precast Concrete Federation

PAGE 17 Sustainability - Site Specific Award: 2nd and 3rd Place CHIEF EXECUTIVE’S COMMENT

PAGE 18 Sustainability - Site Specific Award: Highly Commended May I thank all those people who took the trouble to enter our awards schemes this year. I hope that this publication continues to have impact through the supply chain in demonstrating that this is a vibrant and positive industry looking to PAGE 19-23 Sustainability - Site Specific Award: Runners Up growth in market share and earnings through self-improvement. Participation in our awards schemes has a bottom-line payoff. I would urge all precast producers not yet in membership of British Precast to join and take advantage of what we PAGE 24 Sustainability - Corporate Award Winner have to offer.

PAGE 25 Sustainability - Corporate Award: 2nd and 3rd Place and Runner Up

Martin Clarke PAGE 27 Innovation Award Winner Chief Executive of The British Precast Concrete Federation

PAGE 28 Innovation Award: 2nd and 3rd Place

GUEST OF HONOUR PAGE 29-32 Innovation Award: Runners Up The 2006 Best Practice Awards were presented by eminent guest speaker Professor Peter Robery of Halcrow. Peter is the current President of the Concrete Society. PAGE 33 Concrete Targets 2005 We are grateful for his support this year.

PAGE 34 CT2010

PAGE 35 The Awards Night Pictures

Professor Peter Robery

2 3 HEALTH & SAFETY AWARD SPONSORS HEALTH & SAFETY AWARD Sponsored by Cement UK www.lafargecement.co.uk

Collecting the prize on behalf of Stoneflair is Paul Saunders. Presented by Peter Robery (L) and Charles Law – Lafarge Cement UK (R)

This year’s Health & Safety award focused on reducing the impact of noise and vibration on the working environment

WINNER

Company - StoneFlair Result Site Newark The developments have completely eradicated the use of Title – Noise and Vibration, who needs it? vibration tools at the re-built section of the machine with a noise reduction of 27dB. Manual handling improvements and Task a resultant productivity improvement of 50% through that Through an essential plant re-siting taking place at the end of section have all been additional benefits. 2005 the opportunity to produce StoneFlair’s edging range of Contact Details products presented itself at the Newark site. Paul Sanders, Problem Aggregate Industries - StoneFlair, On commissioning of the plant, risk assessment identified Roseland Business Park, that methods used to manufacture the edging range involved Hangar 8, Normanton Airfield, excessive use of impact tools, creating unacceptable noise Long Bennington, Newark, levels. Nottingham, NG23 5FF Solution Tel: 08706 009 111 Through brainstorming sessions, safety meetings and the Fax: 08706 009 112 involvement of site production and engineering departments, [email protected] ideas evolved to change the mould design and production methods. The company technical department was called in to put the ideas into practice.

4 5 HEALTH & SAFETY AWARD Sponsored by Lafarge Cement UK www.lafargecement.co.uk

JOINT 2ND PLACE HIGHLY COMMENDED

Company Marshalls Company Acheson & Glover the cabin, the operator was able to control Site Sandy Site Fivemiletown the crusher in a better environment. Title – The Application of Self Compacting Concrete to Eliminate Vibration Title - Reducing Noise and Vibration of Result and Noise in Bollard Production Primary Aggregate Crusher The results were as follows: casual absence was eliminated, productivity Task Task increased, cost savings were made, and Filling bollard moulds mounted on a vibration table. The operator controls The project was identified as improving health and general working environment the concrete flow and supports the reinforcement frame. the environmental working conditions in improved significantly for the operator. Problem relation to the control and operation of Contact Details The operator is subjected to high noise levels emitted by the bollard the primary crusher. vibration table. It is also necessary for the operator to handle the vibrating Problem Lee Weir, Acheson & Glover, mould and reinforcement frame during filling. Occupational hazards in the form of noise, 127 Crievehill Road, Fivemiletown, Solution vibration, dust, poor ventilation, lighting County Tyrone, BT75 0SY and isolation. Develop the application of using self compacting concrete (SCC) for Tel: 02879 633 027 bollard filling using the existing equipment. SCC does not require vibration, Solution Fax: 02879 633 597 therefore removing both noise and vibration health risks. Collecting the prize on behalf of Marshalls is The primary issues were due to the Howard Smith [email protected] Result crusher operators’ location. By relocating Complete elimination of vibration and noise from this operation with minimal implementation cost and no capital expenditure. In addition an HIGHLY COMMENDED improvement in production times and no increase in materials costs. Contact Details Company Aggregate Industries noise. - Bradstone John Galubickas, Result Site Baston Fen Marshalls, 64 Sunderland Rd, Sandy, A reduction of 15dB was achieved within Bedfordshire, SG19 1C9 Title - Noise and Vibration the factory, while vibration at the fill Tel: 01332 794 023 Task points has been reduced as has the impact Fax: 01332 794 050 of excessive exposure to vibration on the [email protected] Reduce the impact of noise and vibration operatives. within the factory environment Contact Details Problem JOINT 2ND PLACE Allen Jolley, Vibration within this environment is an Aggregate Industries - Bradstone, Company Building Products essential part of the process. Minimisation Manor Farm Works, Baston Fen, Site Hoveringham of the adverse effects was the only option Peterborough, PE6 9PT available. Title – Noise and Vibration Tel: 01778 560 372 Task Solution Fax: 01778 560 694 [email protected] Manufacturing precast concrete stairs and landings in various Purchase new equipment and re-work old configurations. machinery to help dilute the impact of Problem The concrete requires compaction by vibrating pokers and fixed HIGHLY COMMENDED vibrating units. Operators were exposed to high noise levels. Hand/arm Company Marshalls The works management team developed the and whole body vibration exposure levels were also problematical. Site Ramsbottom new layout of the building considering social, economic and environmental impacts. Solution Title – Noise and Vibration Working in partnership with their concrete additives supplier, self Result Task compacting concrete was developed to manufacture stairs and landings Noise and vibration have been engineered Over 40 years old, the design of the old plant in the department. out. Production capability has increased by and additional capacity shoe horned in over Collecting the prize on behalf of Hanson Building 120%. HAVS exposure has been eliminated. Result the years did not lend itself to delivering the Products is Neil Orr The cost per tonne to manufacture has been required goals. The introduction of self compacting concrete has eliminated exposure reduced by 6%. to noise and vibratory hazards. Problem Contact Details The batching plant, mixer platform and Contact Details Sean Butler, production machinery were all in one Clive Richardson, Marshalls, Fletcher Bank Works, building. To compound the noise and house Hanson Building Products, Hoveringham Lane, Ramsbottom, Bury, Lancashire, BL0 0DD keeping problem, each area was located Hoveringham, Nottingham, NG14 7JX Tel: 01706 282 723 vertically on top of one another. Tel: 01636 832 000 Fax: 01706 282 726 Fax: 01636 832 020 Solution [email protected] [email protected] Because of its age and limited capacity, it 6 was agreed to replace the plant in 2005. 7 HEALTH & SAFETY AWARD Sponsored by Lafarge Cement UK www.lafargecement.co.uk

RUNNER UP RUNNER UP

Company Aggregate Industries - Bradstone Solution Company Aggregate Industries - Fyfestone Solution Site Hulland Ward Site A As automation was being planned, a new design Site Kemnay The solution included removing high energy waste, Title – Noise and Vibration of hopper was introduced to eliminate the need Title – Duplex Mould water, dust and noise creating equipment and to use jiggers. extending the existing building. The solution also Task Task Result included creating maximum natural light and a To keep wet concrete hopper dispensers clear of To reduce energy, material usage and noise recycling system. set concrete. The net result of the new hopper was to reduce pollution. To ergonomically design the factory. the time spent cleaning. Time using a pneumatic Result Problem Problem tool was reduced by 75% to less than 30 minutes. Energy, waste, dust and noise are reduced by Contact Details Contact Details Small hand jiggers were used to remove all The problems were high energy usage and eliminating the secondary block making process. the excess concrete which had set. The noise Chris Jennings, material wastage combined with noise, vibration, All trip hazards were removed, water channels Donald Keenan, generated produced an uncomfortable working Aggregate Industries - Bradstone, environmental concerns, dust control and unsafe were created to remove water for recycling and a Aggregate Industries - Fyfestone, Smith Hall Lane, Hulland Ward, Aquithie Road, Kemnay, environment and was identified as a potential and poor working conditions. welfare facility was created. Ashbourne, Derbyshire, DE6 3ET Aberdeenshire, AB51 5PD hazard in terms of HAVS. Tel: 01335 372 222 Tel: 01467 651 036 Fax: 01335 372 048 Fax: 01467 642 342 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Aggregate Industries - Bradstone Solution Company Aggregate Industries - Charcon Solution Site Hulland Ward Site C The solution was to clamp the pans to a vibrating Site Barton-under-Needwood Install an acoustic enclosure to the slat conveyor Title – Noise and Vibration table by the use of electromagnets. These in turn Title – Noise Reduction on the Rumbler Line and stacking table area leaving sufficient open had to be securely fastened to the vibrating table space for the operatives to work. Install lighting Task Task so the pan/table/magnet acted as one. and CCTV and make the top panels of the To reduce the noise associated with the vibration To reduce noise and dust exposure in the rumbler. Result enclosure easily removable to facilitate product tables on the auto line at Hulland Ward. Problem change overs. With the unit acting as one this removed the noise Problem associated with the pan vibrating. Noise levels Reduce the noise and dust exposure without Result Contact Details Contact Details Improved reliability of the vibrating tables were reduced to less than 85dB with a potential to compromising the work station area, restricting Noise levels reduced significantly, although increased the noise levels during the production go lower, and with the benefit of improved energy Chris Jennings, visibility of the plant and product and without hearing protection is still required to be worn. Pat Dempsey, process. The aim was to reduce the noise levels to efficiency. Aggregate Industries - Bradstone, introducing excessive product change over times. Productivity has not been adversely affected. Aggregate Industries - Charcon, a reasonable level. Smith Hall Lane, Hulland Ward, Lichfield Road, Barton-Under-Needwood, Ashbourne, Derbyshire, DE6 3ET Staffordshire, DE13 8EG Tel: 01335 372 222 Tel: 01283 714 481 Fax: 01335 372 048 Fax: 01283 714 480 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Aggregate Industries - Bradstone Solution Company Aggregate Industries - Charcon Solution Site Cleveland Farm The existing hand held method of compaction Site Middleton A major investment in new buildings, equipment Title - HAVS in the Cast Stone Industry needed to be engineered out of the task. Title – Noise Reduction at Middleton Factory and methods of production, all designed to reduce noise, either directly through covering up or Task Result Task changing equipment or indirectly through finding a Job rotation is used to reduce exposure, training The task was to reduce exposure to operatives Although the Charcon factory had been operating way to remove unnecessary vehicle movements. from hand-held vibrating hammers during the is given on the best grip/pressure when using the at Middleton for a number of years, the community Result compaction of the mix into the moulds. jig, gantries reduce the need to hold the tool and around it had changed, and Charcon needed to there is a reduction in vibration exposure from No complaints about noise levels have been Problem Contact Details respond to this. Contact Details 12m/s2 to 6m/s2. received from the local community since the Problem To assess how high the vibration levels were, to Rick Trinder, improvements have been put into place. Charcon Tony Elliot, find out how long the equipment should be used Aggregate Industries - Bradstone, Noise levels at the plant had become unacceptable, believe they have made a significant investment Aggregate Industries - Charcon, Cast Stone Dept. Cleveland Farm Works, Porter Lane, Middleton-By-Wirksworth, for, how awkward is it to use the equipment, it and needed to be reduced. in managing a transition to become a “good Fridays Ham Lane, Ashton Keynes, Derbyshire, DE4 4LS, has to be gripped, and how cold the operators got Swindon, SN6 6QP neighbour.” Tel: 01629 823 476 when using it. Tel: 01285 646 871 Fax: 01629 825 755 Fax: 01285 646 899 [email protected] [email protected]

8 9 HEALTH & SAFETY AWARD Sponsored by Lafarge Cement UK www.lafargecement.co.uk

RUNNER UP RUNNER UP

Company Aggregate Industries - Masterblock Solution Company Brett Landscaping and Problem Site North End Works Advance Environmental, an independent Building Products Vibrating tables have been taken out of use Title – Containment of Noise on Site company, were employed to carry out a noise level Site Barrow Upon Soar because of practicalities, and the existing poker monitoring assessment during the night. gave off excessive levels of vibration. Task Title - Reduction in Exposure to Vibration from Result Wacker Vibrating Pokers Solution To ensure compliance with environmental legislation regarding noise emissions. It was found that the vibrator on an outside Task After trials with gloves which were all aggregate hopper was the problem. Production unsatisfactory, Brett looked at alternative pokers Problem To reduce the level of hand/arm vibration exposure planning was changed to negate use of vibrators to operatives when removing excess air from with the help of the Wacker representative. North Wilts District Council Environmental Office Contact Details Contact Details at night. The vibrator was not used between 1700- concrete in bespoke moulds. Result registered a noise complaint. 0800 hours and a time clock was fitted to ensure Dave Warriner, Robert Godfrey, A significant reduction in vibration exposure and this. A letter received from the North Wiltshire Aggregate Industries - Masterblock, Brett Landscaping and Building Products, North End Works, Ashton Keynes, a poker that an operator could use all day without Sileby Road, Barrow upon Soar, District Council Environmental Office confirms Wiltshire, SN6 6QX exceeding safe levels of exposure. Nr Loughborough, Leicestershire, LE12 8LX. resolution. Tel: 01285 646 800 Tel: 01509 817 180 Fax: 01285 646 897 Fax: 01509 817 197 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Aggregate Industries - Bradstone Solution Company CEMEX Rail Products Solution Site North End Works To carry out assessments on hand held vibration Site Washwood Heath Self Compacting Concrete (SCC) was developed and implemented which met client specification Title – Noise and Vibration (power tools) and fixed vibration (tables used to Title – Noise and Vibration Reduction manufacture concrete products) to establish the for precast concrete sleepers. Task Task most efficient equipment to reduce vibration. Result To control vibration through hand held vibration The production facility has 8 gang moulds and 8 Result The introduction of SCC to the production process and fixed vibration tools within the factory pokers mounted onto a travelling casting bucket/ reduced the noise levels by approximately 20dB environment and to reduce wherever possible By using equipment with lowest typical weighted machine. 2 as a result of the removal of vibrating equipment vibration from machinery or experienced by acceleration value (m/s ) along with job rotation, Contact Details Problem from the machine. Contact Details individuals using the equipment. and aided by personal protective equipment, the severity of vibration exposure to users of Ray Winter, It was a noisy casting process and hand-held Phil Tromans, Problem the equipment has been reduced. This in turn Aggregate Industries - Bradstone, vibrating pokers were also used, which caused CEMEX Rail Products, North End Works, Ashton Keynes, Aston Church Road, Saltley, Vibration within the production facilities and the reduces the risk of HAVS to users of power tools noise and vibration issues. Wiltshire, SN6 6QX Birmingham, B8 1QF maintenance department creates a daily problem or vibrating tables. Tel: 01285 646 915 Tel: 01213 270 844 depending on what tools are required for use. Fax: 01285 646 855 Fax: 01213 277 545 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Brett Landscaping and creating peaks of noise. They are located close to Company Forticrete Solution Building Products the machines and the operators. Site Buxton A specific cross-functional improvement team was Site Barrow Upon Soar Solution Title – Besser Noise Reduction set up to investigate noise reduction. Following a Title - Noise Reduction on Hydraulic Presses After trials to ensure there was no loss of efficiency thorough survey, an action plan was raised and Task Task and suction, the drainage pipes were extended subsequently introduced. Key developments through the back walls of the unit and the Nu-Vac To reduce noise and vibration levels in and around included; replacing the main drive gears and To reduce the recorded noise levels of 93dB that vents mounted outside. the ‘Besser’ block manufacturing area. replacing existing steel guides with polyethylene machine operators are exposed to on a daily Result Problem guides. basis. Contact Details Contact Details A significant reduction in the recorded levels of Following the fitting of an acoustic enclosure, Result Problem Robert Godfrey, Mike Aspinall, noise within the unit was recorded. noise levels within the workstation remained A 50% reduction in noise levels and a noticeable Nu-Vacs were used to draw excess water off the Brett Landscaping and Building Products, Forticrete, unacceptably high, with the typical reading being reduction in through-floor vibration. pressed slabs and vent air through exhausts, Sileby Road, Barrow upon Soar, Hillhead Quarry, Harpur Hill, Nr Loughborough, Leicestershire, LE12 8LX. 92dB. Buxton, Derbyshire, SK17 9PS Tel: 01509 817 180 As part of the Forticrete ‘Raising the Bar in Health Tel: 01298 233 333 Fax: 01509 817 197 & Safety’ initiative, further noise reductions were Fax: 01298 230 000 [email protected] [email protected] felt necessary.

10 11 HEALTH & SAFETY AWARD Sponsored by Lafarge Cement UK www.lafargecement.co.uk

RUNNER UP RUNNER UP

Company Hanson Building Products Solution Company Marley Eternit noise emitted by the chains striking the pallets Site Derby Source and install air compressors and air- Site Burton on Trent was in the region of 110dB. Title – Noise and Vibration Reduction powered torque tools into the three manufacturing Title – Clanger Noise Reduction Solution departments. Task Task After calling in a specialist noise control company, Result the intention was to enclose the conveyor area Securing and removing fixing bolts to culvert The goal was to reduce noise output from the where the clanger unit was installed in an acoustic moulds using electric impact wrenches. Both the compressors and torque tools operate ‘clanger unit’ caused by the chains hitting silently eliminating noise from this part of the enclosure containing sound absorbing material. Problem aluminium pallet moulds. process. The torque tools operate with little or no Result The electric impact wrenches generate high levels Contact Details Problem Contact Details vibration, virtually eliminating the likelihood of By fitting the enclosure, emitted noise was reduced of noise and vibration that would increase the Clive Richardson, The root cause of the problem was a build-up of David Grew, hand / arm vibration syndrome. by 20dB. likelihood of noise-induced hearing loss and hand Hanson Building Products, material on the aluminium pallet moulds and the Marley Eternit, / arm vibration syndrome. Derby Works, Alfreton, Derby, need for it to be removed. Because the material Lichfield Road, Branston, Burton on Trent, Derbyshire, DE21 4BN Staffordshire, DE14 3HD build-up contained cement the heavy chains acted Tel: 01332 546 300 Tel: 01283 722 222 Fax: 01332 372 208 as hammers to dislodge any excess material. The Fax: 01283 722 242 [email protected] [email protected]

RUNNER UP RUNNER UP

Company H+H Celcon Solution Company Marley Eternit Solution Site Trial lagging of exposed steam blow-down Site Delamere The knife unit was connected to a high level Title – Noise and Vibration pipework with the possibility of extending it to all Title – Knife and Strim Unit Noise Reduction exhaust/silencer, while the strim unit was housed. exposed pipework. Task Task Result Result Filling and emptying autoclaves of product. High To reduce noise emissions from the pneumatic This project demonstrated the ability for a local pressure steam is then used to cure the product. Reduction of exposed hot pipework and noise knife unit and from the electrically driven strim project team using local knowledge and expertise levels by 8dB, resulting in all exposed pipe work to provide a low cost/high benefit solution to two Problem unit following a noise survey. being lagged by early 2007. It is not known at difficult problems. The total outlay of the two Contact Details Problem Contact Details Working in the danger area meant that employees present what the noise reduction will be when all improvements was only £570. would be exposed to levels of high noise and hot the work has been completed. Iain Gordon, The tile machine area was historically a noisy Philip Hill, pipework. H+H Celcon, location with noise levels >100dB, the project set Marley Eternit, Quatermaster Road, West Wiltshire Trading about reducing noise levels in this area. Station Road, Delamere, Estate, Westbury, Wiltshire, BA13 4JT Northwich, Cheshire, CW8 2JF Tel: 01373 823 871 Tel: 01606 884 801 Fax: 01373 827 631 Fax: 01606 884 829 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Marley Eternit Solution Company Marley Eternit Solution Site Beenham The team investigated alternative equipment and Site Glasgow The waste skips were lined with rubber and the Title – Replacement of Impact (Torque) Guns identified potential occupational health and safety Title – Noise Reduction turntable was fully enclosed to reduce noise. benefits. Task Task Result Result To reduce the vibration effect of pneumatic impact Following a workplace noise assessment it was The impact noise from throwing off the tiles was guns which are used primarily in the removal of The newly sourced tools reduced both vibration decided that noise levels at the reject tiles throw- reduced to 95dB and the noise generated by the wheel nuts on vehicles. and noise to 83dB, and tools were also lighter in off point were unacceptable. turntable was reduced to 100dB. weight. Problem Contact Details Problem Contact Details Brian Butcher, The existing guns were noisy (in excess of 95dB) Rejected tiles hitting the metal skip caused over Robert McEwan, Marley Eternit, Marley Eternit, and caused high vibration to the operators. Grange Lane, Bath Road, Beenham, 100dB of noise, while noise generated from a steel conveyor turntable, due to the impact of tile Kirkintilloch Road, Bishopbriggs, Reading, Berkshire Glasgow, G64 2PY moulds, peaked at 120dB (it is normally 95dB). Tel: 01189 715 555 Tel: 01417 614 050 Fax: 01189 715 599 Fax: 01417 614 013 [email protected] [email protected]

12 13 SUSTAINABILITY AWARDS SPONSORS

RUNNER UP

Company Marley Eternit Solution Site Sawston The solution was to have automatic cleaning in Title – Automatic Mixer Wash down System situ using high pressure water jets. Task Result Its implementation generated a 90% reduction To find out how to safely clean down the mixer at in the use of vibrating chisels which significantly the end of the shift reduced the risk of vibration-induced injuries. Problem The main issues were; confined space, use of Contact Details Nick Cardon, vibration tools, damage to mixer internals and Marley Eternit, noise being greater than 95dB. Dales Manor Business Park, Sawston, Cambridge, CB2 4TJ Tel: 01223 495 409 Fax: 01223 495 444 [email protected]

RUNNER UP

Company Topblock Solution Site Alfreton After an independent survey, a tool amnesty was Title – HAVS - Control held so that all hand-held power tools could be assessed and where necessary new tools were Task bought. Training was also offered and regular Following the company’s health screening program vibration measurements taken. it was identified that several individual employees Result were suffering from HAVS. Employees that could have been at risk were Problem Contact Details identified and control measures were put into Initial assessment of the site highlighted that there place to prevent any worsening of existing cases. Alan Thompson, were numerous hand-held tools producing varying It is hoped that these new measures will prevent Tarmac Topblock, Bluebell Close, Clover Nook Ind. Est. levels of vibration, with no means for measuring new cases from developing. Alfreton, Derbyshire, DE55 4RA the vibration levels and no maintenance scheme Tel: 01773 835 124 to ensure their efficiency. Fax: 01773 836 726 [email protected]

RUNNER UP

Company Tarmac Building Products and consistent plan for the management of their Site Company Wide condition or their continuing risk. Title – Employee Occupational Health Risk Solution Assessment and Action Plans All operatives were subject to an individual risk Task assessment based on any existing conditions and their working environment. They were then The company wanted, by the end of 2005, to given appropriate actions for controlling existing eliminate any new cases or progression of existing conditions and site-wide proceedings were cases of: Noise Induced Hearing Loss (NIHL), Hand identified to prevent any new cases being caused. Contact Details Arm Vibration Syndrome (HAVS), dermatitis and Result Graham Green, occupational lung disease. Tarmac Building Products, Problem The scheme is still in its early stages but it has SD Dept, Millfields Road , Ettingshall, already delivered many changes, including , WV8 6JP Instances of the above conditions were not fully replacement of high-vibration hand tools and the Tel: 01902 353 522 recorded across the company. Individuals were installation of sound proof enclosures. Fax: 01902 353 920 known to site managers but there was no clear [email protected]

14 15 SUSTAINABILITY SINGLE SITE AWARD Sponsored by The Concrete Centre www.concretecentre.com

SINGLE SITE 2ND PLACE

Company Marshalls Site Maltby Project - Biodiversity and Conservation The site formed a partnership with the local Wildlife Trust and over the last twelve months it has been working towards the new Wildlife Trust’s Biodiversity Benchmark. To get to this point the site has had to change the way in which it manages its Integrated Management System and incorporate biodiversity/ wildlife conservation into it. At present no other manufacturing business in Britain has gained accreditation. Having achieved this they are rolling the benchmark out to other sites enabling them to demonstrate that they can work alongside and help to protect wildlife. Collecting the prize on behalf of Marley Eternit are: Nick Mace Good biodiversity and environmental practices form part of the (2nd Left) and Phil Hill (3rd Left) Presented by Peter Robery Collecting the prize on behalf of Marshalls are the company’s social and economic responsibilities, as well as being Maltby Team (Far Left) and Andrew Minson – The Concrete Centre (R) paramount for long-term sustainability. Contact Details Ian Manley, Marshalls, Ruddle Mill Lane, Stainton, Rotherham, South Yorkshire, SE6 7RH Tel: 01709 810 013 Fax: 01709 817 779 [email protected] This year’s award scheme rewarded excellence in the sustainability field. The broad scope of sustainability covered environmental, social and economic issues. The category was again split into two sections - single-site and corporate entries. SINGLE SITE 3RD PLACE SINGLE SITE WINNER Company Marshalls Site Brookfoot Project – Waste Management Helping to Support the Local Benefits include: reduced risk of environmental Company Marley Eternit Community pollution, improved housekeeping, early identification of Site Delamere All waste generates a cost and in 2001 the site reviewed its environmental hazards, quick and effective responses to packaging waste streams to facilitate sustainability and improve Project – Competence Training and Awareness at incidents, positive environmental culture and improved the Environmental Management Systems. Delamere environmental performance with minimal capital spend. The site now runs a full packaging waste recycling scheme and Marley Eternit has actively developed the skills and As a result of the training package, employees have has reduced costs to landfill whilst simultaneously converting knowledge of its workforce to raise environmental significantly contributed to the continued reduction waste into profit. In 2001 the site generated around 1200 tonnes awareness. of environmental non-conformity during BSI audits, of packaging waste culminating in a landfill cost of around of internal performance and management system audits, £20,000 p.a. To stem this rising trend, a new employee initiative The comprehensive training package targets site- was launched resulting in a saving of 350 tonnes in the first year and reduced pollution incidents. specific practice, control measures and responsibilities. of the scheme and around 850 tonnes by 2003. At the end of Success of the training is assessed by an ‘End Test’ where Contact Details 2005 total waste packaging has reduced to a mere 40.5 tonnes equating to savings of over £19,000. Furthermore, they have Collecting the prize on behalf of Marshalls is trainees answer questions in relation to an environmental Nick Mace, generated a profit of £11,000 from sales of the waste and have Richard Marshall booklet. A pass mark of 80% provides the benchmark Marley Eternit, channelled these returns into projects to help the community. for competency. A computer-based training programme, Lichfield Road, Branston, Burton upon Trent, Contact Details TESS, is used to provide a more detailed insight into the Staffordshire, DE14 3HD Andrew Ambler, impacts of industry upon the environment. Tel: 01283 722 512 Marshalls, This project describes how the culture of employees has Fax: 01283 722 242 Brookfoot Works, Southowram, improved the overall environmental performance of the [email protected] Halifax, West Yorkshire, HX3 9SY site as a result of increased competency. Tel: 01422 434 152 Fax: 01422 434 160 [email protected] 16 17 SUSTAINABILITY AWARD Sponsored by The Concrete Centre www.concretecentre.com

HIGHLY COMMENDED RUNNER UP

Company Hanson Building Products to the blow down water to elevate Company Aggregate Industries- Bradstone incoming water which introduces oxygen. the temperature from ambient to Site Purfleet - Thermalite Site Hulland Ward The uses a number of toughened, 80oC. When called for, water is now load bearing plastic cells which are wrapped Project – Boiler House Efficiency pumped to the 8 tonne tank at 80oC, Project – Water Harvesting product range in a water-tight membrane. These units are and is then heated to 90oC by the During October 2005 a fundamental The system allows collection, storage and easily clipped together to form both the boiler. Savings in fuel were seen by review was undertaken of the boiler re-use of rainwater that would otherwise rain tank and the base of a garden patio or using blow over to heat 8 tonnes of house operations of the Purfleet have gone to waste. Rainwater is collected driveway, and replaces the granular stone water by 10oC rather than heating 30 Contact Details plant. in the holding tank beneath the patio, lawn base in a traditional application. tonnes by around 45oC. The follow up or drive. Leaves and other debris are first Pat Hastings, The main aspect of the project was survey shows a current cost saving in filtered through a geotextile membrane and Aggregate Industries - Bradstone, concerned with energy savings and Smith Hall Lane, Hulland Ward, excess of £40,000 p.a. is now being the water is drawn off via a hand or electric better steam utilisation, once the Ashbourne, Derbyshire DE6 3ET achieved. pump. Odours are kept at bay by the action of data was gathered from the existing Tel: 01335 3722 278 Hanson is now in a position to Fax: 01335 372 048 system. purge the autoclaves and has seen [email protected] A contract company was employed to a significant increase in product re-survey the system and assess the strengths. thermal performance, then quantify and validate energy and utility savings Contact Details RUNNER UP based on measured performance of Adrian Wilson, the system. Hanson Building Products, Company Aggregate Industries - Bradstone supplier costs 50.1p per cubic metre. Use of Motherwell Way, West Thurrock, abstraction, collection and recycling cuts this The decision was made to redirect Site Hulland Ward pipe work to an 8 tonne tank in the Essex, RM20 3LB consumption by approximately 82%. boiler house roof and connect it to Tel: 01708 682 235 Project – Water Use Reduction Since January 2002, abstraction, collection the boilers. The tank was connected Fax: 01708 682 256 Hulland Ward site is deeply committed to and recycling activities have saved the [email protected] the recycling and conservation of water not company over £245,000. The amount of only for today but for the future, to deliver water saved would fill almost 200 Olympic continuous improvement, sustainability and sized swimming pools. Contact Details ISO 14001 standards. Phil Montgomery, Aggregate Industries - Bradstone, The financial benefits to the company are Smith Hall Lane, Hulland Ward, HIGHLY COMMENDED substantial as fresh water from the local Ashbourne, Derbyshire DE6 3ET Tel: 01335 372 222 Company Marshalls case the customer being stakeholders, Fax: 01335 372 070 shareholders, Local Authorities and Site Hambrook [email protected] the local community. It was decided Project – Sustainability Through that the site would need to develop Benchmarking an effective environmental plan to protect the future, making prudent For a number of years the site has RUNNER UP use of natural resources whilst at maintained and improved an effective the same time maintaining stable Company Aggregate Industries- Charcon the packaging waste costs. and robust Integrated Management economic growth and employment. A costing exercise was carried out and it System which meets the current Site Leighton Buzzard was calculated that the packaging waste was needs of the business. This year the Contact Details Project – Minimisation of Packaging Waste site has introduced benchmarking in costing the site approximately £980 for the Steve Hambury, Approximately 2,800 reels of banding tape conjunction with the British Standards boxes and corner protection per year and Marshalls, are consumed each year to maintain the Institute. a further £1200 per year to have the waste Hambrook Works, Broad Road, block paving pack integrity during transit. cardboard removed from site – total cost During the assessment Hambrook Hambrook, Nr. Chichester, Each reel of banding was contained within £2180. By removing this excess packaging Contact Details achieved a BSI Gold Award. West Sussex, PO18 8RG a cardboard box, strapped using polyester from suppliers the site were able to reduce Ian Sherratt, As part of the exercise it was Tel: 01243 578 106 banding, supported on cardboard interleaving materials going into landfill and made a cost Aggregate Industries - Charcon, Grovebury Road, Leighton Buzzard, recognised that they had to listen to Fax: 01234 578117 and corner protection, and then wrapped in saving. [email protected] Bedfordshire, LU7 4RU “the voice of the customer,” in this stretch-wrapping. It was hoped to minimise Tel: 01525 382 576 Fax: 01525 383 070 [email protected]

18 19 SUSTAINABILITY AWARD Sponsored by The Concrete Centre www.concretecentre.com

RUNNER UP RUNNER UP

Company Bison Concrete Products Environment and sustainability are fully Company Hanson Building Products using concrete cutting jetting equipment and embraced by the workforce and are agenda - Thermalite installing more efficient water pumps. Site Swadlincote items on the works council. Employees Site Hams Hall Carrying out this work allowed savings of Project – Recycling at Swadlincote are actively involved in recycling many 20.6 % of total annual usage, which equates Swadlincote factory is the first carousel things including; wood, cardboard, cans, ink Project - Recycling of Condensate Water to a cost saving of £30,918. This recovers flooring plant in the world. The recycling cartridges, wire etc. They also represent The project’s objective was to minimise the 610m3 of water each week from the steam system was conceived as an integral part requests from the local community and as a use of mains water by recycling condensate system. result Bison have just provided materials for Contact Details Contact Details of the production process from the earliest water produced from the factory’s steam By using the heat energy from the condensate stages of development and is Bison’s first a local rambling path. Dawn Edwards, autoclaves. Tim Sugden, Bison Concrete Products, to pre-heat this mixing water, 437 tonnes of attempt at fully integrating recycling in the Hanson Building Products - Thermalite, Millennium Court, The project involved the installation of new steam are saved, at a cost saving of £5,252. Hams Hall Distribution Park, Canton Lane, production process. The lessons learnt can be First Avenue, Centrum 100, pipework and cleansing of existing pipework Coleshill, Birmingham, B46 1AQ applied to traditional plants in the future. Burton Upon Trent, Derbyshire, DE14 2WR Tel: 01675 468 000 Tel: 01283 495 000 Fax: 01675 468 010 Fax: 01283 740 354 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Buchan Concrete Solutions The sustainability of this project will be Company Hanson Building Products for business. Training and involvement of measured in the long term reduction of - Thermalite personnel was carried out. The result of all Site Byley CO emissions, combined with minimal this was a significant saving on annual waste 2 Site Hams Hall Project - University of the West of England - maintenance costs and the architectural costs. Bristol individuality achieved on the external Project - Waste Streams Benefits include no capital investment The company was awarded the sub-contract elevations. This will ensure the project not It was identified that significant savings required as current facilities exist to achieve to provide the precast concrete frame solution only becomes a local landmark, but will also could be made by a simple review of how the goals. A simple change in work ethic and Contact Details for the new £77million Student Village at the be a long term investment reinforcing the Contact Details company dealt with waste and its packaging. culture will be required to enable the project Tim Sugden, University of the West of England. successful future of the University of the Julie Cagna, A review of waste streams was undertaken. to move forward. Buchan Concrete Solutions, Hanson Building Products - Thermalite, West of England. All waste contractors were asked to re-quote Kings Lane, Byley, Middlewich, Hams Hall Distribution Park, Canton Lane, Cheshire, CW10 9NB Coleshill, Birmingham, B46 1AQ Tel: 01606 843 500 Tel: 01675 468 012 Fax: 01606 842 215 Fax: 01675 468 010 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Forticrete from site. Forticrete now recycle all waste Company Hanson Building Products Agency started and site visits were made. water into storage tanks. This is then recycled The concerns identified by the employees Site Leighton Buzzard Site Ringwood back into the concrete mixers and equates to were confirmed by the Agency with specific Project – Water Harvesting over 1000m3. Project - Dust Suppression emphasis being put on the minimisation and control of dust. The company recycles the waste water Not only have they optimised the use of site Land use changes around the Ringwood site produced from the production facility and water but made significant cost reductions in increased environmental concerns. These A fully automated sprinkler system using created waste water storage capacity of the disposal of waste water. concerns included airborne dust caused by water abstracted from the adjacent lake was Contact Details Contact Details 41,060 m3. Part of the manufacturing process vehicle movements and ‘wind whipping’ of installed, which allowed full control of all requires the washing down of paint and resin Tony Foulkes, aggregates from storage bays. airborne dust on site without impacting on Stephen Alvis, Forticrete, the production capabilities. Hanson Building Products, applications, (both water-based fluids). In Hillhead Quarry, Harpur Hill, Buxton, Consultations with the local Environment Ringwood Works, Ibsley Airfield, the past this would have been disposed of Derbyshire, SK17 9PS Ringwood, Hampshire, BH24 3PJ by using waste carriers to remove the waste Tel: 01298 233 333 Tel: 01425 475 910 Fax: 01298 230 000 Fax: 01425 471 094 [email protected] [email protected]

20 21 SUSTAINABILITY AWARD Sponsored by The Concrete Centre www.concretecentre.com

RUNNER UP RUNNER UP

Company Hanson Building Products - This information was then disseminated to Company Marshalls recycle all wet-tipped concrete waste, reduce Thermalite the other two Thermalite sites, enabling and recycle all rejected concrete products Site Ramsbottom them to use the same format to apply to their and reduce the use of virgin material and the Site Newbury - Thermalite own sites. Common areas were investigated Project – Water and Materials Recycling impact on the local community by reducing Project – Waste Management for ‘best practice’ savings and recycling System inbound haulage. As part of the factory’s ‘waste management opportunities at all sites. In August 2005 Marshalls commissioned a All the targets where successfully achieved new manufacturing unit at their Ramsbottom resulting in annual benefits including; objective’, a study was carried out to identify site. Employees were involved from project a reduction of 2,880m3 of mains water and categorise all of the waste streams Contact Details Contact Details conception and assisted with the planning, consumption, a reduction in landfill Phillip O’Flynn, Sean Butler, produced on site, in order to establish design, location and innovative ideas requirements of 9,725 tonnes, a reduction potential areas for reductions. Hanson Building Products - Thermalite, Marshalls, Enterprise Way, Thatcham, incorporated into the project. in consumption of 7,180 tonnes of virgin Fletcher Bank Works, Ramsbottom, Berkshire, RG19 4AN Part of the projects aims were to: reduce the material, the elimination of 292 articulated Bury, Lancashire, BL0 0DD Tel: 01635 875 703 amount of mains water consumed by the vehicle journeys, a reduction of 13,140 miles Tel: 01706 282 723 Fax: 01635 875 705 manufacturing process, maximise the use of road haulage (8,500 litres of diesel) and a Fax: 01706 282 726 phillip.o’[email protected] of free water available on site, reduce and saving of over £150,000. [email protected]

RUNNER UP RUNNER UP

Company Marshalls opportunity on site to use the same material Company Roger Bullivant The problem faced by the company was the to construct a bird bund and have a Sand amount of waste generated by using bought-in Site Eaglescliffe Site Burton upon Trent Martin colony. Marshalls Eaglescliffe has mesh. It was felt that the waste was excessive Project – Sand Martin Colony worked with a local bird club over the years Project – Bespoke Mesh and it was decided to install an automated Segregation of waste is part of the daily ,who have carried out a number of on-site mesh machine. routine along with recycling wooden pallets, surveys. This collaboration has encouraged The machine has reduced waste and saved steel and concrete. However, there has been an the bird population. the company in excess of £100k a year. opportunity regarding sustaining biodiversity Contact Details Contact Details in the local environment and attracting bird Edward Trainer, Stephen Parker, species from afar. Recycled fine aggregate Marshalls, Roger Bullivant, Eaglescliffe Works, Durham Lane, Walton Road, Drakelow, Burton upon Trent, from the segregated waste concrete is used Eaglescliffe, Stockton-on-Tees, Staffordshire, DE15 9UA as a replacement for sand and there was an Cleveland, T516 0PS Tel: 01283 525 070 Tel: 01642 792 500 Fax: 01283 743 828 Fax: 01642 792 506 [email protected] [email protected]

RUNNER UP

Company Marshalls from the elements and the bund would fill up with rain water. Site Falkirk Discussions were held with SEPA (Scottish Project – Fuel Farm Environmental Protection Agency) about the The present fuel farm, built some 30 years concerns with the present fuel tank. The tank ago, was situated at the main entrance to the farm did not breach environmental legislation, site and caused severe traffic congestion when but, like Marshalls, they were concerned vehicles were refuelling at the end of the day. about the potential impact if a major spillage Contact Details At the fuel farm there were two fuel tanks occurred. As a result, a new and improved Gerry Maley, Marshalls, above ground level and one underground fuel tank was installed. Bleachfield Works, Dollar Industrial Estate, tank. The present tank farm had no protection Falkirk, FK2 7YS Tel: 01324 614 900 Fax: 01324 614 949 [email protected]

22 23 SUSTAINABILITY CORPORATE AWARD Sponsored by The Concrete Centre www.concretecentre.com

CORPORATE 2ND PLACE

Company Marley Eternit Project - Packaging Waste Reduction and the Waste Hierarchy The company has gone above and beyond the Packaging (Waste) Regulations by looking at product packaging (e.g. optimising plastic thickness, cardboard interleafing and use of timber pallets) in order to reduce usage wherever possible. Additionally the company has looked at the packaging that raw materials are delivered in with the intention of minimising such packaging wherever possible. For example, the bulk delivery of raw materials where appropriate and ensuring that suppliers take back Intermediate Bulk Containers. Collecting the prize on behalf of Marley Eternit are Norman Richards and Rebecca White Compared with 2004, the packaging savings in 2005 amounted to 163 Contact Details tonnes of timber pallets (approximately 10,000 in number), 43 tonnes of Norman Richards, cardboard and 119 tonnes of plastic wrap. This amounted to a financial Marley Eternit, Collecting the prize on behalf of Tarmac Building Products saving of approximately £110,000. Lichfield Road, Branston, Burton upon Trent, is Graham Green. Staffordshire, DE14 3HD Presented by Peter Robery (L) and Andrew Minson – The Tel: 01283 722 348 Fax: 01283 722 242 Concrete Centre (R) [email protected]

CORPORATE 3RD PLACE

Company Aggregate Industries - Fyfestone Project – Enviromasonry Through BRE Certification and their Environmental Profiles Scheme, Fyfestone have become the first UK manufacturer of architectural masonry to be certified and listed in the Approved Companies and Approved Construction Products, Red Book Volume 2. Developed in response to the demand for sustainable products for construction, the Enviromasonry range seeks to balance aesthetic demands with a measurable environmental footprint, under BRE Certification. CORPORATE WINNER The Enviromasonry range is manufactured on modern automated plants and produced from specially selected secondary recycled Collecting the prize on behalf of Aggregate Industries is Paul Lane aggregates. Cement replacement materials are also incorporated to Contact Details Company Tarmac Building Products a regular two-page newsletter was issued to every minimise environmental impact whilst maintaining quality throughout. Fyfestone Enviromasonry complies with BS EN 771-3. All products are Steve Wharton, employee that outlined general advice on energy saving Aggregate Industries - Fyfestone, Project – SavE - Tarmac Save Energy Information manufactured under the quality procedures of BS EN ISO 9001 and at work and at home. Thirdly, periodicals such as the Fyfestone, North End Works, Campaign Environmental Standard BS EN ISO 14001. Production processes and Ashton Keynes, Wiltshire, SN6 6QX in-house ‘Tarmac World’ and intranet site ‘T-junction’ inputs/outputs are analysed to measure performance and determine Tel: 01285 646 800 In 2004 Tarmac set out on a campaign to reduce energy carried SavE articles. The company suggestion scheme areas for continual improvement. Fax: 01285 646 897 [email protected] by 15% per unit production across the business. The has been put to good use collecting energy saving ideas campaign was badged as SavE (Save Energy). To achieve from employees at all levels and rewarding the best such a reduction required a significant amount of input ones. RUNNER UP and commitment from all levels of the business. One The result has been a much-heightened awareness of the most significant factors that could influence the amongst all levels about what the company sites and Company Aggregate Industries - Charcon In conjunction with suppliers, they have outcome would be from the employees on the shop minimised the packaging of raw materials individuals are doing to save energy and feedback on Project - Recycling in Charcon floor. To ensure that their commitment was obtained and how well their efforts are being rewarded. used by Charcon. retained, it was decided that they would need to be kept Rejects from the production process are Overall final benefits are in the region of informed of progress and that any achievements made Contact Details now recycled rather than being sent to £15k for minimal outlay. landfill. Used shrink-wrap and pigment bags should be published. Graham Green, Charcon has been able to introduce the are bailed and sold-on rather than being Tarmac Building Products, measures at all 11 sites. All sites were issued with a SavE branded notice board disposed of in a skip. Bulk oil is used instead Millfields Road, Ettingshall, Contact Details onto which were affixed a number of regularly updated of oil drums to reduce cost. Bulk oil tanks Wolverhampton, WV4 6JP are easier to bund, they are easier to handle Paul Lane, pieces of information from energy used at site, from Aggregate Industries - Charcon, Tel: 01902 353 522 and may involve no disposal costs. key performance indicators to best practice. Secondly, Smith Hall Lane, Hulland Ward, Fax: 01902 353 920 Ashbourne, Derbyshire, DE6 3ET Tel:01335 372 511 [email protected] Fax: 01335 370 286 24 [email protected] 25 INNOVATION AWARD SPONSORS INNOVATION AWARD Sponsored by Castle Cement www.castlecement.co.uk

Collecting the prize are the Bison Concrete Products Team Presented by Peter Robery (Far left) and Bob Bellamy – Castle Cement (2nd Left)

The innovation award is open to a wide interpretation of innovation from factory to site, software to concrete materials, marketing to logistics. The award is open to Full and Associate members.

WINNER

Company Bison Concrete Products There is no wastage at Swadlincote. At every point during production, waste material, both wet and dry, is conveyed Project Swadlincote hollowcore flooring plant to a recycling area which it passes through to reclaim the The new factory at Swadlincote is designed in an constituent parts of the concrete. innovative way, with the objective of manufacturing Bison The entire production process takes only 12 hours and precast pre-stressed hollow core flooring of high quality since the process is highly efficient the resulting product and in volume at a very economic cost. In conventional combines very high quality and accuracy with significant hollow core plants machines move along stationary beds economy, enabling it be delivered at highly competitive laying concrete onto pre-stressed wires. At Swadlincote rates to a radius of 200 plus miles from the plant. the casting beds move in a carousel formation through the production process. Contact Details Swadlincote is a pioneer in drawing office to plant Alan Clucas, technology. Details from drawings are transmitted online Bison Concrete Products, to the computerised control system at Swadlincote Millennium Court, First Avenue, enabling today’s drawing to be tomorrow’s product Centrum 100, Burton upon Trent, without human intervention or delay. Derbyshire, DE14 2WR Additionally every individual slab produced at the plant is Tel: 01283 495 000 identified with a transponder card containing full details Fax: 01283 544 900 of its size, weight, project and eventual on-site position. [email protected]

26 27 INNOVATION AWARD Sponsored by Castle Cement www.castlecement.co.uk

2ND PLACE RUNNER UP

Company Bison Concrete Products Company Aggregate Industries surface, which results in rapid overland flow of rainwater into rivers. Also by providing Project - Sustainability In Action Project - Lifting Hooks Investment products with contain recycled or secondary Recycled materials and sustainable drainage Following demands from their customers to offer a product with materials there is a simple correlation with are two of the methods used by Aggregate both reduced waste materials to landfill and cast-in lifting hooks, Bison sourced a patented technology for Industries to achieve sustainability within the automatic installation of lifting hooks. The project involved reduced requirement to extract primary their industry. Aggregate Industries have materials from quarries. In 2005, Aggregate extensive R & D and investment in excess of £2 million. The been developing Sustainable Drainage Industries recovered and recycled 3 million resultant equipment installs lifting hooks to all hollow core Systems (SUDS) in response to general tonnes of materials in the UK. Contact Details flooring unit product depths (100mm to 450mm) with a minimum concern over the way that the built Kevin Greaves, factor of safety 5.6. environment reduces the permeability of the Aggregate Industries, Hulland Ward, Ashbourne, The benefits to the customer are: Derbyshire, DE6 3ET • Improved health and safety on site Tel: 01335 372 226 Fax: 01335 370 074 • Much greater speed of erection Collecting the prize for Bison Concrete Products are Carl Abbott [email protected] • Elimination of damage to soffit of product (2nd Left) and Martyn Pawson (R) • Significantly reduced damage to blockwork bearings during erection. RUNNER UP Contact Details David Skey, Company Bison Concrete Products The technology is capable of adding general arrangement drawing for a project, design Bison Concrete Products, Project - Transponder Technology Tetron Point, William Nadine Way, calculations and CDM regulations at a later date. The system also has hand held readers Swadlincote, Derbyshire, DE11 0BB Bison’s project allows for equipment that inputs data onto a transponder card and to abstract data from the card. Tel: 01494 681 600 then applies it to varying depths of flooring Fax: 01283 544 900 The system enables a fail-safe approach product. It also allows for the development to identifying a specific slab during the [email protected] of software to input the data to transponder production process and in transport. It also Contact Details card including; delivery load number, provides a lifetime access to data, should David Skey, location of unit on load and unique bed change of use of the building be required. serial number. Bison Concrete Products, Tetron Point, William Nadine Way, 3RD PLACE Swadlincote, Derbyshire, DE11 0BB Tel: 01494 681 600 Company Buchan Concrete Solutions Fax: 01283 544 900 Project – Wide Prestressed Flat Slabs [email protected] Buchan Concrete Solutions was awarded the sub-contract to provide the precast concrete frame solution for the new £77million Student Village at the University of the West of England. At the start of RUNNER UP the construction period main contractor had incurred a 2 week delay to the contract programme resulting from planning Company Bison Concrete Products traceability and unit weight. There is also the provision of additional print heads allowing issues and Buchan was challenged with its recovery. Project - CAD CAM Technology marketing data to be printed onto the unit, Twelve months later and 4 weeks early, Buchan completed the The use of this technology eliminates increasing brand or customer awareness. A challenge and delivered 1,974 student accommodation rooms, 288 human error in transferring data from the visual aid can be provided to assist in unit kitchen/diner areas and associated core access areas. This put office to the shop floor. It provides accurate checking. Carillion two weeks ahead of schedule and back on track. guidelines to add detail to the product, i.e. Data, load number and location can be skewed ends to units, open cores, cut out They developed wide prestressed flat slabs to increase the speed Collecting the prize for Buchan Concrete Products are Peter printed on the product to ensure sequential holes, weep holes and location of lifting Contact Details of build. Dunnion (2nd Left) and Alistair Jack (R) loading and erection on site. hooks. David Skey, Contact Details The technology has the ability to print Bison Concrete Products, Tetron Point, William Nadine Way, Julie Cagna, technical data onto the unit providing Swadlincote, Derbyshire, DE11 0BB Buchan Concrete Solutions, Tel: 01494 681 600 Kings Lane, Byley, Middlewich, Fax: 01283 544 900 Cheshire, CW10 9NB [email protected] Tel: 01606 843 500 Fax: 01606 842 215 [email protected]

28 29 INNOVATION AWARD Sponsored by Castle Cement www.castlecement.co.uk

RUNNER UP RUNNER UP

Company Hanson Building Products Stephenson Construction developed a technique Company Marshalls they had to listen to “the voice of the customer,” to build in an in-situ reveal joint to cope with in this case the customer being stakeholders, Project - Learning Resource Centre - Cobiax Project – Sustainability through Benchmarking the tolerances of the semi-precast product. This shareholders, Local Authorities and the local On the Sheffield University project, Hanson has resulted in an exceptional finish throughout. This year Hambrook site has introduced community. It was decided that the site would Building Products and Cobiax Technologies Ltd The Cobiaxdeck offers 20% time improvements benchmarking in conjunction with the British need to develop an effective environmental plan to are delivering the Cobiaxdeck semi-precast over traditional methods, eliminates beams and Standards Institute. The benchmark methodology protect the future, making prudent use of natural system with two way void forming that is quicker reduces the number of columns. In addition, evaluates the progress of an organisations resources whilst at the same time maintaining a and up to 35% lighter than traditional in-situ by void forming the slab with the Cobiaxdeck management system and uses a scoring matrix to stable economic growth and employment. Contact Details define the maturity of that system. Contact Details concrete slab production. Cobiax uses spherical product, the amount of embodied C02 can be hollow void formers made from recycled plastic reduced by between 30 and 50%. The result is Gerry Feenan, During the assessment, the Hambrook site Steve Hambury, to remove the non-working dead load of flat slabs, more manageable, lighter structures with less Hanson Building Products, achieved a BSI Gold Award. Marshalls, while maintaining the biaxial strength. risk, higher qualities of finish and a flat slab. Birchwood Way, Cotes Park Industrial As part of the exercise it was recognised that Hambrook Works, Broad Road, Estate, Somercotes, Hambrook, Nr. Chichester, Derbyshire, DE55 4NH West Sussex PO18 8RG Tel: 01773 602 432 Tel: 01243 578 106 Fax: 01773 603 134 Fax: 01243 578 119 [email protected] [email protected]

RUNNER UP RUNNER UP

Company Hanson Building Products in days – rather than the more usual weeks – for Company Roger Bullivant The machine will deliver value engineering as such installations. mesh links are designed to demand, eliminating Project - Combined Sewer Outfall in a Box Project – Bespoke Mesh Speaking on behalf of the client, Paul Laybourne human error. This plant is just one of the stages in Bespoke mesh is recognised as the way forward The combined sewer outfall (CSO) was used by said: “Northumbrian Water are regularly looking further automating production at RBL Drakelow, for the industry as the reinforcement can be Northumbrian Water to help the contractor meet at ways to improve processes already in place and will eventually be linked to the proposed pre- designed and produced as required instead of the a tight AMP4 year 1 regulatory deadline. and to minimise disruption to our customers. cast carousel plant. over designing involved with manual production, The Type 5 CSO in a box was installed in less The ‘CSO in a box’ product provides flexibility to The biggest saving will be the reduction in mesh which has led to the high level of wastage than five hours from the first lift through to the the project programme and significantly reduces wastage which currently costs the company Contact Details experienced by the company over the years. Contact Details completion of the base, main and weir walls. overall work timescales. in excess of £100k every year. This saving will Roger Bullivant have installed a new automated Following delivery of the static screen, the Steve Walker, continue to increase as the business grows. Steve Parker, mesh machine. installation was completed with the addition Hanson Building Products, Roger Bullivant, of bespoke roof slabs. This meant that overall Birchwood Way, Cotes Park Industrial Walton Road, Drakelow, construction, road closure time and inconvenience Estate, Somercotes, Derbyshire, DE55 4BH Burton upon Trent, to the water company’s customers was numbered Tel: 01773 600 226 Staffordshire, DE15 9UA Fax: 01773 600 295 Tel: 01283 525 070 [email protected] Fax: 01283 743 828 [email protected]

RUNNER UP RUNNER UP

Company Hanson Building Products Hanson Formpave overcame these problems Company Roger Bullivant Doors will only require support from steelwork by designing a terraced sustainable drainage above the panels. Tracks can be connected Project – Aquaflow Permeable Blocks Paving Project - ProWall system that would substantially slow the volume directly to the internal face of ProWall and dock Project - Formpave of rainwater discharged from the site. This would The ProWall fully insulated panels span between shelters externally if required. Door openings will Formpave were asked to design a sustainable restrict the outflow of rainwater to Environmental dock pits which not only ensure a rapid also be incorporated, to suit dock door sizes. onsite erection programme but eliminate the drainage system for the car park of the MET office Agency requirements for green-field run-off. Using 50 N/mm2 grade Class 2 sulphate resisting requirement for the more traditional areas of headquarters. Formpave’s design used its Aquaflow permeable concrete with a Styrofoam insulation core cladding and steel posts/rails. To complement the The project had the additional task of providing a paving blocks and storm water source control gives a ‘U’ value in excess of the new 2006 Contact Details system above dock levellers, solid ProWall panels Contact Details drainage system that could deliver a low volume system to attenuate the rainwater that fell on requirements. can be utilised above perimeter retaining walls as of water discharge – only 5 litres per second the areas of the car park, thereby managing peak Katherine Robinson, Steve Parker, cladding panels. Panels are manufactured from per hectare for a 1 in 100 year storm event flows. Hanson Building Products, Roger Bullivant, grade 50 concrete. – in conjunction with being constructed on a 1:14 Toftham Avenue, Coleford, Walton Road, Drakelow, slope. Gloucestershire, GL16 8PR Burton upon Trent, Tel: 01594 836 999 Staffordshire, DE15 9UA. Fax: 01594 810 577 Tel: 01283 525 070 [email protected] Fax: 01283 743 828 [email protected]

30 31 CONCRETE TARGETS HEALTH & SAFETY SCHEME 2005 WINNERS RUNNER UP The winners of the final year of The Concrete Targets Scheme 2000 - 2005 were announced at the inaugural dinner in May at the Arena Conference Centre, Leicester. Company SLP Precast/Grace Construction This is due to the elimination of the potential for Products reinforcement corrosion during the serviceable life of the structure. Project – Strux 90/40 – A Practical Application The performance of STRUX 90/40 synthetic The replacement of traditional steel reinforcement structural fibres in the design mix for precast with synthetic macro fibre technology from Grace concrete revetment units for the project at Construction Products, called STRUX 90/40, was Acheson & Glover Precast Blackpool has been demonstrated by testing Marshalls used in large precast revetment units for a major Buchan Concrete Solutions concrete beams. The tests demonstrate the ability Tarmac Topblock coastal defence project at Blackpool. Replacing Contact Details Hanson Building Products of STRUX 90/40 fibre reinforcement to provide 4 STAR CEMEX Concrete Products steel reinforcement not only led to a more Lafarge Roofing the concrete with a residual flexural strength. John Edwards, CEMEX Precast efficient production process but gave the precast SLP Precast/Grace Construction Products, Marley Eternit units a significant enhancement in durability. Hamilton House, Battery Green Road, Lowestoft, Suffolk, NR32 1DE Tel: 01502 587 322 Fax: 01502 585 525 [email protected]

Forticrete H+H Celcon 3 STAR Tarmac Precast Concrete Tarmac Toppave

If concrete were to be 2 STAR Aggregate Industries UK invented now it ROLL CALL OF HONOURS would be Over the last 5 years of the scheme the following companies have reduced their accidents by at least 50% hailed as Buchan Concrete Solutions 75% a miracle. Tarmac Building Products 63% CEMEX UK Building Products 63% Hanson Building Products 61% To find out why get your copy of “A Little Book Of Concrete - A guide Aggregate Industries 60% to one hundred advantages” Marley Eternit 50%

t: 0116 253 6161 w: www.britishprecast.org e: [email protected]

32 33 CONCRETE TARGETS 2010 HEALTH & SAFETY SCHEME THE NIGHT! Acheson & Glover Lafarge Roofing ACP (Concrete) Marley Eternit Aggregate Industries Marshalls Bell & Webster Merseybeams Bison Concrete Products Milbank Floors Brett Landscaping Milton Precast Buchan Concrete Solutions Robeslee Concrete Carter Concrete Sandtoft Roof Tiles CEMEX UK Building Products SCC Ebor Concretes Stanton Bonna British Precast staff get all dressed up! The Venue Ennstone Building Products Tarmac Building Products Forticrete Thorp Precast Hanson Building Products Titan Precast H+H Celcon Trent Concrete

THE ABOVE MEMBERS* HAVE ALL SIGNED UP FOR THE CONCRETE TARGETS 2010 SCHEME ALREADY. HAVE YOU?

The ladies...... and gentlemen arriving Colin Richardson from Bison Concrete Products who For further information about the awards sponsored the drinks reception schemes please contact: says a few words Colin Nessfield, Technical Manager on:

Tel: 0116 222 9848 Email: [email protected]

*list correct as of October 2006

www.britishprecast.org/concretetargets Norman Brown from ABC Competition was tough on Quick, is there a doctor in the house? The dancing was definitely 70’s inspired Structures switches to his the Scalextric track ‘Operation’ gave some quite a buzz! night duties

34 35 DRINKS RECEPTION Sponsored by Bison Concrete Products

CHARITY GAMES ARENA Sponsored by BASF

BAR & TABLE SPONSOR Sponsored by Roger Bullivant

We raised £1500 on the night for Diabetes UK and thank everyone for their kind donations

British Precast thanks our partners for their support

MUSGRAVEDESIGN&ADVERTISING

British Precast Concrete Federation Limited 60 Charles Street, Leicester, LE1 1FB www.britishprecast.org/awards