Sharing good practice 2018 / 19 WAYS TO MAKE YOUR WORKPLACE HEALTHIER AND SAFER

ENTRIES FROM THE MPA HEALTH AND SAFETY AWARDS

AVETTA

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www.3M.co.uk/AuraGen3 Achieving Zero Harm Working with MPA to improve Health and Safety in 2019

Zero Harm will only be achieved when everyone in the industry is working with Health & Safety as their top priority. MPA facilitates a number of initiatives and services to help its members achieve this. Please review these and consider how you would like to utilise or support them in 2019. MPA’s 'Safer by initiatives'

Safer by Competence

Safer and Healthier by Leadership

Employees Contractors

Safer by Safer by Safer by Safer by Design Sharing Partnership Association

'The Fatal 6'*

Contact Workplace Workplace Struck by with moving transport and Work at Respirable moving or Road Traffic machinery and pedestrian height Crystalline falling Accidents 1isolation 2interface 3 4Silica 5object 6

* High consequence hazards

Safer by Competence Safer and Healthier by Leadership l Work with MPQC to enhance skills in the sector l Work with MPA to support the ‘Helping Great Britain work well’ Strategy

l Sign up to the ‘MPA Pledge’ and commit your organisation to

l Utilise the driver’s/contractors passport system achieving Zero Harm

l Share the MPA safety resources within your company l Attend MPA Safer and Healthier Leadership courses

l Submit your safety statistics in a timely and accurate manner

l Champion the use of 'Mates in Mind' www.matesinmind.org

l Champion RCS initiatives and MPA’s health surveillance programmes

l Submit your Nepsi data

l Champion Vulnerable Road User and Driver Training initiatives

2 visit www.safequarry.com for more details or email: [email protected] Supporting MPA Health and Safety Initiatives

Safer by Partnership – Contractors Safer by Design l Support the MPA Contractor’s Charter l Ensure new mobile plant complies with Safer by Design guidance l Utilise MPA’s Contractor Safety Forums www.safequarry.com/Safer_by_design.aspx l Embed MPA (Avetta’s) contractor’s database

www.avetta.com

l Incorporate the MPQC-SPA Competence Map to enhance contractor skills l Utilise MPQC’s Contractor Safety Passports

Safer by Association l Review how existing plant compares with Safer by Design l For smaller members and organisations without specialist guidance personnel, trial the H&S site evaluation and improvement tools

Safer by Sharing 'The Fatal 6' l Sign up to Safequarry.com or Safeprecast.com and Support 'The Fatal 6' initiative by reviewing AM share the safety alerts and acting on these high consequence

www.safequarry.com AM hazards within your organisation: www.safeprecast.com 1. Contact with moving machinery and isolation

l Sign up to the Safequarry, 2. Workplace transport and pedestrian interface Safeprecast and Driver's 3. Work at height Apps AM 4. Workplace Respirable Crystalline Silica l Support and attend MPA’s Safer by Sharing Days 5. Struck by moving or falling object 6. Road Traffic Accidents

Public Safety l Support MPA’s Stay Safe campaign and review your public safety risk assessments for active and disused sites. Review the6 RoSPA inland water safety document l MPA Cycle Safe – support or host a cycle safety event l l Submit entries to the MPA Health Support the CLOCs and FORs initiatives and Safety Awards, then share the resulting Best Practice Guide l MPA Cycle Safe Send your incident alerts, toolbox Campaign Supporting talks and other info to MPA CLOCS Standard STAY l Utilise QNJAC H&S guidelines and SAFE other guidance via safequarry

visit www.safequarry.com for more details or email: [email protected] 3 Foreword

The theme of the 2018 MPA Health and Safety Conference was encouraging a culture of continuous 'Closing the Gaps … Focussing on Priorities', reflecting our improvement and open and challenging determination to reverse the recent decline in the industry’s dialogue. safety performance and progress towards our collective goal of MPA believes that success will only be achieved by strong leadership, Zero Harm. collaboration and the sharing of health and safety information, case The conference recognised that more effective communication and studies, alerts and best practices. Maximising the potential of this supervision would be key elements in closing the gap between the publication to help drive change in our businesses will be a good industry's collective health and safety aims and the realities on the example of these beliefs in action. ground. The industry’s agreement to focus its energies and resources on Our commitment to safety also extends to members of the public who the 'The Fatal 6', the high consequence hazards that have been the main visit our sites and with whom we share the roads. MPA will continue to cause of fatalities over the last decade in our business, reflects another run its public safety campaigns and support the wide range of initiatives major step in helping us achieve this. to improve the competence and safety of the industry's drivers. It was interesting to note that a high proportion of the entries were Nigel Jackson, Chief Executive mitigating risks associated with one of the six themes within 'The Fatal 6'. In several cases, a serious incident had been the genesis for the 'The Fatal 6'* innovation. 1. Contact with moving machinery and isolation I believe that many of the innovative solutions and new processes 2. Workplace transport and pedestrian interface highlighted can be adapted or applied to a wide range of other 3. Work at height organisations. They will make a material difference to the safety, health 4. Workplace Respirable Crystalline Silica and wellbeing of everyone working within the mineral products 5. Struck by moving or falling object industry. 6. Road Traffic Accidents Part of a leader’s role is to facilitate and encourage an open and trusting *High consequence hazards environment in which these types of initiatives and behaviours flourish, Sponsors MPA would like to thank the suppliers to the industry who have sponsored both our awards ceremony 6 and this publication. The main sponsor was the Industrial Diagnostics Company (IDC). Individual sections Lead sponsor show the companies which have sponsored them.

The Sir Frank Davies Trophy for companies with less than 1000 employees: Winner – Kilwaughter Chemicals Trophy sponsored by 3M The individual award winners from the Health & Safety Conference Entries from 29 companies – MPA members, contractors and suppliers: Aggregate Industries Day Group Ltd GRS Marshalls PLC Smith & Sons Atlantic Pumps Driveline Engineering Grundon McGee Group (Bletchington) Ltd Brett Group EPC UK Ltd Hanson UK Midland Quarry Products Tarmac Ltd CEMEX UK Finning Hillhouse Group Sapphire Energy Wainwright Colas Ltd FM Conway Imerys Aluminates Sibelco Wincanton plc Creagh Concrete Products Forterra Lhoist UK Singleton Birch Ltd

4 visit www.safequarry.com for more details or email: [email protected] Introduction

This Guide summarises the best ideas and innovations from the MPA’s Health and Safety Awards 2018.

This Guide is a compilation of solutions that MPA companies, contractors and suppliers have applied to minimise and, where possible, eliminate health and safety risks arising from their daily operations in the mineral products industry. The ideas and innovative approaches are often very simple and inexpensive, they can be applied to a range of common industry problems. Organisations of all sizes will find entries within this publication that will be relevant to their own activities.

Please ensure that this Guide is shared with colleagues at all levels within your company. Electronic versions are downloadable from the Safequarry and Safeprecast websites. The digital versions include embedded links to short videos that show the innovation or new process in action and interviews with site operators talking about the benefits that have been realised.

This publication epitomises the industry’s belief that we will all be ‘Safer by Sharing’.

How to use this Guide

It is hoped that by reviewing this Guide, particularly those sections relating to your main area of work, you will recognise solutions that could either be implemented within your own workplace or will generate an idea for an alternative solution.

The Guide has been divided into eight sections to reflect the categories used in the MPA Awards. They focus on those areas that have the most impact on improving health and safety in the workplace. We have indicated which entries were prize winners, and which have video clips available. To help you locate entries relating to a certain subject, we have provided a keyword index. If you would like more information on an entry than is available via Safequarry and Safeprecast websites, please send an email to [email protected] or [email protected]. Please quote the entry number, which is located immediately to the left of the entry title.

Where an entry shows the video symbol the video can be viewed via the Safequarry and Safeprecast websites or the Mineral Products Association YouTube channel.

The blue circles with numbers highlight that this entry illustrates a way of mitigating a high consequence hazard associated with 'The Fatal 6'. The number in the circle reflects which theme it is related to.

The sharing of best practice is crucial in helping the industry to achieve Zero Harm.

Contents

Contractors’ Safety 6 Occupational Health and Well Being 26

Sponsored by Mentor Training Sponsored by Avetta

Engineering Initiatives 9 Worker Involvement 29

Sponsored by Hycontrol Sponsored by LKAB

Behavioural Safety, Safety Culture & Leadership 17 Bitumen, Asphalt & Contract Surfacing 32

Sponsored by Mineral Products Sponsored by Eurobitume UK Qualification Council (MPQC)

Reducing Occupational Road Risk 21

Sponsored by EPC-UK Index 39 Transport Initiatives 23 Health and Safety Working Groups 40 Sponsored by John Brooks TMR

visit www.safequarry.com for more details or email: [email protected] 5 ON VIDEO AWARD WINNER Simple, visual marker Simple, meets standard confirmto edging operators or with different adopt on other sites Easy to reportto confidence edge concernsover drivers have ADT protection implement to cost system Low and others. drivers ADT operation for Safer BENEFITS l l l l l A training campaign on edge protection was also introduced. This This was also introduced. protection on edge A training campaign was protection Edge drivers. all ADT talk to included a toolbox The point in each daily pre-startalso made a discussion briefing. was supportedcampaign of Sibelco and the management by messages on edge that the safety who ensured Wardle, D. everyone to communicated working were protection on the site. sticker the vehicle and implemented now have Plant Wardle D within Sibelco they operate the sites across training programme and at other client's quarrying and construction sites. 2 Contractors’ safety sponsor safety Contractors’ Dingle Bank Quarry > Dingle Bank DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Judging the correct height of edge protection for mobile plant the correct for height of edge protection Judging Dingle Bank Quarry the Sibelco’s At can often be subjective. due repairs needed frequent road on the haul edge protection had revealed protection An audit of the edge weathering. to variances using a range of in its height and individuals significant all that ensure Whilst wanting to checking for it. adhoc measures was at the correct height, theythe edging want operators did not or others carrying jump in measuring to sticks or having around heights. check edging and out of cabs to the earth who provided Plant, work services at the site, Wardle D They a fleet of eight articulatedoperated (ADTs). dump trucks devised a simple and easy means of ensuring the correct height with a simple fitted were the fleet. All ADT’s for of edge protection marker the minimum a visual guide to sticker which provided quick,This reckoner easy and visual the edge protection. height for met the doubt about whether the edge protection any removed minimum height. Taking the guess work out of edge protection out of edge work the guess Taking Sibelco 1156

CONTRACTORS’ SAFETY 6 CONTRACTORS’ SAFETY 1236 RUNNER ON Working with contractors UP VIDEO Aggregate Industries UK > Project Sence > Bardon Hill 1 2 3

DESCRIPTION Segregation – Construction and quarry areas were clearly defined and segregated in order to inform communication and to control Aggregate Industries' multi-million-pound Bardon Hill Quarry access, egress, mobile equipment movement and on-site logistics. extension includes the removal of 7.5 million cubic metres of waste Light vehicle routes have been established to separate them from clays, installing a new primary crusher and constructing over 4km of the quarry plant and to control where and how they interact. Light overland conveyors. The five-year construction project stretches over vehicle routes were continually reviewed to ensure segregation as a 250 hectare site and is due to complete in Summer 2019. the project evolved.

The health and safety of the construction workforce and quarry Transfer of Responsibility (TOR) – A TOR process was used operators on this project is the highest priority. Long before to formally release the control of project areas from the quarry construction commenced, a strategy was developed for managing management teams to the principal contractor. TOR planning the interaction between the construction and quarrying activities – meetings were held between all parties to define the extent of Project Sence construction areas, expected interface between quarry operations and construction activities and how this would be safely managed All construction activities are undertaken under CDM 2015 to ensure compliance with CDM 2015 and Quarry regulations 1999. Regulations, whilst quarry development and waste removal activities fall under Quarry Regulations 1999. K Home International (KHI) were Safety Systems – All contractors received a Project Sence appointed as the Construction Management Contractor as well as induction when they arrived on-site which included; site rules, Principal Contractor/Principal Designer under CDM 2015. expected behaviours, PPE, RAMS and emergency procedures. Contractors were responsible for delivering their activity specific The following measures were put in place to ensure the safety of all induction to their workforce. involved with the project and the effective management, control and separation of the quarrying and construction activities. Risk assessments and method statements were submitted by contractors for every task prior to any work commencing. Once they Selection of Contractors – Safety was central to the procurement were accepted by KHI, a permit to work was issued. Regular site process. As part of their tender submission, each contractor was visits and audits were undertaken by KHI and the required to provide evidence that adequate resources were available contractor to ensure compliance. to correctly implement the Construction Phase Plan (CPP). A detailed HSE profile was prepared for all submissions which informed the The construction workforce undertook personal selection of a contractor with a proactive and positive safety culture. dynamic risk assessments prior to commencement of any activity using the KHI 'Take five booklet'. The CPP is formally issued to each contractor prior to commencement of work activities in order to ensure that they have The KHI Safety Observation booklet is a pro-active been made aware of the HSE requirements, expectations and issues tool that helps to identify hazards and trends. associated with the project. All contractors must ensure that the CPP The booklet can also be used to identify good practice, safe acts, and all other relevant information are issued and communicated to safe behaviours and safety suggestions. Weekly feedback to the all their subcontractors, before they enter the site. workforce including progress against hazards identified.

visit www.safequarry.com for more details or email: [email protected] 7 ON HIGHLY VIDEO COMMENDED UP RUNNER To March 2018, 616,774 hours have been worked with one LTI 616,774 hours have 2018, March To 34 incidents and 60 near misses reported was reported worked888 days since the last LTI all staff across culture safety Strong all. for and healthier environment A safer The yard is a safer environment is a safer yard The work to room has more operative Shovel site around movements of vehicle control Better lorries for tipping zone Safer No reported near misses since installation. Remote control Remote BENEFITS l l l l l establish individual responsibilities and to communicate interface communicate and to establish individual responsibilities arrangements. Daily co-ordination weekly meetings and contractor progress were These all aspects held covering of safety. meetings were and weekly with daily pre-shift inspections, site meetings, reinforced weeklyon the project talks based HSE bulletins and toolbox to KHI actively risks. engaged and listened schedule and upcoming and understand what safety promote workers line to front in order they issues and challenges faced. safety BENEFITS l l l l l 2 3 2 1 DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Communication and engagement – Regular coordination and engagement Communication KHI and Team, Sence Management meetings between the Project the Quarry essential in establishing and Management were teams the amongst culture safety and positive maintaining a consistent construction workforce. included kickThis off meetings priorto the commencement of construction establish the goals and objectives for work to to essential HSE information, communicate the project, to Permission to tip Day Aggregates > Southampton Depot Working with contractors – continued contractors with Working Quarry extension Bardon Hill Repeated near misses were being reported at Day Group’s bagging bagging reported being Group’s at Day near misses were Repeated of the site. the nature this was due to depot at Southampton, the to operate made it difficult and shape of the yard layout The bagged materials safely. production facility dispatch and to in the main thoroughfare, located which are stockingThe bays, delivery by traversed regularly lorries, tele-handlersare and It was essential that deliveryloading shovels. lorries, which instructed re-stocking until they were waited were the bays, the to moved impatient drivers on occasions, However, tip. to in resulted This permission.stocking without waiting for bays tip in an practice. Drivers would an unacceptable and unsafe were other vehicles where manner in an area uncontrolled no opportunity and controlled giving present, a safe ensure to tipping zone. would that light system a traffic introduce solution was to The It the stocking they bays. entered was also the tippers before stop the lights and to control be able to necessary driver to the shovel for or red. of checking on green some way have whether the lights were so and customised, A second-hand traffic light was purchased A remote sign. or go (green) (red) as a simple stop it operated by the so the traffic light could be operated was fitted control flashing light was installed A small green operative. loading shovel would operator when know so the shovel behind the traffic lights, the light was on green. 1145 1236

CONTRACTORS’ SAFETY 8 ENGINEERING INITIATIVES 9 ON VIDEO AWARD WINNER 4 Eliminates the need to work a confined space in the need to Eliminates HAVs to exposure Reduces operator crystalline respirable to exposure Reduces silica operator productivityImproved in cleaning time – 20% reduction all and cleaner working for A safer environment other applications. to Easily transferable 1 BENEFITS BENEFITS l l l l l l As no facility existed to deal with water wash down systems at systems wash down deal with water no facility to As existed the semi-dry cleaning factories, the range of alternative process limited. these risks mitigate were options to and balanced using a counter been resolved have problems The pneumatic wash- ultra-high pressure, designed, ergonomically 55,000 PSI of air to at up can operate system The system. down the The jet of air and vapour is powerfulremove to enough flow. allows system The drum. internal the mixer from concrete cured who is positioned outside the drum, to the cleaning operative, all remove enabling him to easily, the lance hold and manoeuvre the internal debris. a minute water of atomised litres four can feed system The a operation produces The lance. the high pressure through minimal amount of slurry that is easily disposed of without additional plant and equipment. Engineering initiatives sponsor initiatives Engineering visit www.safequarry.com for more details or email: [email protected]

Entrance to mixer – confined space – confined mixer to Entrance

DESCRIPTION

Thinking outside the confined space the confined outside Thinking Needwood > Barton Under Industries UK Aggregate The task was physically demanding, involved the operator the operator involved demanding, task was physically The working hot and dusty conditions whilst wearing in cramped, risks was exposed to associated operative The PPE. appropriate machinery crystallinewith respirable entrapment, silica, HAVS, workingconfined space COSHH exposure. and The cleaning process was an unpleasant task. was an unpleasant cleaning process The an It required drum, the confined space of a mixer into enter to operative the cured break-off to use pneumatic vibration and hand tools hour The workings. the internal mixer for residue concrete a condition to the mixer return was essential to long process to the desired produce concrete efficiently which enabled it to specification. The semi-dryThe in the manufacture used process batching concrete an in-depth, Industries' required products concrete of Aggregate daily clean-down. 1232 ON VIDEO UP RUNNER Detected and prevented 338 over-pressure events 338 over-pressure Detected and prevented alarms 163 high level Detected and prevented 11 PRVDetected and prevented alarms (preventing discharge)

Installation of standardised level gauges and displays Installation gauges and displays level of standardised prior fill NOW to systems tested All silo safety event or high-pressure on fills if a high level stop Automatic occurs Sensors check functionality of PRV’s and silo tops Since installation the modifications have ❍ ❍ ❍ Silo servicing six months to frequency three extended from and cleaner environment Safer tanker make drivers to and easier for deliveries Safer maintain and manage. easier to Systems 90% reduction in operators checking in operators 90% reduction of silo top reductionworking in Significant at height PPC permit current requirements Exceeding and sensors, high level silo fill valves, of PRV’s, Standardisation sensors over-pressure Drivers check capacity prior to disharge check prior to capacity Drivers l BENEFITS l l l l l l l l l l l l

3 New systems installed New systems DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Silo ground level testing level Silo ground Plc > Nationwide Marshalls A SHE review at Marshalls recognised a concern about the number at MarshallsA SHE review recognised working were tops of silos. of times staff the at height on It was 300 manual inspections at the over were that there estimated everyweek. 1,000 silo fills per and circa week It also of silo’s top the silos from discharges of environmental high levels revealed off a silo. one serious in unit had been blown a filter incident, and, findings led to undertakeThese Marshalls survey a detailed of its The 24 sites. across located which are silos 150 cement and PFA survey standard identified that 50% of the silos had either below (PRVs), valves faultyor under-capacity relief sensors safety pressure was virtuallyThere no discharge. of a contents signs or showed the silos and the estate across equipment of safety standardisation Marshall’s as being a high risk assessed the environment. to were to inspectworkregular basis and climbing the silos on a were staff on the silo tops. undertake to A plan was developed work engineering remedial The during deliveries. silo discharge for the potential and reduce solution that could be an engineering design to priorities were work and would was legally compliant systemised, standardised, Marshalls network. the entire across In should addition, the system capacity enable tanker prior check spare drivers to to be fail-safe, with the factory’s Allen Bradley plc’s integrate and would discharge cause analysis. root for – so data could be recorded In undertaken partnershipwere modifications over with Hycontrol, of £1.1million. Marshalls in the now is with an investment a year and about the new local councils systems of informing process that the number of compulsoryanticipates of checks on the top silos will be reduced. 1176

ENGINEERING INITIATIVES 10 ENGINEERING INITIATIVES 1111 HIGHLY Penta tumble drum chute wear plate improvements COMMENDED eliminates confined space hot work Brett > Southampton Depot > Poole ON VIDEO DESCRIPTION The solution was to reinforce the tumble drum chute and fit bolt-in wear bars instead of welding At Brett’s site in Poole, the fully automated Penta Line ‘ages’ in wear strips. The bolt in wear bars were also concrete block pavers by tumbling the cured blocks inside a extremely hard wearing. The bolts holding the strips in place could rotating steel tumbler drum fitted with lifter bars. The tumbling be undone from the outside. The installation cost was £ 4,300 with action is extremely abrasive and causes both significant wear on estimated annual costs of £3,350 per annum. the feed chute and drum, this is compounded by impact damage. The wear and damage are minimised by installing wear strips on BENEFITS the feed chute. However, the interior had to be inspected on a l weekly basis and repairs made. This required operators to work in Eliminated weekly hot work and grinding of wear strips a confined space where hot work was undertaken such as welding l Eliminates category three work in a confined space to replace damaged wear strips taking about two hours. l Saving of four hours of maintenance per week The operators were exposed to risks associated with HAVs, oxygen depletion and fumes, use of gas cutting and arc welding, whilst l New plates easy to replace and long lasting working with restricted space inside the tumble drum. Control measures were in place to minimise the risk from these hazards. l Safer and more efficient working environment. However, it was recognised that the process needed to be made safer.

Before Wear strip After

1148 HIGHLY ON Safe access platform for lorry body cleaning COMMENDED VIDEO Smiths & Sons (Bletchington) Ltd > Gill Mill Quarry 3

DESCRIPTION Smiths Bletchington formulated a design to allow safe access to vehicle bodies via a robust fixed platform structure. It is equipped Smiths Bletchington was concerned about the vehicle body access with a set of steps that can be lowered by a winch, into the vehicle ladders provided by manufacturers, these varied in both design body. This enables the driver to safely descend into the vehicle and quality from truck to truck. In most cases, having reached the body and then use a pressure washer to clean it. top of the ladder on the vehicle body, drivers had to turn through 180° and then descend backwards into the body. The ladders An innovative self-locking gate was added to the design. This could be damaged and were often slippery. prevents the HGV driver leaving the platform until the steps are fully raised, ensuring a driver cannot forget to retract the steps before driving off. The access platform is featured in Smiths haulier induction video - password Smiths.

BENEFITS

l Feedback from hauliers very positive

l Reduced risk of slips, trips and falls

l Safer working at height

l System easy to fabricate for other sites

l Safer and more efficient wagon cleaning. visit www.safequarry.com for more details or email: [email protected] 11 ON VIDEO

AM HIGHLY COMMENDED MPA Driver's App Driver's MPA Removed the hazards associated with this maintenance task this maintenance with associated the hazards Removed commitment to management’s demonstrated Project safety improving user friendly system like Maintenance operators the new, safety engaged in finding solution – enhances Employees culture process efficient and easier More all. working for A safer environment

AM BENEFITS l l l l l l MPA Safeprecast App Safeprecast MPA

Before

AM AM MPA Safequarry App MPA All the videos highlighted in this guide can be watched on your mobile devices using devices mobile on your guide can be watched in this the videos highlighted All channel www.youtube.com/MineralProducts1 YouTube or via the MPA the Apps For info call MPA +44 (0)20 7963 8000 www.safequarry.com call MPA info For or call +44 (0)116 232 5170 www.safeprecast.com e-mail info [email protected] For Download the free MPA Apps Download the free MPA DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Elimination of manual handling & pinch & manual handling of Elimination point injuries Works > Lagen Tile Breedon Roof Tile A plant operator caught A plant operator the tip of his finger whilst the slipper on the replacing ridge plant extruder during procedure. a changeover subsequent incidentThe also identified investigation manual handling risks with moving associated thethe 35kg slippers from the point table to storage of use. with a beam together an overhead both hazards eliminate To weight The with an electrical installed. fitted were trolley winch of the slipper was fully supported the winch whilst it was by aid to the slipper, position. A handle was attached to into moved finer positioning during installation, and liftingto simplify eyes the slippers table for A storage connecting cable. the winch to with lockable the table can be moved wheels was also introduced, along in line with the beam. environment was successfully trialled system in a controlled The help A video was used to plant operators. to introducing before and a new risk on the correct train operators installation procedures the task. for assessment was prepared 1149

ENGINEERING INITIATIVES 12 ENGINEERING INITIATIVES 13 ON 3 VIDEO HIGHLY COMMENDED – new system achieves 8mg/m achieves – new system 3 Significantly reduced risks of injury Significantly all key input from stakeholders involved Project and legislation complies with new standards Plant reduce risk to use of design Effective safer of the system Operation and maintenance efficient operation More impact Reduced environmental New EA limit 20mg/m Replacing the steel resettlement tanks with concrete tanks tanks with concrete resettlement Replacing the steel a housed in pumps, displacement Centrifugal and positive ease of maintenance compound for separate pipeworkInstallation and return including an access of feed maintained gantry are when systems operators for theyInstalling can be where and similar equipment all valves walkways from easily accessed from and/or compounds away hazards potential A safer working environment for all. working for A safer environment New pump compound BENEFITS l l l l l l l l With health and safety at the forefront of the project, key of the project, at the forefront health and safety With including design at each stage of the involved personnel were Key elements of the project contractors reps. and safety operators, included; 1. 2. 3. 4. l , steel, settlement , steel, visit www.safequarry.com for more details or email: [email protected] 3 DESCRIPTION tanks before being returned to to returned being tanks before individual the scrubber via four submersible pumps Singleton Birch Limited operates operates Limited Birch Singleton 300t/d twin gas fired, natural four, shaft Maerz kilns Melton at its Ross being which are production site project included The upgraded. of the recirculation an overhaul pumps and pipe settlement tanks, network. Dirty each from water to one gravity by scrubber flows 85m of four

New tank and access Before – submersible pump – submersible Before Before The settlement tanks progressively silt up with sediment. Each tank settlement tanks progressively The slurryis emptied once a month, and resultant is transported a to movement Cleaning the tanks included the dewater. lagoon to a very operation that of submersible pumps, manually intensive for access. the use of lifting and scaffolding equipment required the risk also exposed to of being scalded with hot were Operators pipe between the settlement tanks. a return when moving water issues with poor access space between tanks, was limited There steelwork. around moving and ground uneven and egress,

The existing system, which was 30 years old, would not meet new would old, which was 30 years existing system, The when of hazards a range to and exposed operators standards undertaken. tasks were essential maintenance

Maerz Kilns wet gas scrubber improvements gas scrubber Kilns wet Maerz Ross Quarries > Melton Birch Limited Singleton 1182 ON VIDEO HIGHLY COMMENDED Potential hazard from toppling light towers removed light towers toppling from hazard Potential working anyone under temporaryfor environment Safer lighting manufacturers by being adopted system safe Fail principles. Design' by of 'Safer Adoption New sensor and fail safeNew sensor and fail mechanism BENEFITS l l l l if the stabilisers were raised. Suppliers were contacted and the Suppliers were raised. if the stabilisers were for specification Conway FM The with them. shared information include this feature. to was updated new lighting towers FM the concept and modified it. took UK, a manufacturer, Trime from 18 lighting towers subsequently purchased have Conway to meet this specification. towers existing them and retrofitted As an initial measure, it was decided to suspend the use of any suspend the use of any it was decided to an initial measure, As the handbrake mechanism did not have other equipment that older models with this safety retrofit the mast and to connected to being undertakenWhilst this was the workshops were device. the mast being prevent asked that would other options review to not deployed. were raised if the stabilisers that worked no existing mechanism in revealed Research a period of trial and Following conjunction with the stabilisers. based on location a prototype the workshops demonstrated error, be raised until the legs the mast to not allow sensors that would position a safe It the mast to also lower would deployed. were 5 2 DESCRIPTION DESCRIPTION visit www.safequarry.com for more details or email: [email protected] light raise/lower Tower House > Vestry Road FM Conway FM Conway undertook an investigation following an incident an incident undertook following an investigation Conway FM light had overturned a tower and injuring an operative where the public. open to a pedestrianfalling close to area a short light had been moved the accident, the tower to Prior not redeployed, distance but the stabilising legs had not been It extended. though the light was even that when an is believed It was also noted over. it toppled leaned on the mast operative the handbrake the mast was not connectedthat, on this model, to the mast when the lowers mechanism automatically – this safety the handbrake had been applied However, handbrake is released. so this was not a contributoryin this instance, factor. to was identified as the failure the cause of the accident Initially, but on further stabiliser legs, the lower it was changed reflection, be raised light to the tower that allows switch The failure. design to if Similarly, not deployed. should not function if the stabilisers are automatically. the light should lower raised, the stabilisers are 1245

ENGINEERING INITIATIVES 14 ENGINEERING INITIATIVES 15 ON ON VIDEO VIDEO HIGHLY HIGHLY COMMENDED COMMENDED

Elimination of a high risk manual handling task Reduced risk of hand injuries and MSD injuries 50% Reduced by downtime Increased (additional £30,000 of product). production Reduced manual handling risks and implementation led design Employee Reduced time plant down removal and timely spillage cost effective More sites use on other for can be adopted Concept workingSafer environment. BENEFITS BENEFITS l l l l l l l l l l This project was a good example of the application of Aggregate example of the application of Aggregate project was a good This the ethos, Empowerment) and Collaboration (Agility, ACE Industries’ an otherwise solution to implementation of a simple high risk area. visit www.safequarry.com for more details or email: [email protected]

DESCRIPTION

DESCRIPTION DESCRIPTION and safer work environment Atlantic Pump and CEMEX > Angerstein Aggs Wharf and Concrete Innovative sliding pump base for an easierInnovative sliding

Field conveyor cleaning scoop cleaning conveyor Field Sands Garside Industries > Aggregates The introduction of a 'SlurryPro introduction The Sliding Base' in conjunction with 6x4 slurryreduced this Warman risk. pump has significantly their following Pumps bespoke is the work of Atlantic The design new design The discussions with CEMEX and other colleagues. and means that the suction be removed pipe no longer needs to the frame. connected to and the pump casings stay replaced parts the wear to unbolting by Access of the pump is achieved apart. end and motor casing bolts and sliding the wet four One of CEMEX’s priorities is to minimise the potential for priorities for minimise the potential to is One of CEMEX’s manual hazardous (MSDs) from musculoskeletal disorders of undertaking way effective and more a safer this task handling, required. was therefore At CEMEX’s Angerstein Wharf, the mains water pump used to take pump used to Wharf, the mains water Angerstein CEMEX’s At the involved process The and rebuild. replace strip, to one day high risk manual handling of heavy pump casing and pipework. It downtime. a full day’s required Slurry to maintain and and notoriously difficult large pumps are than one person and the It more is a task that usually requires repair. risks. several exposed to are involved operators The use of lifting aids. The 'Scoop' was constructed from an old loader bucket was constructed 'Scoop' The utilising a from be easily to enabled the 'Scoop' This attachment. quick hitch CAT when required. the site around moved To overcome this problem and following a lengthy evaluation a lengthy and following this problem overcome To team maintenance the on-site systems, conveying of the sites' a CAT onto fit to was designed This and built a scoop. designed which could insert the scoop under the conveyor Telehandler Manipulation the operator of the boom by spillage. and remove further reach. flexibilityafforded and Some of the conveyors have been designed with little or no access with been designed have Some of the conveyors of clearing traditional way spillage The mechanical cleaning. for manual creating is with shovels, under these conveyors from risk at of serious putting employees back and handling issues, body injuries. lower Garside Sands silica sand operation in Leighton Buzzard comprises Buzzard Garside sand operation in Leighton Sands silica conveyor use Both sites a main road. split by that are of two sites is there bulk materials, as with many sands and, move belts to caused by under the conveyors an element of spillage always sand stickingeither wet the belt, non-operating to head or tail rollers. up on return drum scrapers and build 1180 1191 visit www.safequarry.com for more details or email: [email protected] 'The Fatal'

At the request of MPA Council and Board, the MPA Health & Safety Committee looked back at the fatal incidents over the last decade, identifying 6 high consequence hazards, ‘The Fatal 6’, have been the main cause of fatalities over that period. MPA and its members have agreed that they will focus their resources on tackling6 the issues associated with 'The Fatal 6'.

Contact Workplace with moving transport and Work at machinery and pedestrian height 1isolation 2interface 3

Workplace Struck by Respirable moving or Road Traffic Crystalline falling Accidents 4Silica 5object 6

A working group involving MPA members has been established for each theme. They will develop industry best practice and guidance, raise awareness and develop useable tools for reducing risk.

The new Guidance and other resources will be accessible via www.safequarry.com and from other channels 261

Behavioural safety, safety culture & leadership sponsor BEHAVIOURAL SAFETY, SAFETY CULTURE & LEADERSHIP 1220 AWARD ON Real engagement! WINNER VIDEO EPC-UK Ltd > Alfreton

Employees enjoying a short walk an independent sleep consultant, toured all sites to explain how lack of good sleep affects us.

All employees were issued with a Garmin fitness activity tracker and given access to a Wellness Programme Portal, which aims to keep them engaged and motivated as they work towards a healthy, well-adjusted lifestyle. The Garmin package included the software and the portal, through which various voluntary challenges both locally and globally could be launched. An example of a challenge is the 100-kilometre walk. This encouraged employees to take short 15 minutes walks whilst at work and DESCRIPTION achieve a 100km within a year. EPC-UK has a distributed workforce of nearly 250 people working The 'Commit to be Fit' initiative has been a huge success across the UK. throughout the business with support from the MD downwards. Remote workers responsible for blasting and drilling can spend BENEFITS long periods on their own, while drivers ferrying hazardous materials up and down the country are often out early and late l Improved health and wellbeing culture across business in difficult road conditions. These remote workers make up 50% of the EPC-UK workforce. Ensuring these workers did not feel l 100% engagement from employees neglected or isolated was important for their health and wellbeing. EPC wanted to engage with them on a human level, not just a l High level of voluntary participation in challenges work level. The management of occupational ill-health risk is vital. l Absenteeism is now less than 1.5% The company has committed to 'The Workplace Wellness Charter'. l The number of smokers reduced by 70% This Charter is an evidence-based award scheme which is seen as a statement of intent, showing EPC-UK’s commitment to the l Initiative has developed into family engagement for some health and wellbeing of its people. The charter allows EPC-UK to audit and benchmark its health and wellbeing results against an l Use of technology helps supports engagement and relevance independent set of standards. l A healthier and more balanced lifestyle for employees. In 2017, EPC-UK launched its 'Commit to be Fit' initiative, this aimed to support all employees, especially the hard-to-reach remote workers both on a mental and physical level.

The nationwide programme included presentations from various experts in mental health and wellbeing. Nutrition and daily physical activity were two of the three focal points of the programme’s first year. However, the one that made the biggest impression with employees was the focus on sleep. Dr Neil Stanley,

visit www.safequarry.com for more details or email: [email protected] 17 BEHAVIOURAL SAFETY, SAFETY CULTURE & LEADERSHIP 1219 RUNNER UP ON Safety culture on the A1 Darrington to VIDEO Dishforth contract 2 6 Tarmac Contracting > A1 Motorway Maintenence Depot

■ Proactive identification of safety hazards due to the relaunch of an innovative Safety Observations programme and mobile app. Operatives can also choose to fill out cards. The system has been promoted by management. 'Say it, sort it and report it'.

■ A culture of approachability and personal interactions, ensuring colleagues can relate to any problems they are experiencing. This helps to identify emerging problems at an early stage. The management team has a target to increase personal contact with the workforce by undertaking at least four face-to-face meetings a month.

■ Implementation of Tarmac’s 5 + 2 system that provides DESCRIPTION operatives with a guide to the safety exclusion zone around The A1 (M) Darrington to Dishforth project is a long-term mobile plant. maintenance and operation contract delivered by Tarmac on behalf ■ A third-party Employee Assistance Programme enables of Road Management Services (RMS). operatives to seek professional help for any health and The strong health and safety culture of the workforce was rewarded wellbeing issues outside of work. when the project team reached an incredible milestone of seven ■ Sharing lessons more widely throughout the highways years and 350,000 hours worked with no recordable accidents community. Tarmac has hosted several Highways England or lost-time injuries. This achievement reflects Tarmac’s safety Roadworker Safety Forums. culture and an ethos that ensures the proactive identification and correction of potential hazards is second nature to all those involved. BENEFITS

Tarmac safety initiatives take a holistic approach to safeguarding l Strong health and safety culture throughout workforce both the physical and mental wellbeing of operatives. Through ensuring that everyone returns home unharmed at the end of each l Recognition of management’s commitment to safety day, including customers, contractors, suppliers, employees and the l Individuals and teams recognise their responsibility for safety public – Tarmac will achieve the ultimate goal of 'Zero Harm'. l Open approach to the discussion of safety issues and willingness to address them

l Excellent safety record – 350,000 hours without an LTI

l 1,000% increase in safety observations from 27 in 2014 to 250 in 2017

l Targets for face-to-face safety meetings exceeded by circa 14% 5 + 2 l A safer environment for all. Tarmac’s leadership has introduced a range of initiative’s that have contributed to the achievement of the safety record on this contract, they include;

■ A proactive approach from the start of every project. Early contractor involvement is vital to allow risks to be mitigated and, where possible, eliminated in the preliminary design stages.

■ A 'collaborative ethos' – all the partners put teamwork and collective responsibility at the heart of meeting the safety challenge, ensuring that best practice is shared.

■ Frequent joint operations meetings on the project that have helped to highlight and manage health and safety concerns. Face-to-face 18 visit www.safequarry.com for more details or email: [email protected] 261

BEHAVIOURAL SAFETY, SAFETY CULTURE & LEADERSHIP 1147 HIGHLY ON Contractor / haulier induction interactive video COMMENDED VIDEO Smiths & Sons (Bletchington) Ltd > Gill Mill Quarry 1 2 3

The video inductions are delivered in a dedicated induction suite on-site, this allows inductees to focus without distraction on the visuals and key information being provided. The feedback has been very positive, with the hauliers finding the video engaging and providing the safety information in a clear and interesting format.

To view the videos readers must copy the links below and use the password: Smiths

https://vimeo.com/260909803 – Contractor Induction

https://vimeo.com/260909806 – Haulier Induction

BENEFITS

l Everyone is given a consistent and clear message

l Very well received – some inductees saying it is the best site induction they have experienced

l Ensures contractors and hauliers understand site procedures

l Information presented in an engaging and clear format

l Option to adapt concept for use on other sites

l A safer environment for all

Drivers in induction suite

DESCRIPTION

The health and safety interaction of both contractors and hauliers when visiting quarries is an area of high importance. To fully engage site contractors and hauliers with its safety culture, Smiths Bletchington have developed an interactive, drone based, video induction in partnership with ECP Video Ltd. These videos have now become part of the structured induction programme that is Exert from video given to contractors and hauliers at Gill Mill Quarry. The contractor and haulier videos focus on the topics detailed below:

■ Clearer site orientation

■ Key Hazards

■ Extraction Phases

■ Local Rules

■ Product Locations

■ Isolation Practice (LOTOTO)

■ Safe HGV Tipping Exert from video visit www.safequarry.com for more details or email: [email protected] 19 BEHAVIOURAL SAFETY, SAFETY CULTURE & LEADERSHIP 1234 HIGHLY ‘Stand up for Safety’ campaign COMMENDED Sapphire > Dunbar Works

DESCRIPTION

Sapphire (a wholly owned subsidiary of Tarmac) launched a new BENEFITS multi-site safety initiative in 2017 focused on empowering the four l sites to achieve a strong and effective leadership style. The objective Extremely well received within the sites was to achieve sustainable changes in behavioural safety and l Increased reporting and reviewing of unsafe acts and unsafe improve the safety culture through engaging communications and conditions (+22%) accountability. l Significant housekeeping improvements across the sites The ‘Stand up for Safety’ campaign name was chosen by the sites. The campaign promoted preventive safety achieved through the support l Individuals taking real pride and responsibility for their and engagement of all members of the teams. A system was set up environment that would reward the site teams and individuals for progress and, recognise where employees had 'gone the extra mile'. l Improved safety behaviour and culture across all sites

The scheme involved each site manager completing a PowerPoint l Stronger safety leadership, engagement and effectiveness presentation every four months and presenting it to the Sapphire l Increased communications between the sites and awareness of Senior Management Team (SMT). All managers attend the meeting. what other sites doing The PowerPoint presentations focus on the six criteria below. The l Improved sharing and adoption of best practice information provided includes both quantitative and qualitative measures of what has been achieved over the period being reported. l Encouraged engagement and contributions from all members of An example of evidence provided would be before and after images site team highlighting the impact of a change. l Improved communications and feedback between site teams 1. Statistics on: Lost Time Incidents, Medical Injury, First Aid and management. 2. Near hits reported by type: unsafe acts, unsafe condition and near miss

3. Ratio of the total near hits reported by number of individuals on-site

4. Housekeeping status and improvements

5. List of new safety actions and initiatives launched

6. List of safety actions and initiatives implemented

The criteria and guidelines for each element were shared and agreed by all, in advance. For each site and criteria, the SMT determine a score using a scale of one to 5. For each review period, the members Before of the site receive points equal to the average score obtained but only if equal to four or 5, as the objective is to reward good performance.

Points are accumulated by each individual. Lists of low monetary value point-based items are made available and the team members personally manage their points based on their preference.

The Sapphire GM appointed one member of the SMT to be the Safety Sponsor for each of the sites, this has meant that support and assistance is available to encourage full team engagement, progress and validation of the sites’ efforts.

The images show the sort of on-site improvements that were achieved, in this example in the re-organisation of the way recycled tyres were stored. After 20 visit www.safequarry.com for more details or email: [email protected] 26 Reducing occupational road risk sponsor

REDUCING OCCUPATIONAL ROAD RISK 1213 AWARD ON Aircrete load security – void guards WINNER VIDEO Tarmac Building Products > Aircrete Linford and Alfreton 3 5 6

The building products transport team at Tarmac worked on various solutions; engaging with suppliers, drivers, haulage companies and a local university. Various concepts were trialled using materials such as polystyrene, wood and metal. Eventually, a plastic design was adapted by introducing ‘wings’. The wings allowed the guards to ‘rest’ on the top of the load without falling in.

The various solutions were trialled with the drivers and cameras were installed on selected trucks to measure effectiveness in transit.

A gantry was designed that enabled the drivers, using a tool adapted for the purpose, to insert the void guards into the load DESCRIPTION prior to strapping. The driver does not need to step onto the loaded vehicle. The device is lightweight and storable on the vehicle, and it Due to their lightweight construction, packs of aircrete products can be removed by the crane grab on the customer site. can be double or treble stacked when being transported. A gap or ‘void’ is left down the centre of the load to enable the crane grab BENEFITS to access the packs during offloading. This also enables the clamp l Reduces risk from working at height on vehicle trucks to load the vehicle. l Reduces risk of operator being struck during loading The gap creates a ‘weakness’ in the load when it is strapped up, as there is nothing to prevent the packs moving towards each other l Flexible and low cost device during transit. To protect against this, a driver was required to insert some form of brace between the packs whilst they were being l Increases the amount that can be loaded onto vehicles loaded. This required a driver to either climb on the load or stand ❍ From 32 packs to 38 packs (+19%) on the deck. The driver was exposed to the risks associated with working at height and the possibility of being hit by either the crane ❍ No increase in haulage cost or a pallet. ❍ £267K annualized saving Image of void guard l Improved aircrete products’ security in transit

l Reduced breakages and product damage

l High level of user/driver engagement in process

l Can be applied by other organisations

l Improved safety on both production and customer sites.

Tool to remove guard To overcome these risks any solution also needed to meet the following criteria;

1. The bracing device would need to be adjustable, as the size of the void can vary depending on how it is loaded.

2. It would need to work with a range of different vehicles and cranes that are used within the haulage market.

3. It would need to allow the driver to insert and remove the device without climbing onto the vehicle.

4. It would also need to be lightweight and easy to store on the vehicle.

5. It would need to be available at an acceptable cost for the haulage sector. visit www.safequarry.com for more details or email: [email protected] 1721 ON VIDEO UP RUNNER Reduction in incidents involving drivers Reduction in incidents involving being reported near hits now More and actioned Tarmac and hauliers across engagement with drivers Improved level at site drivers understanding of issues for Better drivers from and feedback messaging consistent More drivers facilities for Improved values. safety and shared feel Team' in achieving 'One Progress BENEFITS l l l l l l l focussed safety week that was held at all Tarmac’s 400 sites in 400 sites Tarmac’s that was held at all week safety focussed pack that information had a dedicated 2017. Each site November for each day. theme with a different content had interactive engage drivers in the activities to and helped enabled sites This discussions betweensite and the the drivers safety facilitate to started the process to build a more Over days, the five operatives. understanding of the issues. and a shared open environment also enabled some the week from Importantly, the feedback site-specific An example of this was the actionsto be put in place. drivers. for room a rest create to of an old storeroom conversion week, the safety take monthly meetings now on from Following these meetings personnel, and site the drivers place involving and on progress feedback open discussions, the basis for provide new issues. the identification of any 6 2 Engaging with senior leadership to review issues, incidents issues, review with senior leadership to Engaging forward. and consider a way Reviewing external etc. best practice in FORS forums Surveying opinions on hauliers and for the operational team transport culture. safety Tarmac Surveying on their opinions for hauliers and drivers communications/engagement. and safety survey review Running a workshop with operational leaders to solutions. outputs and design solutions. deliver working to Establishing a dedicated group Running a workshop with external/collect hauliers – to Tarmac what wider industryunderstand their views, how does, could improve. review workshopto Running a final with operational leaders approach. the proposed Partnership'. Launching the 'Safety DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Safety partnership – haulier engagement – haulier partnership Safety Ltd > National Tarmac Tarmac operates from more than 400 sites across the UK and across than 400 sites more from operates Tarmac year. each transports road of materials by million tonnes 70 over a fleet of 16,000 contracted used across Over are 21,000 drivers include artics, that vehicles owned and tippers and company and communications messaging Consistent trucks. ready-mix is drivers of hauliers and group and diverse this large across relationship with them its to improve Tarmac wanted difficult. values. safety Tarmac’s that they all shared ensure and to was undertaken of research ensure to programme A six-month of the views had a clear understanding of the Tarmac that improvements on the issues and where hauliers and drivers An importantshould be made. part was to of the process of best practice within the industry awareness Tarmac’s raise focus to identify key and issues, and in other sectors, trends changes or effective where actions on those areas the proposed could be made. improvements gathering was undertaken information The in the sequence outlined below. 1. 2. 3. 4. 5. 6. 7. 8. 9. Safety Partnership a this activity from outcome Partnership', The was the 'Safety help bring to that was designed new engagement programme improve to closer together, hauliers and drivers teams, Tarmac activitiesThese the relationships. collaboration and strengthen Team’ ‘One a of trust and help create level build a greater would within the business. feel Vice Martin was launched by the Senior programme The Riley, the launch was a transport to Central Tarmac. of President 1168

REDUCING OCCUPATIONAL ROAD RISK 22 26 Transport initiatives sponsor John Brooks TMR TRANSPORT INITIATIVES 1233 AWARD ON Tyre telematics WINNER VIDEO Day Aggregates > Transport Fleet 6

The driver is warned and able to stop their vehicle before a wheel becomes detached or a tyre blows out or runs incorrectly inflated, avoiding an incident that could have potentially catastrophic consequences.

DESCRIPTION

It is estimated that there are between 150 to 400 wheel detachments each year, they are responsible for three to seven deaths annually. They also result in serious traffic incidents involving damage to other vehicles and injuries to other road users.

Day Aggregates wanted to reduce its exposure to these risks and improve tyre management across its fleet of over 150 vehicles.

TrucTyre and Day Aggregates agreed to partner in a trial of a Cab based receiver tyre monitoring system. In 2016, they were awarded a two year Innovate UK government grant to assist in the development of this system. BENEFITS l Reduces risk of tyre failure leading to accident Sensor l Safer Transport – drivers, tyre fitters and third parties

l Increased vehicle uptime, less traffic congestion

l Lower environmental footprint

❍ CO2 emissions

❍ Lower fuel consumption

❍ Less tyre disposal

l Reduction in workshop maintenance time The system consists of a sensor which straddles two-wheel nuts and is held in place with a bracket, the sensor is activated by a 1mm movement. When the wheel nuts start to work loose, the switch opens, and an RF warning is sent to the driver via a receiver to the cab. In addition, via the TyreWatch telematics platform, a warning is sent to the traffic office of the imminent danger of a loose wheel.

The system also monitors tyre pressure and temperature. By monitoring these elements and taking appropriate corrective action, the operator is able to improve tyre life, enhance the durability and safety of the tyre casing.

The system reduces the reliance on the driver to check and monitor the vehicle tyre. The processing of data and reporting directly to the transport department is automated and continuous.

visit www.safequarry.com for more details or email: [email protected] 23 ON VIDEO UP RUNNER 5 2

Reduced risk of injurydrivers and pedestrians to on-site dust pollution from environmental for Reduced potential similar situations in apply design to Potential all. for environment Safer Eliminated riskEliminated of tip over

www.safeprecast.com Download your FREE copy from www.safequarry.com or

Driver’s Handbook The Handbook is a tool for working drivers to help them understand and manage the risks that they face and create when driving and operating vehicles for work. It will help people make safer choices about the way they drive and behave around vehicles.

Tipping prevention frame prevention Tipping BENEFITS DESCRIPTION visit www.safequarry.com for more details or email: [email protected] l l l l l Preventing vehicle tip overs vehicle Preventing Plant > Tilbury > Grinding CEMEX UK CEMEX’s grinding plant is located on the wharf at Tilbury wharf on the plant is located grinding docks, at CEMEX’s A number of winds. south-westerly strong is exposed to the site delivering as they were articulated over been blown have tippers belt feeders. the apron material on the ramps into raw tip the possibility again, a covered of this happening prevent To the into reverse now Vehicles frame has been constructed. over tipping the safe they off-load into and before frame fully covered of regardless tip over to It vehicles area. impossible for is now such as a ram collapse or mechanical failures conditions, weather a tyre puncture. 1133

TRANSPORT INITIATIVES 24 26 TRANSPORT INITIATIVES 1137 RUNNER ON Managing pedestrian risk UP VIDEO CEMEX UK 6

DESCRIPTION A simple logo featuring a truck and different ‘people’ variants, representing the most at risk groups has been developed. The CEMEX launched a new safety campaign in January 2018 aimed safety messages are reinforced using the logo, a road safety leaflet at pedestrians – 'Don’t chance it . . . ' The campaign is designed and a video. The leaflet and video highlight a number of road to raise the awareness of pedestrians to the risks they may be safety messages besides those directly related to heavy goods exposing themselves to when in close proximity to or crossing vehicles, such as always using a crossing, ensuring that you are in front of LGV’s. This builds on the success of CEMEX’s industry visible and keep looking and listening. leading safety campaign to educate cyclists. As well highlighting the key message of 'Don’t chance it' to Part of the motivation for the campaign has been the involvement pedestrians, CEMEX is also providing drivers with specific training of CEMEX drivers in the fatality of three elderly pedestrians. These related to this group of vulnerable road users. Training drivers was separate and tragic incidents all occurred within an 18 month also an integral part of the campaign. period. While all three drivers were found to be non-culpable, it has been devastating for all concerned. In each case, the In addition to the campaign, CEMEX operates three low-entry cabs pedestrian killed had stepped out in front of the truck in slow where the 90% increased visibility has a significant impact on its moving traffic and had assumed the driver could see them. ability to keep all vulnerable road users safe.

The pedestrian campaign aims to educate vulnerable road users BENEFITS about the dangers around heavy goods vehicles such as the ‘blind spots' as well as highlighting key road safety messages. l Industry leading initiative

Pedestrians account for a quarter of all fatalities on our roads. In l Helps educate and raise public awareness London, the figure is a shocking 53%. Nearly a third of pedestrian l Will facilitate further engagement by other stakeholders fatalities involve 60+ year olds. l Improves safety of CEMEX drivers The problem is growing as the number of pedestrians being killed on UK roads is increasing, this may further accelerate as traffic l Visual demonstration of corporate responsibility levels increase. Whilst there are identifiable higher risk groups of vulnerable road users, anyone who walks is part of the audience l Safer environment for all for the campaign.

One of the challenges for CEMEX was to find a way to maximise the exposure of the safety message to a wide and diverse audience. With a fleet of approximately 900 CEMEX vehicles covering around 39 million miles every year, using the sides of these vehicles to promote the safety messages seemed an ideal opportunity to generate mass visibility to the public.

The 'Don’t chance it…..' message has been applied to some aggregate tippers in London and the North West, this application will continue in a rolling programme across the CEMEX fleet.

visit www.safequarry.com for more details or email: [email protected] 1725 Occupational health and well being sponsor OCCUPATIONAL HEALTH AND WELL BEING 1178 AWARD ON Trief and Kassel factory program reduces WINNER VIDEO manual handling and concrete cutting Brett Landscaping & Building Products Ltd > BLBP > Barrow 1 4 5

Before – manual handling moulds Aligining curves on saw table 3-dimensional curves online

DESCRIPTION By working with local mould suppliers, Olympic Moulds and Dixon Engineering, the team produced a new carrier design. This opens Brett's factory at Barrow produces 11,000 tonnes per annum on the side and has a crossover design of steel, moulded rubber (tpa) of containment and bus-stop kerbs which can weigh up to and wood frames. This enables 3-dimensional, curved kerbs to 300 kilograms. Most of the products are processed on a Coote be mechanically cast. This has allowed 33 of the original 45 floor manufacturing system, this uses six steel moulds held within a moulds to be moved onto the Coote line. carrier. The moulds are mechanically inverted and release the kerbs before they are lifted by powered chain hoist for finishing. A 500kg overhead gantry crane was installed which, together with a specialist handling aid, enables the remaining floor moulds to be The remaining 1,000 tpa turned mechanically to release the kerb from the mould. of production had to be cast in floor moulds as The total investment in the new carriers, moulds, crane and the steel carrier moulds handling aids was circa £90,000 over two years. could only have curves in two dimensions. These BENEFITS kerbs are curved in three New moulds to reduce sawing l Elimination of the majority of manual handling of floor moulds dimensions, needing rubber formed moulds l Elimination of the majority of manipulation of sawn kerbing that the standard carriers could not release. l Reduced requirement for sawing On average, these special kerbs weigh over 100kg and can be as much as 170 kg. After curing, two operatives manually strip them, l Reduced levels of RCS dust generation in the factory turning them out onto a moveable stand before transferring them l More efficient and mechanised operation onto pallets. Though the moulds were never lifted clear of the stand, it needed significant manual effort and coordination to release the l Team effort in finding kerbs, with one operative standing on the movable stand. solution enhances safety culture In addition, around 600 tpa of Coote line kerbs had to be cut to specific dimensions to meet customers’ radius requirements. A l Safer and healthier grab truck was used to transfer these 230kg kerbs on and off the environment for all. saw table. However, they still required to be manually aligned on the 1m diameter saw bed using crowbars. The concrete sawing also releases RCS dust into the factory despite water suppression Specialist handling aid being fitted.

A full review of the floor moulds and sawing was undertaken to develop a program to reduce the occupational health exposures.

The team conducting their review identified the commonly sawn sizes and purchased moulds with these dimensions. Now they can be cast directly on the mechanically controlled Coote line. This change enables the transfer of 500 tpa of production onto the machine, an 80-90% reduction, and eliminated the need to manually align these kerbs on the saw table. New overhead gantry crane 26 visit www.safequarry.com for more details or email: [email protected] 26 OCCUPATIONAL HEALTH AND WELL BEING 1246 RUNNER Educating the workforce on respirable crystalline UP silica and other work-related health issues

FM Conway > Conway House > Vestry Road 4 ON VIDEO DESCRIPTION

Following a review of the available training courses covering construction related occupational health risks, FM Conway was disappointed by the lack of industry specific courses and resources available. Therefore, it decided to develop its own in-house training course.

To start this process, the individuals responsible for the development of the course needed some special training. They attended the NEBOSH Occupational Health and Well-Being Training Courses. They used the knowledge gained to develop a bespoke training course for FM Conway’s employees. Mental Health: An explanation on the different types of mental The first phase of the training programme was to deliver the course health conditions including psychosis (such as Bi-Polar Disorder), to the managers and supervisors working across all of Conway’s sites. personality disorders, schizophrenia and neurosis. The more common It is now being re-tailored for presentation to operatives. type of mental health problems, such as anxiety, depression, panic attacks, phobias are also covered. This is followed up with videos and The course covers a wide range of health issues. It uses a variety discussions on recognising such issues and what can be done to of techniques including interactive sessions, videos, in-house and help manage and control them. externally produced resources to facilitate the course’s delivery. Topics covered include legislation, psychological health, HAVs, silicosis, Phase one of the programme, delivering the training to managers coronary disease, diet and many other health related topics. and supervisors, is nearing completion. Phase two, the delivery of the training to operatives will commence shortly. The feedback and At the beginning of the course, the delegates are asked to state learning from Phase one will be used to modify and tailor the Phase their top hazards involving health and safety. Most of the candidates two delivery. focussed on safety related hazards, very few mentioning health related construction hazards. Although not unexpected, as BENEFITS historically the managers and supervisors training has concentrated l Managers and supervisors better equipped to deal with on these areas, these responses illustrated the need for the training health hazards programme on health issues. l Managers and supervisors better able to understand the Typical examples of how topics were covered are detailed below: requirements of the health improvement plan Silica and Silicosis: Use of the IOSH ‘No Time to Lose – Fake or Real’ l Managers and supervisors have a better appreciation of WHY question set. Explanation of the various types of silicosis. The benefit health is important of X-Rays, health surveillance including lung function testing. The adoption of the correct control measures including local exhaust l Managers and supervisors understand the improvements that ventilation, use of dust masks and the importance of face fit testing, can be made dust suppression and vacuuming techniques. l Circa 150 managers and supervisors trained Hand Arm Vibration Syndrome (HAVS): Provides information on exposure levels and control measures. It introduces the attendees l Developing a more balanced health and safety culture in to FM Conway’s HAVS Calculator which is an adaptation of the HSE FM Conway HAVS Calculator. It incorporates spreadsheets that assist recording and l automates the calculation of exposure points and levels. The course Helping to change attitudes, understanding the behaviour of also includes instruction on safe working practices such as job rotation. employees.

visit www.safequarry.com for more details or email: [email protected] 27 HIGHLY COMMENDED

Teams Teams Interdependent PPE available from a clean and secure source a clean and secure from PPE available enables activities be recorded System of individuals to dust being issued with the correct sized are operators Ensures masks and easily accessible on-site available PPE always Manor and consequent Preston to travel need to Removed loss of time available of masks is always A stock silica. Reducedto risk of exposure Help others conform keeper Others’ Networking contributor Care for others Organisational pride Looking for ‘What If’ Vending machine Vending BENEFITS l l l l l l l were issued to all the individuals on-site who required access to the access to who required all the individuals on-site issued to were A partnership the machine. PPE dispensed by was established with software via remote levels stock monitor to the PPE supplier, Hayley, as necessary. and replenish

Bradley Curve Self Independent Measuring maturity: Personal knowledge, commitment and standards Internalisation Personal value Care for self Practice, habits Individual recognition Leadership peak Dependent Supervision Management commitment Condition of employment Fear/discipline Rules/procedures Supervisor control, emphasis and goals all people Value Training

4 Reactive Natural Instincts

Safety by natural instinct Compliance is the goal Delegated to Health & Safety Manager Lack of Management involvement Injury Rates Rates Injury Safer and Healthier by Leadership MPA is running a series of workshops at different locations throughout the UK in 2019, contact Ian Gibson at [email protected] for more details. A programme that will help leaders to understand how leadership behaviours influences their organisation’s development. Also to analyse their business, to develop their strategies and inspire their workforce to achieve ‘Zero Harm’. Before DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Vending machine for PPE machine Vending > Kingsteignton Sibelco UK Operators at Sibelco’s East Golds site had to collect had to East Golds their PPE from all site at Sibelco’s Operators required, When newwere dust masks Manor site. at its Preston stores collect to them, the supply was ina special journey was required the boxes Once at East Gold, masks. containing 100 masks face boxes would of plant. Operators area in a dust contaminated stored were being kept. record a mask without any to help themselves A further at stores East at Golds was that the for operators difficulty only open between 8am – 4pm. On occasions, Manor were Preston masks if with replacement operators provide it was not possible to had run out outside the opening hours. the stock machine at PPE vending operated, install a card solution was to The workers, management maintenance operators, allowed This East Gold. a week. days seven PPE 24 hours a day, and contractors to access training on issuing machine provided supplier of the vending The Cards in the machine. access the items to and how users with cards 1157

OCCUPATIONAL HEALTH AND WELL BEING 28 26

Worker involvement sponsor WORKER INVOLVEMENT 1118 AWARD ON Dynamic risk assessment WINNER VIDEO Kerneos and Imerys Aluminates > Purfleet 1

DESCRIPTION The five steps are:

Kerneos has been using 1. Think through the task on the job dynamic risk assessments DRAs) for 2. Look for exposure many years, but they were 3. Assess the risk little used and difficult to complete. 4. Take precautions

The size of the book was 5. Do the job safely too large, and the system was not being fully utilised. The team have real ownership of the system and the form which At last year’s annual safety day, a team lead by the maintenance they designed. department, but including both production operatives and non- operational staff, decided to revamp the DRA form. BENEFITS

l Risks more effectively identified and managed before task commences

l Operators and contractors safer

l 2,000 dynamic risk assessments from an operational team of around 40

l System monitored by management and constantly evolving

l System still being tweaked with suggestions from the team

l Often used as central part of behavioural safety tours

l Form has been adopted on-site by some of the regular They reviewed other forms used in industry, both by MPA members contractors and companies from other industry sectors such as Rio Tinto and DuPont. The objective was to identify best practice and learn from l Enhanced safety culture on-site others. They recognised that a smaller, pocket-sized form would l Commitment from everyone on-site to system they developed. be appropriate for their business. The existing question list was reviewed, both adding some more relevant questions and taking out others that didn’t add value.

The site merged this system with the parent company’s 'Take 5' program and relaunched the newly designed, risk assessment book in September 2017.

It was agreed, that as a minimum, any task that requires a permit or lock off, must have a dynamic on the job risk assessment regardless of whether there was a formal risk assessment already in existence.

While formal risk assessments might consider risks on tasks and suitable control measures, it can’t always account for the hazards

SMENT SG World Ltd. Tel: 01270 588 211 E-mail: [email protected],ASSES FORM:No. 20093506200001 - 03/18 IC RISK DYNAM HS FM 0017 Date: faced, especially those faced by maintenance employees in break WO Number: No Plant location: Yes Yes No Task: Before you start circle the appropriate box down situations. The dynamic risk assessment tool allows them to Yes No Yes No Do I fully understand the brief for the task that I have been asked to do? Yes No 1. THINK through the task Are all sources of energy isolated sufficiently? Is LOTOTO done? No Have a clear plan in mind Yes take account of unusual hazards and importantly, helps them to Have I got necessary documentation and permits for the job? Do I have the relevant, safe and compliant tools and equipment for the task? Do I have right PPE I need to complete the task safely? 2. LOOK for the exposure Is the working area and environment safe and suitable? No co-activity risk? How and where the work is done? consider any co-activity which might not have been present when If you answer NO to any of above, take the required action. If in doubt contact yourdli nSupervisorg l han A work instruction, existing risk assessment or method statementManua may be out of tion l or vibra date, please STOP and take 5 steps backp o rand fal 5 minutes to dynamicallyNoise assess any the risk risk and take appropriate action Stolip /tensureri safe working. Non inclusive hazards t r fumes examples to TICK: m heigh Dust o 3. ASSESS Fall fro bject on Vehicles Collision/ Overturning flying o Radiati the formal risk assessment and SSOW were produced. What could happen if things get out of control? Falling/ ty proper losion o plant/ Hazardous substances/ Asbestos / fire exp Risk t Heat others s you or Ergonomic/ Poor posture d space Risk to Confine wning Stored energy/ Live electricity a or dro 4. TAKE precautions Asphyxi Remove impediments to safety Nip/ pinch points, sharp edges Circle residual risk Adverse weather/ temperature HR MR LR back page for instructionControl measure and definitions. HR The form follows five easy steps that help to ensure the team Please complete below assessment for identified hazards and deployed control measure.MR See 5. DO the job safely LR HR Hazard MR have taken extra time to consider the risks in front of them before Watch for changing conditions and exposures LR

Comment: If residual risk is HIGH don’t proceed with the task and contact your supervisor jumping on the task. Yellow copy - Remains in the book I confirm that general safety has been maintained and residual risks are low or moderate to proceed with the task safely. I confirm risks and control measures communicated to working team. White copy - DRA Red box Print Name: ……………………………………………….. Signature: ………………………………………….. Revision 2 visit www.safequarry.com for more details or email: [email protected] 29 HIGHLY COMMENDED Successful Safety at Work’ alerts Work’ at Successful Safety on-Site and Safe Tour Managers Monthly process

All parts in finding solution of business involved all employees Buy-in and commitment from all. for environment A safer Over 3,200 submissions receied via the appOver 3,200 submissions receied since launch positive 20% of the submissions are observations safety behavioural Q2 by all employees out to roll to On target 2018 to plans adapted Communication incorporate key trends organically grow is flexible and can System ❍ ❍

BENEFITS: l l l l l l l l adopt is often unnoticed or unreported. The adopt is often unnoticed or unreported. captured be to enables this information system whole to helping the business as and shared, and learn. continually improve employees provides This Miss / Near – Hazard use reporting to with an instant and easy capability at their fingertips. During the trial, via the app in captured were hazards several system a paper-based where environments or impractical implement.was not available to the opportunityEach submission provides to action, and preventative proactive take positive, system The an accident. for the potential reduces is logged process that each stage of this ensures individuals. appropriate to and communicated reporting – Using the old system, Accident often reported 24 hours afteraccidents were limitations of the reporting due to the event report able to now are Employees capability. mobile any from an accident immediately that all essential and critical ensures This device. assist line management to is available information a thorough complete to and the SHEQ team investigation. was launched on 31st January newThe system It 500 users. 2017 to includes an interactive enablesThis management reporting system. track and reportmanagement to action taken to to identify trends. identified and issues any resolve DESCRIPTION Finning UK & Ireland initiated a company-wide a company-wide UK & Ireland initiated Finning analysis of the reporting safety of behavioural Itobservations, and near misses. wanted hazards submitted were few relatively understand why to The and diversity. of its size an organisation for employees that front-line analysis highlighted a reportingdid not have capability off-site, while identifying the limitations and inefficiency of its reporting paper-based system. traditional, furtherto it was decided research, Following into solution integrated a digital introduce line personel. front all mobile phone devices for the business Working with an external provider, a reportingdeveloped was concept which a period of six for 50 employees then trailled by ensured selection process pilot group The weeks. each from was a full representation that there Throughout market job function. sector and core fully involved were group the focus the trial, provided They and engaged in the project. which and suggestions continuous feedback the concept. in refining invaluable were 93 submissions had been the end of the trial, At reportingmade via the digital app compared 1,400 personal in the the circa with 85 from system. business still using the paper-based the paper-based from move decided to Finning concept. mobile reporting the digital to system also incorporate further would new The system opportunitiesdevelopment identified during this period. log their visual GPS enables users to system The attach photos, position, attach and annotate commentary. over voice videos and record email alertsManagers receive and a direct link to close out being able to Before submissions. any and preventive submission, the corrective any comments Any be recorded. to action is required the will then be forwarded to and/or feedback originator. key three functions are: APPs The employees observation – Finning’s Positive all industrywork across sectors both in the UK often presented are They and internationally. challenges health and safety with significant will individuals involved The whilst on-site. measures. control implement suitable safety solution they innovative and the safe However, What happened Why it happened Flow diagram of resources on the App of resources diagram Flow Transformation in safety reporting in safety Transformation UK > National Finning visit www.safequarry.com for more details or email: [email protected] 1113

WORKER INVOLVEMENT 30 26 WORKER INVOLVEMENT 1162 HIGHLY Dry silo mortar loading – driver assistance COMMENDED Tarmac Building Products > Mortars DSM > Croxden Quarry 2

DESCRIPTION ■ As the driver lowers the gantry and loading sock, the LED strips become red at both the entry and exit of the weighbridge. Drivers DSM Mortars held a team safety stand down event at Croxden Quarry. are therefore aware that the equipment is engaged with their The event brought together front-line operatives, hauliers, fitters and vehicle and not to move. engineering. They created a site hazard map based on all the activities associated with vehicle movements in different areas of the site. ■ Once ready to load the drivers put their keys into an electrically interlocked box next to the batcher’s office – the keys are only The area where drivers raised and lowered the gantry which allowed released once the loading sock and gantry are fully raised after them access the top of their vehicles was identified as the location for loading. persistent near hits and incidents. The gantry also showed evidence of damage from recent contact with the tankers. ■ A ‘mimic’ panel is located in the batchers office so the batcher can see the status of every item and whether it is safe for the driver to A check of the historical records and other incidents at similar sites proceed onto or off the weighbridge. over a 10-year period showed a trend of frequent impacts with the gantries and damage to this driver safety device. One incident had BENEFITS involved the replacement of the gantry due to the extent of damage. l New system has been well received An action group was formed to develop a solution that would prevent future collisions. Short term actions included a revision of the l No impacts since installation site inductions and introducing the policy of holding the driver’s keys l Safer for driver and operatives when his vehicle was being loaded. These actions helped to reduce the risks, it did not eliminate them. l Reduced repair costs for vehicles and gantry

The team then developed a light and drivers key control system to aid l Enhanced safety culture on-site both drivers and operatives to manage safe movements on and off the weighbridge. This involved the following features: l System now being rolled out to other DSM sites across the UK.

■ Green and red LED light strips were attached to the underside of the gantry, drivers can clearly see on entering the weighbridge if all items are in the ‘up position’ – lights green and safe to proceed.

■ The LED strips also indicate the bottom edge of the gantry to aid drivers positioning themselves under the loading point on entry

■ Improved visual assessment for drivers to assess whether their truck is too high

visit www.safequarry.com for more details or email: [email protected] 31 Bitumen, asphalt & contract surfacing sponsor BITUMEN, ASPHALT & CONTRACT SURFACING 1184 AWARD Reducing worker risk through automated inspection WINNER and testing during pavement construction Aggregates Industries UK > Nationwide 2 6 ON VIDEO

DESCRIPTION Before – manual testing The surfacing process requires the gathering of quality data both during and after the laying activity. This traditionally requires the presence of one or two technicians with each surfacing gang to gather and record the data. The data set includes laying temperatures, density, surface texture and surface profile, as well as weather and positional data.

Several serious incidents across the industry involving technicians led Aggregate Industries to review whether it was possible to change the testing process. The goal was to remove the requirement for on-site technicians, eliminating their exposure to a range of hazards.

Some of the hazards significantly increased during night working or in situations where visibility was reduced. The hazards included the following; Following extensive trials to confirm the accuracy of the information gathered, the AIT system is being deployed across all regions. ■ Proximity to live traffic BENEFITS ■ Proximity to construction vehicles l Fewer personnel involved in the paving process ■ Manual handling l Elimination of high-risk transport and pedestrian interface ■ Muscular-skeletal injuries l ■ Hot material interface Technicians removed from exposure to hazards

■ Trip hazards l The automated process is quicker and more efficient

■ Night working l Removes all manual recording and transfer of data

■ Lone working l Equipment manufacturers delivering a factory fitted solution

Working with MATtest Southern Ltd, a suite of new testing l Retrofit solution available for existing plant and equipment methods was proposed. In addition to removing technicians from the need to be on-site, the system would also improve asset l Data from factory-fitted and retrofit solutions is consistent management data for customers and compliance with Building l Releases skilled operatives for redeployment in period of skill Information Management (BIM). The new system was trialled in shortages collaboration with Aggregate Industries clients on a few contracts. l A safer environment with fewer incidents. The system included the following elements:

■ Equipping pavers with GPS, automated weather stations, infra- red (IR) sensors and a data recording unit gathering essential, quality information at an appropriate sampling rate.

■ Equipping rollers with GPS and IR sensors which linked to the paver to help manage the compaction process, record the rolling temperature and the number of passes.

■ Combining the roller and paver data to provide a complete record of the laying process with zero risk to technicians.

■ Equipping a survey vehicle with GPS, a laser scanner and a video recording capability. This provides a complete picture of the pavement surface profile and texture with improved accuracy. It also provided a rolling straight edge testing on the completed pavement. These activities are traditionally manual 32 operations with elements of lone working. BITUMEN, ASPHALT & CONTRACT SURFACING 33 ON VIDEO UP RUNNER 1

Eliminates risk of paddle movement due to stored or applied stored due to riskEliminates of paddle movement force serious injury for been removed has Potential apply User friendly that is simple to system maintenance zero Requires Its new hazards any application does not introduce Industries leads world in the application of this safety Aggregate improvement could be applied world wide System in this procedure standard be used as a mandatory, Could application.

BENEFITS l l l l l l l l visit www.safequarry.com for more details or email: [email protected]

DESCRIPTION lockout system Driveline Engineering and Aggregate Industries UK > Astley Asphalt Plant and Aggregate Industries Driveline Engineering MixLock® mechanical paddle shaft paddle mechanical MixLock® Driveline worked closely with Aggregate Industries AsphaltDriveline worked closely with Aggregate was trialled MixLock® within the ensure Operations Division to Itindustry. been installed at various within Aggregate has now sites to concept through from system safety MixLock® The Industries. Element Analysis using Finite installation was independently tested manufacture and of design, safety guaranteed ensure (FEA) to application. The system involves a simple locking that can be installed plate involves system The procedures. using LOTOTO supply has been isolated once the power themrotates the paddle shafts, the caps from removes fitter The using isolating is then secured plate The until he can install the plate. pins and padlocks. Driveline designed, patented and manufactured the MixLock®. A the MixLock®. and manufactured patented Driveline designed, the global asphalt production industrydevice that provides with a to be effective. lock-off guaranteed safety system ‘mechanical’ A range of ad-hoc methods are used to mechanically ensure paddle mechanically ensure used to A range of ad-hoc methods are these include using a chain block and tackleropeshaft or lock-off, lifting crow a paddle shafts, paddles shafts, slings tied to around a flat metal gears and even between synchronizing bar wedged These paddle shafts. both mixer temporarily across bar tack welded a 100% guarantee can fail and do not provide ad-hoc procedures installation orTheir chamber. within the mixer of personnel safety further can create hazards. potential presence The only established industry upon lock-offThe to is procedure safety does this procedure However, the mixer. supply to the power isolate or energy to stored rotating due not lock-off the paddle shafts from chamber. within the mixer when personnel are an applied force Driveline Engineering identified that the asphalt industryDriveline Engineering worldwide procedure safety proven an established mandatory, did not have The lock-off must shafts. lock-offasphalt mixer ‘mechanically’ to the mixing chamber to personnel enter before be completed undertake tips of paddles, duties such as replacement maintenance plates. and wear 1181 HIGHLY HIGHLY COMMENDED COMMENDED Doors in situ New monitors alert Text Significant safety hazard hazard safety Significant old for has been removed bitumen tanks cost – was low system The £5K filled circa warning Automated system Exploring whether system could be used in other bearing applications e.g. failures. Door cradle BENEFITS l l l l This fault arose because it was possible for the main contactor to possible for because it was fault arose This supply was locked the power where itself in a position fail and weld permanently circuits. on, overriding all the other safety that a recognised it was Once the fault had been identified, quickly. and implemented be designed need to solution would tank was installed that monitors a month, a system Within from in the tank deviates If the temperature temperatures. will the system points, the pre-set temperature high and low triggertext a flashing light and send out a sound a siren, alertto has been further system This enhanced by personnel. relevant incorporating it within the trace heating at the Sheffield plant. System design System 5 Mountsorrel Quarry > Mountsorrel Significant reduction of risk to fitters when workingreduction when of to fitters risk Significant on doors replace doors to fit and efficient operation More simple solution cost and Low other similar situations. can be applied to Principle visit www.safequarry.com for more details or email: [email protected] DESCRIPTION BENEFITS DESCRIPTION Bitumen system telemetry protection system Bitumen system telemetry CEMEX UK > Local Asphalt Sheffield Asphalt loadout door cradle loadout Asphalt Tarmac CEMEX undertook an investigation following an incident in which CEMEX undertook following an investigation nearly the bitumen temperature, over well a bitumen tank went its flash point. reaching of the bitumen tank heating study identified that the design The go over them to tanks could allow aging on all CEMEX’s systems it was possible that the tank would If this occurred, temperature. to worst-case in the scenario, or, fire catch the tank to for rupture, with bitumen. area the surrounding explode and cover twelve-month that, in the previous also found investigation The tank a bitumen had been two other instances where there period, this had been picked plant up by Fortunately, had overheated. reached. were criticaltemperatures staff before l l l l The load out doors on the KVM plant at Tarmac’s Mountsorrel Tarmac’s KVM load out doors on the The plant at task is difficult and exposes the This Quarry be replaced. needed to to risk.to assist fitters available maintenance tool was No special doors. and fitting of the with the removal at the quarrythe fit to a cradle that was shaped Fitters designed enables which cradle can be pickedThe a telehandler up by door. support to position into be easily moved and hold the the door to Work is removed. or door in place whilst it was either being fitted underwaynow further design. on this to improve 1132 1122

BITUMEN, ASPHALT & CONTRACT SURFACING 34 BITUMEN, ASPHALT & CONTRACT SURFACING 35 HIGHLY HIGHLY COMMENDED COMMENDED Risk of working at height reduced Risk of manual handling reduced tripRisk or fall reduced of slip, blockage bin storage lost due to No production in cold weather in finding solution. involvement Employee Risk of a fire significantly reduced Risk significantly of a fire measures and physical new systems by protected better Plant carrying operators access for tasks Safer out maintenance to fire due Reduced downtime risk of significant all. for environment Safer BENEFITS l l l l l can freeze and stop flowing. To clear the blockage, would be staff flowing. and stop can freeze clear to access the bins and attempt work at height to to required and tools. techniques it using manual handling safety to improve how on consulted were Staff and contract fitters in this working area. contractor) an vetted Electrical, (an Avetta Working with Cross trace frame with thermostatically cladded controlled insulated, heating was installed. BENEFITS l l l l l To prevent any recurrence, remedial work additional included remedial recurrence, any prevent To alert to walkwayshigh-level probes the plant and extra pyrometer about the conditions in variousoperator parts of the plant. be the baghouse can now In being detected, of a fire the event by shutting door and upstream, a newly installed fire by isolated the RAP drier. down electric a photo by complemented cell two additions are These form of a solution in the detect plus a long-stop nakedto flames, extinguisher fire system. water-based 3 visit www.safequarry.com for more details or email: [email protected] New walkways 3

New probes DESCRIPTION DESCRIPTION

Fire protection project Tarmac Ltd > Ipswich

Trace heating for cold feed bins for cold feed heating Trace Sheffield > Local Asphalt CEMEX UK Tarmac at Ipswich had a serious high-level baghouse fire, believed at Ipswich had a serious baghouse fire, high-level Tarmac cost fire The an accumulation of soot in ducting. be due to to of the design The months of lost production. many the company drier the high-level two driers, unusual in having plant is relatively had insufficient constructed, plant, as originally The handling RAP. walkway so internal ductwork access, could not be inspected via hatches. At CEMEX’s Local Asphalt Sheffield plant, the traditional, steel Sheffield plant, the traditional, Asphalt Local CEMEX’s At The using a loading shovel. above filled from bins are framed feed under flow to sloped sides of the bin then enable the aggregate in very conditions the material cold weather However, gravity. 1175 1136

HIGHLY COMMENDED High potential hazard of workingHigh hazard potential shaft to duringin close proximity removal using by halved downtime Plant this in-house approach £96K achieved of circa saving Cost this approach by be used on can procedure This other similar Ammann coating plants. One cladding panel was removed, removed, One cladding panel was the shaft be pulleyed allowing to an outside the building onto the above platform improvised skip the two track utilising sets of A 16-tonne plate-mounted rollers. the lower crane was used to The worn shaft the ground. to to was then reversed procedure shaft. install the replacement BENEFITS l l l l ■ For more information you can go to can go to you information more For www.jpmediatraining.com or email james@jpmediatraining or email www.jpmediatraining.com James Pearce has been a BBC broadcaster for two decades and is now one of the UK's leading decades and is now two for has been a BBC broadcaster Pearce James with agency then has worked his own and since in 2013 He founded trainers. communications England football The and business executives. of the country's best-known athletes many country's of the top works closely with many but he also clients, his highest profile are teams 100 CEO's and other business leaders. FTSE of the of conducting with all five including twenty interviews, years James uses his learnings from will that communications effective on a masterclass deliver to Ministers, Prime UK's most recent working anybody is aimed at This important any conversation. approach you that change the way presentations meetings, take into skills will be able to are you These that of business. in the world sales or you increase could help machine. It next the coffee to conversation or just the snatched key messages and prepare to how you James will teach interdepartmental relationships. improve You will also learn the art of handling difficult them with maximum effect. deliver to then how questioner – an essential without losing the trust of your or clients colleagues questions from robust. these skills It so much more a business becomes staff have When of us. so many for tool will quickly James is understand why You is an entertaining session. and extremely educational skills of his clients. the communications of so many with transforming credited the 2018 Health and Safety at Panel on the Communication his appearance Following when they MPA who mentions to anybody a 15% discount is offering James Conference, contact him. JP MEDIA TRAINING A new steel plate was added to the floor surrounding the the floor surrounding was added to plate A new steel the remove jack could be used to so that a trolley mixer, gearbox. comprisingA system of a supporting frame of angle-irons was the internal base of the mixer, to fabricated and welded take of the shaftused to the weight (minus paddle arms & tips) both end bearings be removed. thus allowing to DESCRIPTION Asphalt plant mixer shaft replacement mixer shaft plant Asphalt Quarry > Carnsew Colas Ltd The foreman fitter at Carnsew Quarry, demonstrated an innovative Carnsew at an innovative fitter Quarry, demonstrated foreman The shaft 900kg, weighing mixer a 2.5 metre changing to approach on the mixer be present to personnel needing without any platform. task was necessaryThis abnormal on one shaft due to wear directing due principally filler chute a poorlyto bearing, designed constantly abrading the shaft one of the bearings, filler onto has since been re-aligned. chute This bearing. a two-week advised that Ammann, the Swiss plant manufacturer be necessary. would shutdown effectively decided the task could be more fitter foreman The performed procedure; in-house using the following ■ ■ visit www.safequarry.com for more details or email: [email protected] 1183

BITUMEN, ASPHALT & CONTRACT SURFACING 36 BITUMEN, ASPHALT & CONTRACT SURFACING 37 HIGHLY COMMENDED A 5-fold increase in the number of customers using the facility in the number of customers increase A 5-fold the platform utilising vehicles and larger Almost all hotboxes sheet vehicles access to safe Drivers have the reduced risks cage has significantly Safety use a harnessDrivers do not need to system all A quick and simple sheeting solution for Reduced the risk of injury a vehicle from jumping down from test to vehicles access different can safely Technicians Reduced height risk of fall from other sites could be applied to System sheeted. properly users if vehicles other road for Safer Light beams to prevent the unit from descending onto descending onto the unit from prevent Light beams to beneath. someone stood of operating use outside unauthorized prevent to Timers hours. Maximum mis- and lifting height capacity prevent capped to use. 3 BENEFITS l l l l l l l l l l l 3. 4. 5. to A three-step format guide using a simple diagrammatic In customers. to understanding was provided universal promote addition, a one-to-one at induction and training session was given an open day. visit www.safequarry.com for more details or email: [email protected] Express Asphalt Darwen Express

Traffic light and reversing beams, the platform can only be the platform beams, reversing light and Traffic used when parked safely. in the correct position are all gates ensure sensors to Proximity operation. before DESCRIPTION 1. 2. Additional protection is afforded from a multitude of fail-safe a multitude of fail-safe from is afforded protection Additional including: features The system is wholly controlled by the customer who reverses into into who reverses the customer by is wholly controlled system The height the required to the platform raises caged bay, a dedicated carry inside to and then steps of their vehicle out tasks safely. To provide a sheeting system for these customers at Darwen, these customers for a sheeting system provide To Industries and InvertechAggregate and built Solutions designed using was powered This an adjustable height, sheeting platform. lift a fork lift from mechanism that has been salvaged a hydraulic truck. At Express Asphalt, Darwen, there is a substantial ‘collect’ trade ‘collect’ Darwen, Asphalt, is a substantial Express there At the majority of which do not have of all sizes, comprising vehicles In of 7.5 tonne drivers the past, many sheeting systems. on-board clambering the backs of their vehicles. spotted onto were vehicles the up onto drivers climbing biggest riskThe identified was from asphalt spillage off the hinged metal sweep to ‘Hot Boxes’ of tops it was only assist with sheeting, was a stand to Although there lids. not used by was and therefore, vehicle of larger one size ideal for drivers. many The issue of safe sheeting of vehicles has a long history has sheeting of vehicles issue of safe dating The industryThe this risk through has addressed decades. back several varyinga variety sheeting systems, netting or from of on-vehicle others the ground, from deployed some manually metal lids, even of a button. via the touch fully automated

Adjustable height sheeting platform sheeting height Adjustable > Industries UK Aggregate 1210 HIGHLY COMMENDED 5 Outdoor for drivers screens Reduced risks associated with exposure to falling materials and to Reduced risks with exposure associated burns accuracy improved Loading significantly has access their vehicles people to necessityHuge reduction in the for improved have times on-site Turnaround workplace congestion and improved transportReduced site management invaluable proved text option has already free The Reduced airborne levels hot material exposure dust or rogue their cab whilst under the mixer No incidences of drivers leaving customers from feedback Very positive all. for environment A safer

3 BENEFITS l l l l l l l l l l Target box shown on vehicle shown box Target DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Customer loading screens loading Customer Asphalt Darwen > Express Industries UK Aggregate At Express Asphalt Darwen, Asphalt concerns Express one of the biggest safety At customers and reports of near misses during 2016/2017 involved position whilst under the check their vehicle exiting their cabs to risks of injury significant presented falling material This from mixer. very (up to to and exposure two hot temperatures tonnes) (up to 170°C), fumes. dust, noise and vehicle the onto climb would In customers of incorrect the event loading, creating the product, manually relocate to back of their vehicle falls from with manual handling, associated hazards to exposure height and hot materials. Darwen,At is stationed at the opposite operator the mixer means of line of sight or side of the building with no direct surveys that Customer revealed communication with the driver. difficulties as visual drivers presented the loading tunnel on-site feedback the darker into Customer daylight tunnel. from moved be improved said that the acuity needed to of the loading zone door was but they also needed an indication of when the mixer of their cab or the safety leave open so that they didn’t about to their vehicle. move to install a staff brainstorming session it was decided Following from customer the visible to that were LED screens two outdoor their cab. is linked a high definition camera located to upper screen The the rear onto door which points directly the mixer adjacent to Box’ ‘Target is a On the screen under the mixer. bed of a vehicle the load will drop. exactly the driver showing where revolutionary time plant real provides screen lower The second warning of the impending a five giving information can screen This clock. of hot material via a countdown discharge There with the customer. visually communicate also be used to pre-set several are messages which can be sent at the click of a unusual situations such as text option for along with a free button their vehicle. in or around warning about a hazard the driver green, flashes bright the screen Once loading is complete, to is finished and that it is safe indicating that the loading process out and sheet up their load. move 1209

BITUMEN, ASPHALT & CONTRACT SURFACING 38 Index Permission to tip Working withcontractors Working Taking outofedgeprotection theguesswork Thinking outsidetheconfinedspace Thinking Silo ground level testing eliminates confinedspacehot work Penta tumbledrumchute wear plate improvements Safe bodycleaning accessplatform for lorry Maerz Kilns wet gasscrubberimprovements Kilns Maerz Elimination ofmanualhandling&pinchpointinjuries Tower lightraise/lower Field conveyor cleaningscoop Innovative slidingpumpbase Innovative Real engagement! Real Safety contract culture to Dishforth ontheA1Darrington Contractor / haulier induction interactive video Contractor /haulierinduction ‘Stand upfor Safety’ campaign Aircrete –void guards loadsecurity Tyre telematics –haulierengagement Safety partnership Preventing vehicle tipovers health issues Educating theworkforce onsilicaandotherwork-related handling andconcrete cutting program reducesTrief manual factory andKassel risk Managing pedestrian Vending machinefor PPE testing during pavementtesting during construction through risk automated and worker inspection Reducing loading–driver assistance silomortar Dry Transformation insafety reporting assessment risk Dynamic Customer loadingscreens Adjustable heightsheetingplatform Asphalt plantmixer replacement shaft Fire protection project Trace heatingfor coldfeed bins protection system Bitumen system telemetry Asphalt loadoutdoorcradle system lockout MixLock® mechanicalpaddleshaft OCCUPATIONAL HEALTHAND WELLBEING CONTRACTORS’ ENGINEERINGINITIATIVESSAFETY BEHAVIOURAL SAFETY, CULTURE SAFETY &LEADERSHIPREDUCINGOCCUPATIONAL ROAD RISK Title WORKER INVOLVEMENTBITUMEN, ASPHALT &CONTRACT SURFACING l l l l l l l l l l l l l l l l l l l l l l l l Video Link 10 11 11 13 12 14 15 15 17 18 19 20 21 23 22 24 27 26 25 28 32 31 30 29 38 37 36 35 35 34 34 33 8 7 6 9 Page number 1145 1236 1156 1232 1176 1111 1148 1182 1149 1245 1191 1180 1220 1210 1147 1234 1213 1233 1168 1133 1246 1178 1137 1157 1184 1162 1113 1118 1209 1210 1183 1175 1136 1132 1122 1181 Entry number 3 ,5,6 1,2,3 1,2,3 3,5,6 2, 6 2, 5 2, 6 1,4 2,5 2,6 3,6 2 2 3 3 6 4 4 6 4 2 1 3 3 1 5 1

Fatal 6 l l l l l l l l l Asphalt & Coated stone l l l l l l l Quarry,recycling and waste l Readymix & Mortar l l l l l Concrete & Precast l l Cement & lime l l l Contracting l l l l l l l l l l Transport & delivery l Marine l l l l l l Company wide l l l Contractors l l l l l l l l Dust and fumes l l l l l l l l l l Maintenance l l l l l Guarding & isolation l l l l l

TRANSPORT INITIATIVES Mobile plant l l l l l Hazards & incidents l l Risk Assessments

l l l Safer processing l l l l Induction & training l l l l l l l l l l l Manual handling & storage & HAVs l l PPE and emergency equipment l l l l l l l l l l l Working at height & confined spaces l l l l l l l l l Traffic management l l l l Mobile technology, videos, camera, radio 39 l l l Health and wellbeing Health and Safety Working Groups

Lime Gavin Kinson Hanson UK Helen Wallace Lhoist UK Ltd Ian Tomlinson Hanson UK Andrew Graham Lhoist UK Ltd Mark Goslin Tarmac Ltd Darren Presgrave Lhoist UK Ltd Darren Stokes Tripod Crest Lindsay Downes Singleton Birch Ltd Ian Gibson Mineral Products Association Andy Howe Tarmac Cement & Lime Ltd Malcolm Simms Mineral Products Association Graham Cooper Tarmac Cement & Lime Ltd Kevin Stevens Mineral Products Association Ian Gibson Mineral Products Association Bitumen Safer by Partnership Matt Avery Aggregate Industries Rhys Bush Avetta Jason Barker CEMEX UK Materials Glyn Barnes Bam Richie Ian Burrows Eurovia Roadston Paul Mack Barry Wood Plant Andrew Cox FM Conway Andy Taylor CEMEX UK Gary Dowell Hanson UK Grahame Thompson Clark Contracting Arnold Marsden Tarmac Ltd Alan Dawson D&C Engineers Gary Schofield Total Ian Knott EPC-UK Transport Working Group Darryl Hodgett Finning (UK) Bradley Etheridge Brett Group Jason Moore Hope Materials Robert Wilkinson CEMEX UK Roseanne Hayward MPQC Dominic Day Day Group Jason Craig QUBE Electrical Maintenance Engineers Adam Goode Erith Richard Hotchin QUBE Electrical Maintenance Engineers David Fry Hanson Richard Solly Rema Tip Top Jay Laverick Hargreaves Group Howard Austin Roltech Engineering John Warner Hills Group Ian Jones Stokey Plant Hire Peter Parle FM Conway Ian Gibson Mineral Products Association Trish Jagger MP Skills Kevin Stevens Mineral Products Association Kevin Wilson MQP/Hanson Occupational Health Paul Needle Smiths Bletchington Peter Luxmore CEMEX UK Operations Sean McGrae Tarmac Ltd Craig Buttenshaw CPI Mortars Ltd Lee Downer TJ Transport Marian Garfield Hanson UK Jerry McLaughlin Mineral Products Association Helena Robinson Hope Construction Materials Kevin Stevens Mineral Products Association Melanie Brewster IDC Leadership and Workforce Engagement Steve Ford Sibelco Europe Chris Leese CEMEX UK Philip Bason Tarmac Ltd Andy Taylor CEMEX UK Kevin Stevens Mineral Products Association Tyrone Partridge Day Group Cement Mike Cowley FM Conway Mary-Ann MacInnes CEMEX UK Cement Andrew Cox FM Conway Carl Platt CEMEX UK Cement Nigel Clamp Hanson UK Graham Dunwell Hanson UK Andy Price Sibelco James Breen Hope Cement Ltd Kevin Stevens Mineral Products Association Meirion Webber Kerneos Limited Performance Statistics Andy Jones LafargeHolcim Andrew Taylor CEMEX UK Operations John McNamara Lagan Cement Group Tyrone Partridge Day Group Karen Farr Tarmac Ltd Paul Lacey Hanson UK Ian Gibson Mineral Products Association Marine Contract Surfacing & Asphalt Steve Davies Aggregate Industries Alan Barrett Aggregate Industries Tom Longland Aggregate Industries Mark Wheeler Aggregate Industries Nigel Reeve Britannia Aggregates Mark Fisher Breedon Aggregates Steve White Britannia Aggregates Dave Lewis Breedon Aggregates Kurt Cowdrey CEMEX UK Marine Scott McDonald Breedon Aggregates Ken Hunter CEMEX UK Marine Russell Spooner Brett Aggregates Mark Williams CEMEX UK Marine Jason Barker CEMEX UK Rod Lafargue Hanson Aggregates Marine Jon Burton CEMEX UK Sam Phillips Hanson Aggregates Marine Phill Beaumont Colas Ltd Gordon Tuck Tarmac Marine Wayne Tomlin FM Conway Bruce Bradley Tarmac Marine Brett Coupland Eurovia Keith Marshman Tarmac Marine

40 Building the connections that build the world

Avetta delivers a SaaS-based platform that mitigates the unseen risks of outsourcing, fostering sustainable growth throughout the supply chain. Through a proven vetting and evaluation process, Avetta is able to create dependable connections between clients, suppliers and contractors. For we believe industry and commerce are built on trust. When you believe in the people you work with, amazing things transpire. Industries grow. New technologies are born. And progress becomes inevitable.

Let’s connect at avetta.com (UK) +44 (0) 1628 450 400 (US) +1 949 936 4500 Download the free MPA Apps

MPA Safequarry App MPA Safeprecast App MPA Driver's App

AM AM AM

All the videos highlighted in this guide can be watched on your mobile devices using the Apps or via the MPA YouTube channel www.youtube.com/MineralProducts1

For info call MPA +44 (0)20 7963 8000 www.safequarry.com

For info e-mail [email protected] or call +44 (0)116 232 5170 www.safeprecast.com

Mineral Products Association Tel 020 7963 8000 Gillingham House Fax 020 7963 8001 38-44 Gillingham Street [email protected] London www.mineralproducts.org SW1V 1HU www.safequarry.com

The Mineral Products Association Written by Daybreak Communications Ltd, Winchester is the trade association for the Designed by Generate UK aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and Managing editor: Kevin Stevens, MPA silica sand industries.

Printed on paper and board which is totally chlorine-free and © Mineral Products Association 2019 produced from pulp from sustainable forests.