Sharing good practice 2019 / 20 WAYS TO MAKE YOUR WORKPLACE HEALTHIER AND SAFER - ELIMINATING ‘THE FATAL 6’

ENTRIES FROM THE MPA HEALTH AND SAFETY AWARDS

AVETTA

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3M.co.uk/EEP-100 Achieving Zero Harm Working with MPA to improve Health and Safety in 2020

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 2020. 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 by 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 and Support the CLOCs and FORs initiatives British Precast Health and Safety Awards, then share the resulting Best Practice Guide MPA Cycle Safe Campaign Supporting l Send your incident alerts, toolbox CLOCS Standard STAY talks and other info to MPA SAFE l Utilise QNJAC H&S guidelines and other guidance via safequarry

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

The theme of the 2019 MPA Health and Safety Conference was 'Clearer, Simpler, Looking forward Smarter'. The 'Sharing good practice' As a result of the disruption created by COVID-19, MPA decided to guide 2019/20 is an exemplar of this. defer the H&S Awards for 2020. However, the time has been used The entries demonstrate some simple to review and update the process for organisations submitting but innovative ways of eliminating entries. This autumn, we will be launching a new series of forms for hazards in the workplace or clever submissions to the MPA H&S Awards. The process has been updated solutions to problems achieved by based on feeback from both members and judges. It has been individuals working together with a designed to make it easier to submit entries and provide greater clarity of purpose, to make their work clarity and relevance for all those involved. environment safer. I look forward to the H&S Awards in 2021 when hopefully, we will The industry’s agreement to focus its energies and resources on see increased levels of entries reflecting both the extended period ’The Fatal 6’, those areas which generate most of the high consequence between events and a more efficient process. hazards in our business, reflect a strategy that is clear and simple. A high proportion of the entries included in this guide are mitigating hazards associated with one of 'The Fatal 6' themes. In several of the entries a serious incident was the genesis for the innovation described. 'The Fatal 6' Support 'The Fatal 6' initiative by reviewing and acting on Many of the innovative solutions and new processes highlighted in these high consequence hazards within your organisation: this publication can be adapted or applied to a wide range of other 1 Contact with moving machinery and isolation organisations. They will make a material difference to the safety, health 2 Workplace transport and pedestrian interface and wellbeing of everyone working within the mineral products industry. 3 Work at height I urge you to share this publication with your colleagues. 4 Workplace Respirable Crystalline Silica 5 Struck by moving or falling object Nigel Jackson, Chief Executive 6 Road Traffic Accidents Sponsors 6 MPA would like to thank the suppliers to the industry who have sponsored both our awards ceremony 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 – O'Donovan Waste Disposal Ltd. Trophy sponsored by 3M The John Crabbe Trophy for outstanding permormance in Health & Safety: Winner – Tarmac. Trophy sponsored by Avetta 140 entries from 25 companies – MPA members, contractors and suppliers: AG (Acheson & Glover) F M Conway Lhoist Quinn Building Products Aggregate Industries UK Ltd F P McCann Mansfield Sand Co Ltd Roche Manufacturing Ltd Brett Group Finning UK & Ireland Marshalls Stanton Bonna Concrete Ltd Brilliant Ideas Ltd Forterra Building Products Martin Engineering Ltd & Tarmac Cemex UK GRS Bagging Singleton Birch Ltd Terex Colas Ltd Grundon Sand & Gravel Ltd Myers Group Day Group Hanson O’Donovan Waste Disposal 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 2019.

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

Contractors’ Safety 6 Occupational Health and Well Being 24

Sponsored by Mentor Training

Engineering Initiatives 8 Worker Involvement 27

Sponsored by Hycontrol Sponsored by LKAB

Behavioural Safety, Safety Culture & Leadership 15 Bitumen, Asphalt & Contract Surfacing 32

Sponsored by Eurobitume UK

Reducing Occupational Road Risk 18

Sponsored by EPC-UK Index 35 Transport Initiatives 21 Health and Safety Working Groups 36 Sponsored by John Brooks TMR

visit www.safequarry.com for more details or email: [email protected] 5 ON VIDEO AWARD WINNER – The site team and contractors work team site The – ‘Collaborative’ that everyone safe ensure to remains together – Effective use of electronic media developed media developed use of electronic – Effective ‘Ambitious’ staff initiative through - The site team are committed to maintaining their to committed are team site The - ‘Proud’ good practice of contractor management System was shared across Tarmac as a demonstration as a demonstration Tarmac across was shared System of good practice with and supervising when engaging contractors

Employees and contractors working together to achieve safer and contractors workingEmployees safer achieve to together working environment values Tarmac’s Initiatives reflect ❍ ❍ ❍ ❍ l l 4 3 2 Contractors’ safety sponsor safety Contractors’ 1 Ravelrig Quarry > Ravelrig A reduction in the number of near hits logged against contractors on-site accidents recorded Zero documentation to all relevant have now Contractors undertake tasks Recording both positive and negative feedback and getting feedback and negative both positive Recording and improvements new initiatives safety to ‘buy in’ them to adopt the encouraged the contractors example to by Leading as employees same standards and monitoring of in the control assisted All employees ‘One team’ contractors acting as carrying management team The out contractor task audits.

BENEFITS DESCRIPTION visit www.safequarry.com for more details or email: [email protected] l l l Statistics show that contractors are four times more likely to have likely have to times more four that contractors are Statistics show an accident than an employee. Ravelrig quarry workingpride a safe in maintaining take team great site contractor that management recognised team The all. for environment Tarmac communications between improving could be enhanced by in ‘Best Practice’ achieve was set to A goal and contractors. employees contractor management and active supervision. enhance the to introduced were A wide range of initiatives collaboration. with contractors through relationships included:These ■ ■ ■ ■ a wide range of checks duringThe the task audit could cover the suitability of the policies such as the application of LOTOTO, The risk permits assessments and work. to using, they were tools evidence of monitoring the levels on excellent provide audit forms and supervision work being applied during the contractor’s supervisor the task audit and contractor sign Tarmac The activities. agree report necessary, acknowledge where to and, the findings on corrective actions going forward. an iAuditor administration of the audit was made easier by The It the assistant quarry by App developed enables the manager. using the App which be completed contractor task audits to use on tablet for maintenance was installed on the company copies of the audit reports be App also enabled hard to The site. reference. for and filed downloaded near record was used to system On Line (SOL)’ ‘Safety Tarmac’s It conditions. acts record was also used to and unsafe unsafe hits, The engagements and communications with the contractors. the contractor were task audits from corrective actionsresulting the to of adding pictures initiative The the system. also added to additional evidence of good excellent provided task audits forms practice being carried the contractors. out by Contractor management & active supervision & active management Contractor Tarmac 1366

CONTRACTORS’ SAFETY 6 CONTRACTORS’ SAFETY 1309 HIGHLY Management of delivery tankers on site COMMENDED Aggregate Industries UK > Sheffield Asphalt

DESCRIPTION

Sheffield Asphalt plant is a large site with high volumes of wagon movements. The liveried AI wagons are quite easy to control and see as they are always in full view of either the plant or weighbridge.

However, AI had an issue with the daily deliveries of consumables such as filler, fibre and fuel. These were delivered by external tankers whose drivers were not necessarily familiar with the site and procedures. The delivery points for these tankers are also out of view of the site staff.

In the event of a fire or emergency, it was possible that these tanker drivers could be overlooked when the alarm was raised, and the AI staff congregated at the assembly point. A robust system of registration on site was required that would enable AI to easily identify which tanker drivers were on site.

It was decided to use a swipe card system for these drivers, it was the same system that AI used for registering its own employees on site.

BENEFITS

l AI would know who was on site at all times

l AI could identify tanker drivers on site in an emergency

l Utilised existing system

l Safer site management 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

visit www.safequarry.com for more details or email: [email protected] 7 ON VIDEO AWARD WINNER

4 3 Improved functionality operator Improved for of equipment and safety and improved information Decisions based on real-time efficiency other applications of heavy equipment to Transferable very sites initial test positive. from Feedback Simplifies the operation of crushing and screening equipment of crushing and screening Simplifies the operation at all times Keeps in control the operator Increased visibility live-camera through views Ability intervene the cab to leaving without immediately tripsReduced and falls risk of slip, Reduced direct contact with heavy duty crushing equipment level at ground equipment dust and other moving to Reduced exposure BENEFITS l l l l screening jobsite. A video demonstration and testimonial from RJT from A video demonstration and testimonial jobsite. screening on https://vimeo.com/329759484. can be viewed Excavations l l l l l l l 2 Engineering initiatives sponsor initiatives Engineering DESCRIPTION visit www.safequarry.com for more details or email: [email protected] and screening OMNI by Terex revolutionises crushing revolutionises by Terex OMNI > Co. Tyrone > N. Ireland Terex GB > Dungannon The equipment used to crush and screen rock is located in busy and is located rock crush and screen equipment used to The Typically, hazards. potential with many environments challenging several managing for will be responsible operator an excavator clearing the stockpiles, tasks, loading the dump trucks and different supervising in the crushing and the multiple machines involved is the operator to available control process The process. screening restricted. is He often are and his views of the material flow limited undertaking a range of hazards exposed to In these tasks. particular, other falls or being hit by trips, the riskhe is exposed to of slips, his cab or operating the egressing when accessing and vehicles equipment. screening of the crushing and controls the and improve these hazards to minimise the exposure To OMNI. has developed Terex It is a efficiency of the operation, first-of-its that connectsnew, kind innovation and integrates enables the system The the machines and the site. the operator, all the activities with the crushing control associated to operator the comfort of his operation from and safety and screening reduced the risk has significantly innovation This cabin. excavator of injury. interfaceA tablet-based in the cabin of the excavator is located the crushing to Wi-Fi It is connected via alongside the operator. interfaceThe to enables the operator equipment. and screening on relayed information the equipment using integrated control The multiple camera views. remote, and from the tablet dashboard critical views such as material transition points cameras provide enables the system The each machine. and chamber inlets for maximise decisions to make and real-time to immediate operator could the operator For example, the efficiency of the operation. issues of the machine train when any material flow pause the entire arise keep or change settings to material specification in check. alerts provides when that indicate Terex OMNI by Additionally, is making adjustments and the someone on the ground process read-only to other personnel on the jobsite access ability offer to through their safety enhancing (such as the wheel loader operator), view of the operation. the remote will completely is that this system sites test from feedback The and efficiency the safety revolutionise of the crushing and 1384

ENGINEERING INITIATIVES 8 ENGINEERING INITIATIVES 9 ON ON VIDEO VIDEO UP HIGHLY RUNNER COMMENDED A better and safer working environment for all working for and safer A better environment of 80% A reduction in dust levels in most areas respiratory removed wear protection Need to 4 sites remaining planned for Similar system at site culture enhanced safety involvement Team Removes people from area of risk when opening/closing HV area people from Removes breakers circuit injury riskReduces potential of significant Reduces risk of fire that can be replicated. cost solution Low BENEFITS BENEFITS BENEFITS BENEFITS l l l l l l l l l The schedule and budget. to installation was completed The the only addition to The success. was an immediate system bulk water a trial internal, was an period, following system, supply if required. water a back-up provide container to ‘remotely’ from outside the substation. from ‘remotely’ 1 4 visit www.safequarry.com for more details or email: [email protected]

DESCRIPTION DESCRIPTION

Dust suppression Tarmac Building Products Ltd > Croxden DSM

Arc flash safety initiatives safety Arc flash Cement Plant Industries > Cauldon Aggregate The solution consisted of a water pump pressurised to 70 bar to pump pressurised of a water solution consisted The The mist was sprayed a fine mist. to the water which atomised of hundreds stretching piping system a polyurethane through The risk of water areas. the affected the plant to across metres borne UV lamps and a bacteria introducing was minimised by chlorination water system. Croxden DSM was selected as the trial because it had the site Croxden worked engineer with the site The issues with dust. most severe team The areas. the problem identify to managers and operatives system worked a mist/spray design with a specialist contractor to requirements. work within the site that would It was decided that the fine mist spray option provided the best It option provided was decided that the fine mist spray included This solution when taking consideration. all factors into system. with the mist-based legionella for the potential A company engineer was tasked engineer with identifying a suitable dust A company the risk of occupational reduce that would system suppression across work environment and safer a better ill health and create including researched options were Various the 5 plants operated. local dust extractionvacuum systems, and fine mist sprays. systems Tarmac Building Product’s dry silo mortar Building Product’s (DSM) business was Tarmac in the issues with the amount of dust produced significant having of levels showed working Dust monitoring results environment. In of worker limits. certain dust in excess exposure of plants, areas of dust actively see dust plumes and a covering it was possible to walls and equipment. on floors, A socket was installed and connected to each HV circuit breaker. breaker. A socket each HV circuit was installed and connected to with an umbilical with a pendant. was provided Each switchboard the sockets pendant could be connectedThe to on the circuit be switched to breakers the circuit allows system The breakers. It was recognised that this exposed operators to the risk to of It that this exposed operators was recognised serious injury incident, this flash had risk of an arc in the event A simple and low-cost be minimised. solution was designed to objective was to The at Cauldon. the team by and implemented be outside the to the operator allow that would devise a system breaker when the circuit from away 13 metres substation or circa opening or closing it. A risk analysis at Cauldon Cement Plant highlighted that a high- that highlighted Plant A risk Cement analysis at Cauldon (HV)Voltage risk task was the opening and closing of High circuit be opened or could only Almost all these units at Cauldon breakers. breaker. of the circuit the front on closed using the switch 1370 1304 ON VIDEO HIGHLY COMMENDED Reduction and lost production in downtime savings Short due to on investment payback popular with operators New system Reduced hazards manual handling manual handling on Meets UK standards Reduced trips risk and falls of slips, Reduced risk of injury whilst working with panels – trapping and pinching work environment A safer Maintenance significantly easier and more efficient easier and more Maintenance significantly a panel without assistance – reduced can remove Operators requirement resource After BENEFITS l l l l l l l l l l 1 The guard panels do not require a frame construction a frame panels do not require guard The is marked weight section clearly on each guard Panel veryLightweight panels are remove easy to paint no need to free, 100% corrosion are Panels plus) (10 years UV protection long life have Panels to fit most applications easily configurable Panels – on hook and hang system a mount using drop have Panels on handrails when removed panels can be stored and fully encapsulated bolts securingThe panels are the missing bolts) (No more system in the plastic guarding retained activities associated accommodate to can be designed Guards controls and trip wire greasing remote e.g. sound deadening qualities panels have The Before DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Light weight plastic guards weight plastic Light Hill Industries > Bardon Aggregate Aggregate Industries’ sand and gravel quarry and gravel sand at Newbold produces Industries’ Aggregate main conveyor The per annum. of one million tonnes in excess plant, has the processing material to that feeds pile, the surge from a high capacity belt. It very is subjected the to around high wear maintenance. tail end drum which is in constant need of routine planned gain access for to removed regularly are guards The barge replacing activities idlers, maintenance such as changing and skirts,boards bearings and pulleys and replacing cleaning, belt. the conveyor replacing and held in place manufactured of steel were guards original The and re-fitting Removal bolts. of these heavy guards numerous by associated hazards The was time consuming and labour intensive. the manual handling of heavy to related with these panels were slips and and awkward trapping and pinching of fingers, sections, panels on walkways. guard removed trips over plastic decision was takenThe trial to the Diacon, quick release, system The MES International supplied by system Limited. guard features: was installed and incorporates the following 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1305

ENGINEERING INITIATIVES 10 ENGINEERING INITIATIVES 1333 HIGHLY ON Bottom opening skip COMMENDED VIDEO Marshalls PLC > Marshalls Landscape Products > Sandy Works 2 4 5

DESCRIPTION BENEFITS

At Marshalls' Sandy Lane l The skip can accept all granular and block wastes concrete facilities the l waste such as rejected Forklift driver remains in cab – reduced risk of slips trips and concrete blocks, unused falls concrete and aggregates l Reduced exposure to dust is taken to holding bays for reprocessing. l Reduced risk manual handling injuries and crush injuries The waste products Before are placed in skips and l Bottom opening skips can be made to suit the capacity of the transported around the site by forklift trucks. forklift trucks

The original waste skips used on the site were hinged. This allowed l Modular design that can be integrated across the business the body of the skip to tip forwards discharging the contents of the skip into the waste bay. The driver would raise the skip on its forks and then pull a release handle allowing the skip to tip under gravity. Once the waste had been released, the driver would exit the cab and pull the skip back to the level, engaging the release handle which prevents the skip body from tipping.

The tipping body skip presented numerous hazards:

■ Slips and trips when exiting forklift truck to activate the release handle.

■ Slips and trips walking over the waste in the waste bay

■ Strains from the manual effort required to activate the release handle under load

■ Exposure to the airborne dust from the discharged waste

■ Driver exposed to elevated load when re-setting the skip onto the level

■ Potential manual handling, crushing and impact injuries from the moving body of the skip

The Marshalls’ Sandy Works team engaged with a local fabrication firm, P. H. Engineering Services Ltd, to find a better solution for the waste handling. They designed a square bodied, robust skip that employed a strong hinge at its base. The hinge allowed the whole base surface of the skip to rotate, effectively creating a door to release the waste products.

The skip is transported by picking it up with a forklift truck from the base. When in the area where the contents are to be discharged, the forklift truck places the skip on the ground, withdraws the forks from the base and then aligns the forks with two lifting points at the top of the skip. The forks are then raised lifting the skip upwards and allowing the hinged base of the skip to open discharging the contents. The driver then lowers the skip whilst gradually reversing, allowing the base to close. The skip is then picked up from the base for transporting back to the production facility.

visit www.safequarry.com for more details or email: [email protected] 11 ON ON VIDEO VIDEO After HIGHLY HIGHLY COMMENDED COMMENDED Operator no longer needs to access trailer – working no longer needs to Operator at height Reduced manual handling No interaction between pedestrian and vehicle breakages handling of gullies – avoiding and secure More injurypotential efficiencyImproved and speed of unloading Grab device could be used on other sites Eliminates injuries from cutting cutting injuriesEliminates from operation risksEliminates of trapping on forks work to no longer needs Operators forklift to in close proximity 1 forkliftOperation only requires and a 2 man task is now the across sites Hopper will be used on 19 other GRS Bagging UK BENEFITS BENEFITS l l l l l l These risks were mitigated by developing a new developing lifting by accessory mitigated risksThese were be enabled a gully to grab The working alongside a manufacturer. excavator. from the trailer bed solely using an offloaded directly l l l l l 3 DESCRIPTION Stanton Bonna Stanton were Ltd Concrete concerned about risksthe inherent with the associated unloading of gullies the trailer at the from An site. customer’s climb had to operator the trailer and onto 2 5 DESCRIPTION At GRS Bagging, there was a frequent was a frequent there GRS Bagging, At empty to one bulk bag requirement could beThis another. of material into reasons; the of different a multitude for the bag bag, product was in the wrong supplier bag the wrong was damaged, had been used. 2 Before either attach a sling or position the gully so that forks could be either attach a sling or position the gully so that forks high-risk activitiesinserted Both methods involve the spouts. into such as working and at height, manual handling of heavy products, the interaction and pedestrians. between vehicles visit www.safequarry.com for more details or email: [email protected] Gulley grab lifting accessory Stanton Bonna Concrete Ltd Bulk bag splitting hopper bag splitting Bulk GRS Bagging This activity traditionally involved the use of 2 forklift activityThis traditionally involved trucks and The One forklift be supporting3 operators. would an empty bag. second forklift be emptied raise the bulk bag of product to would the emptypositioned directly above until it was and manoeuvre put would an operator the two Once forklifts in place, bag. were open. his arm bag and slice the bottom under the suspended top the empty directly into flow the materials to allow would This in cutting task and had resulted hazardous was a This bag below. the use of knives,injuries trapping of arms from and fingers falling be hit by to the operator for the potential between the forks, working who was on-foot, in close product and the operator, the two forklifts. to proximity a specially design introduced GRS Bagging these risks, mitigate To an empty suspends which operator The on some forks bag hopper. forkliftThe then picks up and underneath located the hopper. are this new bag. into be discharged raises the full bag which is to a splitting of the hopper onto the top the full bag into He lowers open break blades on the splitter The on the inside. device located the bag waiting into fall freely the material to the bag allowing the newly filled bag from He can then pick up and remove below. of the hopper. the bottom 1382 1380

ENGINEERING INITIATIVES 12 ENGINEERING INITIATIVES 13 ON VIDEO HIGHLY COMMENDED

A safer environment for all for environment A safer chance of accidents and incidents and their associated Less costs efficient plant A more tasks Reduced when completing maintenance downtime reputation Enhanced company Enhanced morale of employees of company culture safety Reinforced RAPID mixers - Access lids are provided around the mixer the mixer around provided lids are - Access RAPID mixers and cleaning for the interior of the mixer access to easy for Hydraulic the lids struts aid opening and hold maintenance. casing, in the mixer open. An inspection is provided hatch visual provides This mesh inside. with hinged lids and wire inspection access. of the mix consistency whilst preventing maximum access for for allows plant platforms RAPID batching mixer; maintenance; on 4 levels, and cleaning, maintenance rotary hopper; all weigh access to conveyor; and aggregate stairs. is by levels Mixer and bucket interlock skip a Castell by access is controlled isolation. effective ensure to with controls system

BENEFITS l l l l l l l ■ ■ ■ increased measures Whilst the implementation of the control 10%, they have by approximately the final cost of the project will be reduced the potential risks that operators significantly exposed to. visit www.safequarry.com for more details or email: [email protected] 3

The need to access ‘danger zones’ on the plant to perform on the plant to zones’ ‘danger access need to The certain sufficient safeguards actions ensure and the need to in place and being used. were height when workingMinimising of a fall from the potential was levels Moving between different platforms. on elevated also considered out verticalDesigning stairs with All access is by ladders. vertical not permitted landings, ladders are incorporates This bucket skips. for platform A maintenance whilst and wash out chute the platform secure to gates safety position have gates safety The workingpersonnel are on it. the bucket being moved that prevent indication switches setting closed unless in a maintenance whilst they are

DESCRIPTION delivery system

Stanton Bonna Concrete New RAPID batching plant and concrete plant RAPID batching New ■ ■ ■ ■ When designing a new batching plant Stanton Bonna Concrete Bonna Concrete plant Stanton a new batching When designing the operating and maintaining of employees made the safety that during the they ensured this, achieve To priority. plant a top risks with the initial planning phase all the potential associated for was considered of control hierarchy The reviewed. plant were the and built into solution agreed each risk and an appropriate part be an integral to of the designed were controls The design. plant. It consideration: into took 1383 '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 1259 AWARD ON 'Quinn Safety Hub' WINNER VIDEO Quinn Building Products > Derrylin > Northern Ireland 1 2 3 4 5 6

DESCRIPTION ■ Feed all records into a centralised reporting system

Quinn Building Products, as part of Quinn Industrial Holdings, ■ Provide all information in real time, thus providing up to the has developed a new state of the art digital health and safety minute information on the progress of investigations and management solution as a major part of its Safer by Competence recommended actions policy. The system provides a cloud-based, centralised health and ■ safety management solution which is fully integrated for all Quinn Provide evidence of competency divisions. ■ Schedule and complete audits and inspections The project required significant financial and resource investment, ■ Track the performance of KPIs set for each Division collaboration with stakeholders in all Quinn divisions and the involvement of many external contractors. The outcome of this The development of the Hub promotes and encourages a culture work, which took over 12 months to complete, was the 'Quinn of accountability and continuous improvement. It enhances the Safety Hub'. The Hub consists of four modules that focus on the ability to monitor the progress and resolution of issues as they management of incidents, audits, training and contractors. arise in real-time.

The Hub includes a mobile App enabling the use of tablets or mobile phones to report incidents and hazards, complete audits, inspections and investigations and raise actions on site.

Traceability and accountability are achieved for each action raised by assigning it to an individual, giving responsibility to follow through, complete and close out the action.

1 & 2 - Health & Safety Management – Incidents and Audits

The Hub uses ‘Effective’ and ‘Learn Up On’ training management software, with the functionality to:

■ Report and investigate, incidents, near misses, hazards and positive observations throughout the organisation

visit www.safequarry.com for more details or email: [email protected] 15 BEHAVIOURAL SAFETY, SAFETY CULTURE & LEADERSHIP 1259 AWARD ON Quinn Safety Hub - continued WINNER VIDEO Quinn Building Products > Derrylin > Northern Ireland 1 2 3 4 5 6

BENEFITS

l An enhancement to our PDCA (Plan – Do – Check – Adjust) approach to risk management

l Improved compliance, as a result of better reporting and rigid compliance controls

l Assisted with the implementation and certification to OHSAS 18001 and ISO 45001 Health and Safety Management Systems

l Real-time reporting and visibility 3. Training l Traceability and accountability The Hub allows for the complete management of all training. Part of the Hub development included the integration of ‘Learn Upon’ l Interactive contractor management training management software to create a uniquely tailored system. l Full training management The Hub provides: l Removal of time-consuming paper-based reports, ■ Delivery of online video-based training, including inductions documentation and audits and toolbox talks. l Central location and ease of retrieval for all safety and training ■ Easy identification of employee and contractor current training information during internal and external audits status using a traffic light system l Evaluation of both divisional and overall company ■ Alerts for managers in advance of training expiry, allowing performance using KPIs them to schedule training in line with operational needs. l 2018 accidents and incidents greatly reduced overall versus ■ The ability to ensure compliance pre-Hub figures (2016):

4. Contractors ❍ AIR down 41%

The contractor module enables the company to: ❍ Reportable (3 Day +) injuries down 46%

■ Efficiently manage contractors. All contractor information ❍ Lost time injuries down 42% is now in in one central place: insurance, employee training l Auditors involved in certification have commented on its records, health and safety documentation, etc. positive impact ■ Always ensure compliance and traceability l HSENI’s Ken Logan, MBE, described the system as “a fantastic ■ Provide a self-serve option for contractors, who receive direct management tool for the senior managers within the notifications and access to upload their own information and company”. documentation l Other organisations across UK have requested information ■ Deliver induction training online via videos prior to contractors’ about the system arrival on site. l Enhanced safety culture throughout Quinns Hub Promotion l A safer working environment for all. The launch of the Safety Hub was heavily promoted externally through a news release, video promotion and social media campaign, and internally through the newsletter, intranet and face to face communications and internal training workshops. A video was used to emphasise the significance of the development and to add to the promotion of a safety-first culture. The visibility of the internal campaign has helped raise awareness of the importance of making health and safety a priority for every individual in the company.

16 visit www.safequarry.com for more details or email: [email protected] 261

BEHAVIOURAL SAFETY, SAFETY CULTURE & LEADERSHIP 1280 RUNNER ON 'Safety Savvy' roll out UP VIDEO CEMEX UK Ltd > National 1 2 3 4 5 6

The training is around a 4-hour safety discussion involving no more than 15 participants, this ensures a high level of participation from those involved. The participants are encouraged to tell stories about their own experiences and feeling, a very different approach to more traditionally based health and safety presentations than many participants were more familiar with. This approach helped participants to become very engaged.

The rollout of 'Safety Savvy' has taken place in 33 locations around the UK, reaching over 2,400 Cemex employees and contractors. Around 9,720 hours of safety savvy training has been completed across the UK. This will be an on-going programme.

BENEFITS

l 82% of the business has engaged with Safety Savvy

l The 12th month rolling employee LTI frequency rate has reduced from 0.5 to 0.2

l Total number of LTIs in the 12 months reduced from 7 to 2

DESCRIPTION l Safety Savvy recognised as having made a significant positive effect. In 2018, CEMEX UK was looking at ways to help every individual to become motivated about safety. The goal was for individuals to l Positive feedback from participants examine their behaviours in relation to safety, not just at work, but l Individuals have better understanding how they can affect an in all walks of life and recognise that safety is about ‘You’ wherever improvement in H&S you are, whatever you do. l Individuals have more confidence to “say something” or CEMEX UK developed its 'Safety Savvy' campaign and training intervene in relation to H&S based on a book by Andrew Sharman & Dr Tim Marsh - 'Safety Savvy'. l Demonstrates CEMEX’s commitment to H&S and the achievement of zero harm 10 volunteers, from around the country, went on a week-long 'train the trainer' programme. Exploring the best methods l Improved safety culture across the business. of communicating difficult subjects with potentially severe consequences. l The employee’s perception about the programme is summarised by this quote “A different approach really shakes A dynamic half-day training course was designed to raise things up, 'Safety Savvy' created a buzz and got people awareness of how our personal behaviour influences the health talking and thinking about safety”. and safety culture in our business. It looked at:

■ How to reduce reliance on luck and stay safe all day, every day

■ The Organizational, Social and Personal factors that influence safety

■ Say Something! – the importance and impact of speaking up for safety

■ Living, Loving, Laughing & Giving – the four keys to personal wellbeing

■ Making it personal – your commitment to being Safety Savvy

visit www.safequarry.com for more details or email: [email protected] 17 ON VIDEO AWARD WINNER Easily accessible course for drivers and hauliers Easily accessible course for deliveryConsistent of material up and followed monitored can be accurately Progress or updated be improved enables the courses to Feedback workforce. trained and safer Better BENEFITS l l l l l used as part of the driver’s Continuing Professional Development Professional used as part Continuing of the driver’s support and could be used to (CPD) section D4 Professional next FORS Audit. Development on the haulier’s receive to of 80% in order a score achieve to required Drivers are to required the certificate is driver is not met, the – if this score take again, ensuring understanding of the topic the test their total in question. that are question, those questions scoringby down is broken As This enables incorrectly can be identified. answered frequently areas. problem to address be modified to tests eToTS the future and business areas regions summaries for provides system The can therefore team logistics The the training. completed that have need further that may identify areas guidance. of 2018, Aggregate in September Since their introduction been 2,300 passes have and over Industries has issued 3 eToTS rolled training targets eToTS have the aim is to Ultimately, awarded. health adopting the latest of instil a culture all its hauliers to out to standards. and safety Industriesnumber of eToTS the increase plans to Aggregate Industries It Aggregate them out to available. will also roll incorporated that utilise haulage services, companies such as Concrete. London the link below: please follow see an example of the training, To https://docs.google.com/a/aggregate.com/forms/ d/1BVywYu21jWW-nyHIKmBer3ZiDHWGxMIYCpfJU2V 6 2 Reducing occupational road risk sponsor risk road occupational Reducing Poor or inconsistent cascade of information from the haulier to haulier to the from cascade of information or inconsistent Poor the driver of the training of the coverage No measure individual drivers training kept of for No record No check of understanding at the end of each talk health of evolving awareness concernsto the as Significant amongst the workforce protocol and safety

DESCRIPTION visit www.safequarry.com for more details or email: [email protected] eToTs Online Training eToTs Hill Quarry Industries > Bardon Aggregate Aggregate Industries utilises a very the wide to deliver fleet Aggregate large fleet includes The produces. that the company range of products 1000+ trucks and 1,500+ hauliers, 500+ franchised and regular 200 sites. across deployed are and drivers vehicles The drivers. Industries 1,000 external also works with over hauliers Aggregate a further around 5,000 drivers. for responsible good quality Industries haulier provided has always Aggregate talks toolbox via established which was administered training, However, an email. attaching the training material to sessions or by a number of issues with the delivery were of these talks: there ■ ■ ■ ■ ■ an online has developed the company these issues, overcome To training This (eToTS). Safety Talk Out to Time e-learning – platform that hauliers existing training compliments any programme undertake special any and does not require with their drivers software or equipment. the is sent as a link to training system GoogleThe form-based and can be the drivers, which is then easily cascaded to haulier, drivers can Alternatively, tablet or phone. accessed on desktop, Aggregate around located posters scan a QR code on eToTS access the training material. to sites Industries’ Industries are whether all drivers monitor is able to Aggregate taking poorly seriously safety and encourage hauliers who are adopt a culture embrace the training and better to represented the same always it isn’t ensure Checks can be made to of safety. and the same ones completing the training, haulier drivers it. avoiding training one of our eToTS successfully completes Each time a driver a certificate they receive of completion which can be sessions, 1302

REDUCING OCCUPATIONAL ROAD RISK 18 26 REDUCING OCCUPATIONAL ROAD RISK 1270 RUNNER ON FORS Gold operator UP VIDEO O’Donovan Waste Disposal Ltd > Markfield Road 2 6

CheckedSafe

O'Donovan introduced the CheckedSafe app which is used by all drivers when carrying out daily walk-around checks. During the inspection drivers can log information with the click of a button. The information can be viewed by others in real-time. The information is used by the transport team to speed up the process of fleet maintenance. The App records the GPS coordinates, the duration of the check, any detailed notes added by the driver, pictures of any defects and the actions taken to correct them.

Operational management system

O'Donovan’s bespoke operational management system monitors driving behaviour in ‘real-time’ and enables transport managers to communicate with DESCRIPTION the entire fleet immediately, via a digital two-way O'Donovan works continuously to ensure it is an exemplar for radio. Allocation of work is managed meticulously as traffic updates hauliers, recognised for its commitment to road safety, employee come in. HGVs follow routes with the least congestion and will training, industry best practice and the safety of all road users. This cause the least disruption including avoiding cycle-hotspots and has been achieved through the application of a wide range of routes that have schools at peak times. The system allows managers initiatives and the strong leadership. to track individual driver’s locations and flags driving styles such as sudden braking, harsh cornering and idling, allowing further training Vehicle adaption needs to be identified quickly.

O’Donovan was the first independent waste company to achieve the Fleet Operator Recognition Scheme (FORS) Gold Standard accreditation which it has now held for eight years in a row. O'Donovan exceeds the recommended best practice of FORS by including the following safety enhancements on its the entire fleet.

■ Nearside blind spot side sensors

■ Reversing cameras

■ Nearside CCTV cameras

■ Forward Facing CCTV Cameras

■ Audible left turn alarms Training ■ Enhanced side impact bars With a high-level multi-lingual training policy underpinning its ■ Fresnel lenses (as well as Class V and VI mirrors) commitment to employee’s professional and personal development, education is considered an essential component for motivating The management team has played a key role in developing and upskilling staff, whilst maintaining and delivering high-quality innovations in the industry working through CLOCS. It has helped in services in the safest possible way. the redesign of lorry cabs to improve driver vision and introduction of glazed lorry passenger doors. O'Donovan was the first company O’Donovan headquarters is a certified training centre, approved in the UK to add the Mercedes-Benz Econic skip-loaders to its fleet, by JAUPT (DCPC) and British Safety Council (BSC), making multi- encouraging others in the industry to follow. It now has the largest lingual training accessible to all staff. It is shared with fellow waste direct-vision, low-entry fleet for an independent, waste haulier in companies in a bid to encourage others in the waste sector to London. adopt best practice. Drivers handbooks are published in multiple languages and there are five multi-lingual mentors on hand to assist with questions and ensure understanding. visit www.safequarry.com for more details or email: [email protected] 1719 ON VIDEO UP RUNNER 6 Insurance premiums reduced by 20% by Insurance reduced premiums 22% by reduced Accidents efficiency by 26% has increased Fuel 19.5% by per kilometre Carbon emissions reduced travelled Enhanced sustainability credentials as an industryRecognition leader safety to with commitment Skilled workforce savings operational with significant efficient business More all risk Reduced for road BENEFITS First dedicated waste company to achieve ISO39001 certification achieve to company waste dedicated First – May BSI 2018 from l l l l l l l l l 2 visit www.safequarry.com for more details or email: [email protected] A new addition to the training syllabus is ‘Security and counter the training syllabus is A new addition to personal to attention a driver’s focus better which aims to terrorism’ threat It the potential security. recognise helps drivers and vehicle theft or loads and the use ofvehicles of specifically, of terrorism; as weapons. vehicles qualified in RHA in-cab equipping themSeveral are drivers training, with the skills carry to out in-house driving support assessments to reducing accidental fuel economy, covering staff, and mentor damage. and classroom-based PDP’s sit alongside their comprehensive To training curriculum, drivers also take part Urban Driving in Safer getting with an instructor, roads Drivers cyclecourses. on London’s practical, first- them gives This and buses. HGVs to in close proximity hand experience of the challenges cyclists them to face and helps users, of other road and understand the behaviour anticipate better especially cyclist, driving. when they are driving backed behaviour Improved up with anti-idling campaigns and DCPC courses like driving Lo-City in safer Driving has resulted fuel efficiency. and better FORS Gold operator - continued Gold operator FORS Road Ltd > Markfield Waste Disposal O’Donovan 1168

REDUCING OCCUPATIONAL ROAD RISK 20 26 Transport initiatives sponsor John Brooks TMR TRANSPORT INITIATIVES 1258 AWARD ON POD truck cleaning project WINNER VIDEO Marshalls > Marshalls Premier Mortars and Screeds 3 4 5

Before

DESCRIPTION

The internal cleaning of Marshall’s gravity fed mortar delivery trucks known as PODs was a difficult and unpleasant task. Dried mortar system. Confined Space training was carried out at these key sites. needed to be removed on a regular basis from the internal walls A video demonstrating the cleaning process was produced as a using an electrical breaker. The hazards associated with this activity training and reference aid. included difficult access and egress, working at height, confined BENEFITS space working, exposure to dust and chemicals, and the possibility of being struck by falling material. In the event of an accident, extracting l Reduced working at height risk an injured individual from inside the POD vehicle was difficult. l Reduced hazards associated with access and egress Following 2 incidents in 2017, involving material falling from the l Reduced risk from falling objects walls during cleaning, this practice l Reduced exposure to dust and chemicals was stopped. l Reduced exposure to HAVs A solution was needed to either eliminate the need for a person to l Reduced need for confined space working enter and clean the POD or reduce the number of times the cleaning l Safer system for confined space working and rescue is completed and make the l After cleaning process less hazardous. Increased volume of delivery to customers l In addition, it was recognised that the design of the POD truck Reduced waste and cleaning paddles was inefficient. As they were not close fitting enough to l More efficient and safer operation. the compartment body, this potentially resulted in around 1m3 of wasted mortar sticking to the side walls and floor with each delivery. An improvement in paddle design would minimise the amount of mortar being left in the compartment when deliveries were made and reduce the amount that needed to be cleaned off.

Marshall’s solution comprised of two elements:

■ A flexible scraper that contacted the walls was added to paddles; this significantly reduced the amount of mortar left sticking to the sides. All POD vehicles have had a standardised version of this modification installed.

■ An adjustable pressure washer was fitted with turbo nozzles. The POD vehicle is moved alongside a gantry, an operator using the pressure washer is then able to clean the POD vehicles from above. The nozzle can be rotated to enable the operator to clean the nearside of the vehicle without it being re-positioned.

The new system was installed at all operational sites. A new preventative cleaning practice was issued that included vehicle daily check sheets for both logistics and operational staff to complete.

In the event of a need to enter the vehicles, a solution was devised and implemented at several key sites, using a Davit Arm and rescue visit www.safequarry.com for more details or email: [email protected] 21 ON VIDEO UP RUNNER Ensures drivers qualifications and training up drivers qualifications Ensures date up to inductions site are driver’s Ensures operators with weighbridge Popular Allows real time checks of driver competency time checks of driver real Allows data entry efficient, accurate More and easily to date to at site accessible records

BENEFITS l l l l l and remote staff to quickly staff as identify drivers and remote person who holds the the named and approved permits and qualifications. required and unique with a driver photo 'OneCard', The the risk fraud and also prevents I.D number, instant the allows system The of duplication. of a competency and the uploading awarding A stamped. of evidence time and date which is a that represents system safer smarter, simpler, management of Tarmac’s forward for major step drivers. Popular with drivers – less paper and easy to use – less paper and easy to with drivers Popular industry innovation changing Potentially and supply chain partners customers Useful to industrywide facilitate to data sharingPotential on drivers. Popular with management Popular

l

l l l l 6 2 DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Tarmac 'OneCard' - electronic drivers’ passport drivers’ - electronic 'OneCard' Tarmac Quarry > Halecombe Tilbury Tarmac Tarmac has introduced innovative smartcard technology innovative has introduced Tarmac it manages and supports the way change to in the drivers maximum provides system card The construction industry. and competencyassurance of the safety either of all drivers along the supply or being dispatched sites Tarmac’s entering chain. reader The entry is scanned at site or exit points. ‘OneCard’ The time data check and has visibility of an with a real is provided competence individual driver’s mandatory with any together induction criteria. An example be highlighting of this would had been whether the driver whether before, the site to their induction expired had and whether all their required in date. were competencies 11,000 drivers circa have Tarmac party third of which 95% are number of The contractors. records mostly paper-based is huge. held on these drivers Checking, maintaining and accessing this information was becoming a significant The challenge Tarmac. for both static allows new system 1372

TRANSPORT INITIATIVES 22 26 TRANSPORT INITIATIVES 1279 HIGHLY Mobile plant audio shut off COMMENDED CEMEX Materials > Willington Quarry 2

DESCRIPTION BENEFITS

The cabs of modern mobile plant are fitted with a range of l Minimises risk of driver electronic safety devices such as reversing aids, weigh loaders, not hearing reversing communication and audio entertainment equipment. Most of alarm this equipment includes some form of audible notification or warning system. The proliferation of equipment has increased the l Reduced risks of collision possibility of an operator becoming confused, missing an audible on site alarm or notification. Should this occur, the risk of a of a collision or l Simple modification incident involving the mobile plant would be increased. carried out by an auto At Cemex’s Willington Quarry the team looked at what could be electrical engineer done to reduce any distracting noise and maximise the effect of l Does not negatively the audible warnings from reversing alarms. affect any other safety This was achieved by linking the in-cab entertainment mute systems control to the Sensor vision reversing aid on the mobile plant. The l Now standard on all Cemex’s loading shovels in the Midlands modification mutes the entertainment system in the cab when the area proximity reverse alarm sounds. The only sounds emitted in the cab are that of the in-cab reverse alarm drawing the full attention l System could be easily adopted for other plant. of the operator to the potential danger. The entertainment system is restored to normal levels once the machine is out of the danger radius of the Sensor vision or changes direction of travel.

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.

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

visit www.safequarry.com for more details or email: [email protected] 1723 Occupational health and well being sponsor OCCUPATIONAL HEALTH AND WELL BEING 1352 AWARD ON RCS reduction WINNER VIDEO Hanson Aggregates 4

DESCRIPTION Live RCS Monitoring

One of the key health and safety priorities for Hanson is the effective Following the installation of the engineering controls and the management of RCS. A cross divisional working group was set up evidence from the occupational health services, Hanson felt to focus on RCS reduction, they worked with RCS Steer Company, reasonably confident that the management controls for RCS were a specialist in this area. Over an 18 month period, they developed relatively effective. a comprehensive set of procedures to assist managers with the control systems to reduce exposure to RCS. The holistic approach However, RCS Steer Co, were concerned that the existing adopted included investment in engineering solutions, training, monitoring of the RCS levels was very retrospective, based on occupational health monitoring and live real-time RCS monitoring. analysis of exposure over an extended period, the analysis of which often adding further delay. To effectively monitor actual Engineer Controls exposure to RCS, a better monitoring standard was required.

Hanson invested £3 million as part of its programme to reduce RCS In 2018, Hanson engaged in a trial of the world’s first ‘real time’ exposure, this included the following investments: Respirable Crystalline Silica monitoring device designed, patented and manufactured by Trolex Ltd. ■ Installation of clean side/dirty side changing facilities The live RCS monitoring enables personnel to establish the levels ■ Upgraded welfare facilities of airborne RCS within a building prior to entering. Individuals can therefore determine the level of risk control required prior to entry ■ Installation of boot cleaners or any tasks being completed. ■ Installation of PPE/overall cleaning vacuum pods The system also assists with the evolution of the engineering ■ Personal air flow masks controls installed across the business, for example the misting/ foaming systems. Very accurate information can be gathered ■ Processing plant misting and foaming systems about the effectiveness of the control measures put in place.

■ Plant encapsulation and mobile plant mini vacuum cleaners BENEFITS

■ Installing misting / foaming systems in primary crusher l Significantly enhanced control of RCS buildings l High level of employee awareness of RCS ■ Elimination of the potential exposure of RCS during the overall cleaning collection service by bagging all dirty overalls in l Early identification of health issues through X-Ray programme dissolvable bags. l Real time data enables impact of investment to be accurately Training and Development measured

The majority of Hanson’s managers and supervisors have been l Management able to quickly identify and rectify any RCS black trained in the industry recognised MPQC Management of RCS, and spots all employees received internal awareness training. l Employees know RCS levels in real time - can select Occupational Health Monitoring appropriate PPE before entry

750 employees were given a chest X-Ray. Identification of l Providing gold standard for industry silicosis at an early stage significantly improves the prognosis for l Improved health and wellbeing for all employees employees. In addition to detecting silicosis, 105 cases of other abnormalities were identified from the chest X-ray and were referred on to an appropriate medical professional for advice.

24 visit www.safequarry.com for more details or email: [email protected] 26 OCCUPATIONAL HEALTH AND WELL BEING 1272 RUNNER ON 'Dynamo Welfare Project' UP VIDEO O'Donovan Waste Disposal Limited > Markfield House 6

The pioneering training gives the employees the tools to:

■ Take control of their reactions

■ Manage the effect of energy draining situations that occur

■ Train themselves to sustain consistent reactions

■ Balance and take a step back to assess interactions

■ Improve their communication – both listening and speaking when feeling challenged

The training takes place in small groups of circa six employees DESCRIPTION and includes demonstrating to them the effect that stress has on their heartbeat. Through the education and training employees ‘Safety above and beyond’ is O'Donovan’s pioneering ongoing have learnt how to identify when they are experiencing (or about strategy to drive safer standards across its operations and the wider to experience) a negative or adverse reaction to a situation. It has industry. The health, safety and wellbeing of its staff, customers and given them the tools to minimise the impact it has on them and the wider community, is paramount and the business ensures this empowered them to respond in a positive and constructive way. ethos is embedded in all company activity. Monitoring and assessment of the ongoing strategy and its A crucial element of the strategy is the inclusion of a strong stance implementation have been vital to the success of the training. An on supporting mental health and wellbeing. The aim is to assist staff assessment tool was introduced before and after training. in maintaining positive mental health and, where required, to deal more effectively with any personal or work-related problems they BENEFITS may face as well as learning self-awareness tools to help manage negative emotions including stress. l Training has been well received by employees

As a waste business operating in the construction and demolition l A 32 % reduction in organisational daily stress (from 61% to 29%) sector, O'Donovan values its staff as its biggest asset. Results from l recent industry surveys revealed 55% of workers had experienced A 15% decrease in absenteeism mental health issues. This reinforced the management decision to l A reduction in incidents encompass the well-being focus of their ‘Above and Beyond’ safety strategy – an action that needs to be prioritised in the supply chain. l Safer drivers

The confidential wellbeing support programme is called ‘Dynamo’ l Reinforces O’Donovan’s commitment to ’Safety above and and is believed to be the first of its kind in the waste sector. beyond’ O'Donovan took a totally innovative approach and introduced a ground-breaking interactive training module that provides l Improved health and wellbeing for all staff with simple and effective techniques to alter their stress l Provides industry leadership reactions - allowing them to take control of uncomfortable situations that affect them. Examples of potentially stressful situations they may encounter on a day to day basis include traffic jams, public-transport journeys, dealing with demanding people or even conflict. Any of these situations could trigger stress or anxiety.

The training module helps them to take charge of life’s challenges by using a number of exercises like breathing control or situation awareness. A skill that will be useful in every aspect of daily life.

visit www.safequarry.com for more details or email: [email protected] 25 HIGHLY COMMENDED

Teams Teams Interdependent Operatives enthusiastic and enjoyed participation enjoyed enthusiastic and Operatives the skills have deal with serious now to incidents Operatives until the emergency can manage incident Operatives services attend consequences of an incident at a remote Reduced potential site team Increased the confidence within the those who work remotely Increased the morale for all for environment A safer Help others conform keeper Others’ Networking contributor Care for others Organisational pride Looking for ‘What If’

BENEFITS l To address these risks, it was agreed to organise a “First Person on Person “First a organise to it was agreed these risks, address To Aid and in Emergency Course First Training 3 Scene (FPOS) Level the skill, operatives give would course This Management”. Trauma knowledgemajor incidents should to deal with and confidence they arise. scene management, resuscitation, training course covered The C-spine immobilisation pelvic splinting, bleeding, catastrophic is a mixtureThe course of practical topics. other first aid and many Itassessments and theory-based is supervised study. a trainer by experienceinstructor as a senior officer and 20 years` with over each complement the training, To within the Ambulance Service. Aid rucksack which included such was issued with a First delegate each and defibrillators, £1,900. as oxygen, items kit cost in excess 4-day they course, the intensive, attended 36 operatives in quarrying engaged employees 84% of Marshall’s represented activities. l l l l l l

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 6 Management commitment Condition of employment Fear/discipline Rules/procedures Supervisor control, emphasis and goals all people Value Training

Reactive Natural Instincts

Safety by natural instinct Compliance is the goal Delegated to Health & Safety Manager Lack of Management involvement Injury Rates Rates Injury Location of the quarries and their proximity to local A&E of the quarries to and their proximity Location the emergency times by servicesresponse Excessive ability with major trauma incidents deal to operatives’ The at these sites and risks present of hazard nature The typeThe of injuriesoccur could that potentially means of contactingThe the local emergency services by or mobile land-line telephone the management of emergencies Inadequate planning for Safer and Healthier by Leadership MPA is running a series of workshops at different locations throughout the UK in 2020, 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’. DESCRIPTION visit www.safequarry.com for more details or email: [email protected] First Person on Scene (FPOS) – training level 3 level – training Scene (FPOS) Person on First Saws PLC > Cromwell Marshalls 1. 2. 3. 4. 5. 6. 7. The first aid risk assessment carried out for remote quarryremote first aid The for risk assessment carriedworkers out work determinedat that the existing first aid sites, at Marshall’s following risks The for operatives. suitable qualification was not identified: were 1264

OCCUPATIONAL HEALTH AND WELL BEING 26 26

Worker involvement sponsor WORKER INVOLVEMENT 1379 AWARD ON Worker engagement WINNER VIDEO Tarmac 1 2 3 4 5 6

DESCRIPTION WhatsApp Best Practice Sharing Group

Standards of safety in Tarmac Building Products were both To promote best practice around the business, a WhatsApp group inconsistent and lacking in areas. This was reflected in a high has been set up with posting enabled from every site and every number of accidents and incidents across the business. A step manager of the business. To date, hundreds of best in class photos change was required. The division had the worst safety record in and ideas have been shared giving fantastic cross-collaboration Tarmac 4 years in a row. across all product lines.

In January 2018, every operational member of staff in the business Regular Workshops/Conferences was invited to participate in a safety stand down to discuss how this situation could be improved. The feedback was that the A set of regular workshops and conferences have been set up where business needed better worker involvement. Working groups and leaders of the business visit different sites to present and discuss safety leadership teams were set up to reflect on this and identified the initiatives and strategies. Additionally, site managers and supervisors following initiatives to be delivered. participate in both on and off-site conferences, holding workshops to discuss improving specific areas of safety. The learnings points from What Good Looks Like (WGLL) the workshops are then promoted throughout the business.

Engaging with sites, best standard practices were identified and BENEFITS placed in a booklet which was distributed throughout the business, this set new standards for the division. To measure sites against l Tarmac’s Building Products division achieved the best safety these standards, cross business groups consisting of directors, record in Tarmac over the last 2 years – reflecting a significant regional operations managers and site managers were set up to change in everyone’s attitudes to safety visit sites. The group’s role was to engage with all the operational l Created an interdependent safety culture through all levels of staff at the site and to determine the standards achieved and what the organisation further improvements could be made. Sites were awarded a status of red, amber, bronze, silver, or gold to reflect its position. All 42 l Overall WGLL statuses of sites has improved sites were visited during the year and every single member of staff involved. This process continues today. l Reduction in LTI’s and recordable incidents

Reward and Recognition l Reduction in high potential learning events

A system was set up on our intranet allowing every employee to l Effective sharing and adoption across the business of best make submissions on behalf of their colleagues. Submissions could practice be made for either individuals or groups of people. The objective l Workforce is rewarded for their positive contributions was to identity who had gone above and beyond what was normal in terms of safety or who had identified an initiative that improved l High level of engagement and pride in achievements safety. The reward was linked to the bronze, silver, or gold awards. A monetary gift was made to the successful nominees who were l All levels working together to achieve a safer environment also recognised in the monthly safety e-magazine and the division’s intranet. 55 individuals have been recognized so far with contributions reducing manual handling, confined space and work at height risks. visit www.safequarry.com for more details or email: [email protected] 27 ON VIDEO UP RUNNER Further phases of development planned phases of development Further reporting external to defects Automatically contractors reportingContractors work carried out on site. requirements. contractors with invoice Assist checks logging. Contractor been done at the time it’s work that’s Scheme logging PPM been done

Easy for managers to progress and close out maintenance tasks and close out maintenance progress managers to Easy for form efficiently with online managed Downtime requests Real time reporting facilitating rapid action on key issues Ability of other plants / areas. view downtime to plants can be based on other of plant downtime Planning status. Monthly and emailed reports created with a mobile device can use the system. Anyone No paper required User friendly ❍ ❍ ❍ ❍ ❍ ❍

l l l l l l l l l Consistent formats of employee reports of employee and filing formats Consistent individual plant data connected to all relevant QR codes ensure items and interrogated. recovered easily achieved, Data capture records digital in easily retrieved forever Information is stored a saves picture (A alongside other information stored Photo’s thousand words) between sites Information easily shared Before

Digital revolution in maintenance reporting in maintenance revolution Digital Coating Plant > Stourton CEMEX UK BENEFITS: DESCRIPTION l l l l l l An annual engagement survey the need at CEMEX highlighted reporting and records the maintenance improve significantly to a lot of duplication and created system paper-based The system. too much time spending were assistants Managers and inefficiency. filling in, checking for reports. requests and then filing Downtime everyone to being lost or not communicated in were maintenance be informed. the supply chain who needed to They this. review to was set up in the asphalt team A small team time reporting that enabled real an in-house solution developed on plant and the work carriedof defects them. Every rectify out to This piece of machinery was labelled with a unique bar code. reading of plant by simply identify the item to enabled an operator on a mobile information the bar code and then call up appropriate simple reports complete He is then able to inputting datadevice. work completed, checks issues identified, time, such as the date, in is stored information This undertaken take if relevant, photos. and, the cloud. and paper reporting has been automated made whole system The an online through be requested Downtime can now redundant. parts all by a calendar which can be viewed this updates form; of the the operations manager is sent to request downtime The business. then notifies all parties system The request has that the approval. for or declined. been accepted visit www.safequarry.com for more details or email: [email protected] 1288

WORKER INVOLVEMENT 28 26 WORKER INVOLVEMENT 1268 HIGHLY PPE selection flowcharts COMMENDED Aggregate Industries > Newark > Express Asphalt 4 5

DESCRIPTION the risk assessment and method statement process. Once all the risks have been identified and, as part of implementation of control The management team at Express Asphalt in Newark were concerned measures, the PPE selection flowchart could be used as a tool to that analysis of incidents had identified that, the injuries incurred guide the operator in the selection of the appropriate PPE. might have been either avoided or their severity reduced if the injured party had been wearing the correct PPE. The draft PPE flowchart was reviewed by managers and all the operators, they provided feedback on how it might be improved. This In particular, a recent spell process was used to create a suite of PPE flowcharts. The charts use of eye injuries, revealed images and help the user follow a process of elimination to select the that workers had been most appropriate item of PPE to protect them whilst undertaking the carrying out a task above task. head height and had some object or debris The flowcharts are easily accessible, for example they are placed on make contact with their the health and safety board where most of the risk assessments and eyes. They were wearing method statements are written. There are also laminated copies in the standard safety glasses risk assessment folders. rather than sealed safety glasses or goggles which BENEFITS would have prevented the l Positive feedback from all levels eye contact. l Simple and largely pictorial design makes easy to use To help improve PPE selection one of the managers designed a ‘PPE Selection Flowchart’ that could be used to aid people in selecting l Easy to use in site inductions the appropriate items of PPE for the specific task they were about to undertake. The flowchart is designed to prompt thought during l Less chance of operator or contractor selecting inappropriate PPE

1287 HIGHLY Safe system of work review, format and booklet COMMENDED CEMEX Materials > Braintree Logistics 2 6

DESCRIPTION and small groups spent time undertaking the activity whilst taking pictures of each step of the task. Once the first drafts were developed, The safe systems of work (SSOW) and risk assessments used by a step by step practical approach was put into place using several Cemex’s logistics operation were lengthy, wordy documents. Whilst different drivers until the final correct method of work was agreed. they were very detailed and covered all the relevant points, they were not very user friendly in terms of being simple and effective for the A pictorial SSOW booklet was produced and given to every driver to drivers to refer too. keep in their vehicles, ensuring that they have an immediate reference point for every SSOW when required. During an annual review in 2018, representatives from BENEFITS the logistics team including l drivers, the operations Very positive feedback from and the H&S managers the drivers commented that the SSOWs l Easier to follow SSOWs needed to be reviewed to increase their impact on the l Reduced chance that operation. tasks will be undertaken incorrectly A small team of drivers, supervisors and operations l Employee involvement in managers met and decided key health and safety issues to introduce pictures to compliment the SSOW. The l Reduced risk of injury SSOWs were divided up visit www.safequarry.com for more details or email: [email protected] 29 HIGHLY COMMENDED Slips, trips and falls incidents reduced from 52% to 23% of all 52% to from trips reduced and falls incidents Slips, incidents in 2018 machinery moving Incidents involving parts 25% from reduced 11% of all incidents in 2018 to of the dangers in their awareness employee Greater environment safety for individual responsibility Greater reporting in hazard An 80% increase all for environment A safer Before and after: Gregor MacGregor in the AG Dungannon site Dungannon site andBefore after: in the AG MacGregor Gregor at height. a working to implementing his improvement

BENEFITS: l l l l l l AG’s ‘Good Catch’ scheme: Empowering workers to workers Empowering scheme: ‘Good Catch’ AG’s environment create a safer working proactively > Company wide AG (Acheson & Glover) DESCRIPTION visit www.safequarry.com for more details or email: [email protected] In 2016, AG introduced a company-wide hazard reporting hazard a company-wide In introduced 2016, AG as part initiative of a wider strategic ‘Good Catch’ programme to takegreater staff empower it aimed to level, at Board developed safety. on-site for responsibility stronger that it was believed because was introduced initiative This needed between managers and communication channels were where six sites its across a culture create to site-workers. wanted AG to highlight and implement changes where felt empowered staff efficient a more was scope for there could be improved, safety friendly could be alternative environmentally operation, or a more progressed. at all a roadshow through scheme was initiated ‘Good Catch’ The explain to talks’ ‘toolbox and campaigns with poster along sites, AG worked manager The health and safety with the site the benefits. scheme was reinforced The the scheme. promote managers to safe e-zinewith regular and recognised that highlighted updates ofaware were that all employees briefingsThe ensured behaviours. the outset. from get involved to motivated the new scheme and were placed at each were leaflets and information boxes ‘Good Catch’ was established for system reward behavioural and a positive site cards ‘GoodCatch’ fill out would Employees individuals and teams. innovative and a suggested hazard which included both the safety the member discuss the issue with manager would site The solution. solutionfor the would be agreed a date of staff and importantly, knew employees ensure that their concerns to actioned be to by, be dealt with in a timely manner. would behaviour each month safe recognition, staff increase To though recognised were ‘Good Catches’ or recommendations, fish and quarter, the end of each At individuals. to awarded vouchers team who closed out and actioned to the site offered chips were ‘Good Catches'. the most staff, in the scheme; maintenance of staff got involved All levels were among mobile plant drivers and office staff plant operators, were ‘GoodCatches’ roles where types of different the many discussed at individual are submitted ‘GoodCatches’ The identified. additional ideas and feedback for allow meetings to committee site sharing for meetings also allow These on the close out of the issues. sites. them across surpassed key performance programme behavioural The indicators reported the number of hazards increase to the Board set by was a There causes of incidents. the most prominent and reduce of the implementation in some incidents due to dramatic reduction housekeeping to and guarding. improvements suggested 1323

WORKER INVOLVEMENT 30 26 WORKER INVOLVEMENT 1355 HIGHLY Bespoke moveable stop signs COMMENDED Hanson Aggregates > Needingworth Quarry 2

DESCRIPTION bucket in a bespoke notch welded to the upright and the bottom lip of the bucket into the lower angle of the bottom part of the base At Hanson Aggregates’ Needingworth cross. quarry the stock yard can change on a daily basis, with stocks moving, The numerical signs were cut from flat steel and painted to match depleting and or being added too. the site QA dockets. The signs were placed on to the upright of a steel The loading shovel operators were cross base. constantly exiting their machines to BENEFITS Before move, recover or even find the old stockpile identification signs. The signs l Clear marking of stockpiles were often lost within the retreating stockpile or were run over by the vehicles being loaded. When l Drivers no longer having to exit shovel to move signs this occurred, it created potential slip, trip or fall hazards and could damage transport on the site. l Reduced risk of slips, trips and falls for drivers

The traditional signpost, which was fixed into an old metal drum l Removal of hazards created by old signs filled with concrete, was always found to be unmovable, due to the l Removal of manual handling hazard uncertainty of the weight distribution, the manual handling issues and the dangers of sharp edges from metal fatigue. l Sign being used for other purposes, The shovel drivers suggested a new design at a weekly meeting. This directions, marking car idea was followed up with a local fabricator and a prototype created. parks The first model was not sturdy enough and fell over in high winds. The second version was created in the on-site workshop and was found to l Collection wagons be very successful, this bespoke “movable stock sign” then went into know where they need full production. to go

The sign can be lifted and placed into position by using a unique l Reduction in waiting design that matches the measurements of the loading shovel time due to improved buckets. It is picked up by placing the top lip of the loading shovel efficiency

After

visit www.safequarry.com for more details or email: [email protected] 31 Bitumen, asphalt & contract surfacing sponsor BITUMEN, ASPHALT & CONTRACT SURFACING 1390 AWARD ON Reversing differently, innovative critical WINNER VIDEO safety thinking FM Conway 2

to track how often the technology is deployed, meaning that we can identify the need for further training to ensure that safe practices become fully embedded across our teams.

■ Stand down day & sweeper permit

A health and safety stand down day was held for its surfacing division where the high potential near miss film was shown and discussed. Emphasis was placed on the importance of ensuring that all the risk controls were implemented, to raise awareness of the hazards and to challenge their risk perceptions relating to sweepers. A new sweeper permit was introduced at the stand down day. The sweeper permit is to be completed by sweeper drivers and supervisors before works commence. The permit was introduced as an additional safety control measure. DESCRIPTION ■ On-site measures In 2018, FM Conway’s analysis of 53,000 near miss reports identified that the control of sweeper reversing manoeuvres was an issue. One A direct radio contact between the sweeper driver and reversing high potential near miss involved a sweeper reversing into a parked vehicle assistant was introduced as an additional safety measure. HGV tipper lorry, narrowly missing an operative standing at the rear An exclusion zone marked with yellow cones and flashing beacons of the vehicle. The incident, which was captured on a video, showed was also introduced on site to identify the area that is required to how closely the operative was to a potentially fatal injury. be swept. Once installed, the sweeper can only sweep within this area. No other operatives are allowed within the exclusion zone, Several control measures were already in place on Conway’s but if someone does enter the driver must stop immediately or the sweepers such as a white reversing beeper, reversing cameras, reversing assistant is to say ‘stop, stop, stop’ over the radio. recording cameras, 5 and 2 blue lights (exclusion zones lights), proximity radar and reversing vehicle assistance. However, despite To ensure the implementation of these new measures the business these control measures, the near miss analysis demonstrated there increased the number of safety site visits. Checks were made to were still serious incidents occurring. ensure the updated RAMS and permit to sweep with additional controls were all in place across all contracts. Conway uses sweepers across its core highways services, but especially for its surfacing division. Although sweepers typically BENEFITS move at slow speeds in this environment, the nature of surfacing works often means that large numbers of construction personnel l Raised awareness of hazards associated with sweepers/ are required to operate in close proximity to machinery and on-site reversing obstacles, raising the risk of accidents. A sweeper will typically spend l Complimentary safety measures in place both technical and 50% of its time in reverse gear whilst on surfacing works. behavioural Minimising this hazard became a priority for FM Conway and a l Technology has been applied to all Conway’s sweepers range of new initiatives were introduced including; l No vehicle high potential reversing incidents on sweepers for ■ Auto-stop technology 9 months The business commissioned Safety Systems Ltd (ISS) to develop l A safer work environment for all a bespoke auto-stop reverse radar system to work in conjunction with the CAM system on the vehicles. Using sensor technology, the l Information is being shared with industry system automatically applies the vehicle’s brakes when an object comes within four metres of the vehicle, coming to a complete and controlled stop. This innovative system complements the existing suite of safety measures already in place.

Importantly, the system is designed to support drivers as a critical risk control measure, and not to replace focus on supervision, training, and positional safety. The new system enables the business

32 visit www.safequarry.com for more details or email: [email protected] BITUMEN, ASPHALT & CONTRACT SURFACING 33 ON VIDEO UP RUNNER

A significant reduction and near misses in incidents A significant chipper operate needed to 33% reduction in personnel trips risk of slips, removes platform – operator operate to Safer and falls is operation – brake release ‘fail safe’ Hydraulic train delivers drive hydraulic movement risk of uncontrolled on inclines with zero Operates visibility all-round for 50% - better by Hopper height reduced operator of gravity centre stabilityImproved with lower risk of trapped hands or fingers hopper removes Fixed braking and improved stabilityImproved ground, on uneven elimination of forward-roll cut-off engine and braking Automatic should lanyard connection and chipper be broken between operator brakingAutomatic when in neutral culture enhances safety Engagement of staff in process

BENEFITS l l l l l l l l l l l l 2 visit www.safequarry.com for more details or email: [email protected] 6 DESCRIPTION Aggregate Industries identified Aggregate that the operation of pre-coated chippers on HRA surfacing was a high risk operation. Following of incidents and neara review miss reports it was decided that of the chippera radical review

Automated calibration using dashboard controls calibration using dashboard Automated pre-selected gates: spread hydraulic Electronically controlled of a button at the touch rates A unique ability extend; to carriageway accommodating widths 12ft-16ft (3.65m-4.87m) from ranging 300mm minimum width of spread shift tonnages Increased greater hopper capacity for load height hopper with lower Fixed Increased fuel tank capacity time for (40l/18l); less down refueling drive chain with tracks rather than hydraulic Safe’ ‘Fail Fully wheels to harder additional specialist plant for the need for Removes ground or uneven reach basic telemetryUniquely provides idle time and hours showing worked CO reduced efficient operation and more for 4 engine Tier Image from the '50s Image from 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Operatives and fitters from AI’s workedSouthern business Regional AI’s from and fitters Operatives the issues with the reviewed They team. design with Pavemac’s existing chipping plants and used their experience help identify to where out and areas be designed that needed to the hazards was The outcome improvement. operational efficiency required the 'KS12-16 Extendachip' incorporates which the a new chipper, and improvements: innovations following design was required. Although there had been some small Although there was required. design had not changed since the 50’s. basic design their improvements, pre-coated chipping spreader design chipping spreader pre-coated Aggregate Industries 'KS12-16 Extendachip' – a revolution in – a revolution Extendachip' 'KS12-16 1265 HIGHLY HIGHLY COMMENDED COMMENDED After Reduced need for confined space work confined space Reduced need for and manual handling welding Reduced burning, maintenance Reduction for in downtime efficiencyImproved of plant in operation Reduced is completely issues as the barrel contamination emptying condition in great as the lifters staying No residues work alternative for available Maintenance team Reduced hazards associated with access and egress associated Reduced hazards working confined space Eliminated easier. drum will be significantly from emergency rescue Any Before BENEFITS l l l l l l l The cost of per barrel of cost of per barrel The manufacturing and installing the lifters and liners is stainless steel equals approximately This £15,000. replacing the costs of using and lifters and liners over the mild steel However, 18-month period. a 12 to does not include all the this figure and the operational efficiencies MQP is benefits. health and safety find out what the still waiting to the new lifters span for actual life second barrel The and liners will be. been converted. has now l l l More efficient maintenance More Reduced downtime visit www.safequarry.com for more details or email: [email protected] BENEFITS DESCRIPTION DESCRIPTION Confined space entry elimination batch heater drum Confined space entry elimination batch Midland Quarry Products > Ettingshall Asphalt Batch heater barrel upgrade heater barrel Batch Cliffe Hill Quarry > Quadratec Quarry Products Midland l l A redesign of the batch heater drum at MQP’s Ettingshall Asphalt drum at MQP’s heater of the batch A redesign the to make to the access and egress has been implemented Plant when essential fabrication or maintenance inside of the drum safer work was required. only been possible drum had previously heater the batch to Access classified as a confined and was therefore via the drum spigot plate heater of the batch plate front the this hazard, eliminate To space. could be lifted, plate front so the complete drum was redesigned This the drum. to “walk in access” allow to secured and safely pivoted the confined space classification. modification eliminated MQP’s asphalt batching plant at Cliffe Hill Quarry at Cliffe plant asphalt batching has MQP’s twin barrels. the lifterHistorically barrels liners in both replace would MQP every 6 months and the actual every lifters roughly 2-3 years. in the of RAP and an increase introduction the following However, The increased. rate the wear in the barrels, operating temperatures every replacement requiring 3 months and the actualliners were lifters everywear rate. doubling the 12 – 18 months – effectively was doubling the amount of rate enhanced wear The confined space increasing in each barrel, required maintenance and plant downtime work, manual handing, burning and welding, cost. . the wear. reduce what could be done to review MQP decided to it was decided Working with a contract company, maintenance liners and bolts in one of lifters, trialto steel, the use of stainless components. the traditional mild steel replaced This the barrels. parts newThe stainless steel installed during a Christmas were After on a monthly basis. and then monitored shut down holiday 12 months they still looked like new! months and is still 18 over for has been operating first barrel The has been required no maintenance of wear, signs any not showing on the inside of the barrel. 1278 1275

BITUMEN, ASPHALT & CONTRACT SURFACING 34 Index Bottom openingskip Quinn safety hub Bulk bagsplittinghopper Light weight plasticguards onsite tankers ofdelivery Management Mobile plantaudioshutoff Mobile Tarmac 'OneCard' -electronic drivers’ passport POD truckcleaningproject operatorFORS Gold eToTsOnline Training roll'Safety Savvy' out Dust suppression Arc flashsafety initiatives OMNI by Terex revolutionises crushingandscreening supervision Contractor management&active New RAPIDbatching systemNew plantandconcrete delivery accessory grabGulley lifting RCS Reduction RCS First persononscenetraininglevel 3 WelfareProject''Dynamo PPE selection flowcharts PPE selection Digital revolution inmaintenance reporting Worker engagement Safe System review, ofwork format andbooklet AG’s Catch’‘Good scheme Besopke moveableBesopke stop signs Reversing differently,Reversing innovative safety thinking critical Batch heater barrel upgrade KS12-16 Extendachip' - pre-coated chippingspreader -pre-coated KS12-16 Extendachip' Confined space entry eliminationbatch heater drum Confined spaceentry 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 Video link 11 15 12 10 22 21 19 18 17 13 12 24 23 25 26 28 27 29 29 30 31 32 33 34 34 9 9 8 7 6 Page number 1333 1259 1380 1305 1372 1258 1270 1302 1280 1370 1304 1384 1309 1366 1383 1382 1352 1279 1272 1264 1288 1379 1268 1287 1323 1355 1390 1265 1275 1278 Entry number 2, 4,5 3, 4,5 2, 3,4 1, 2, 1, 2, 2, 5 2, 6 2, 6 2, 6 2, 3 4, 5 2, 6 2, 6 3, 4 All All All All 1 4 1 3 4 2 6 2 6 'The Fatal 6'

l l l l l l Asphalt & coated stone l l l l l l l l Quarry,recycling and waste l l l Readymix & mortar l l l l Concrete & precast l Cement & lime l l Contracting l l l l l l l Transport and delivery Marine l l l l l l l Company wide l l l l Contractors l l l l Dust and fumes l l l l l l l l l l Maintenance l l l Guarding & isolation l l l l l l TRANSPORT INITIATIVES Mobile plant l l Hazards & incidents l l l Risk Assessments l Safer processing l l l l l l l l l Induction & training l l l l l l l Manual handling & storage & HAVs l l l l l PPE and emergency equipment l l l l l Working at height & confined spaces l l l l l l l l Traffic management and pedestrian safety l l l l l

35 Mobile technology, videos, camera, radio l l l l Health and wellbeing Health and Safety Working Groups

Lime Mark Goslin Tarmac Darren Presgrave Lhoist UK Ltd Alastair Parker Tarmac Helen Wallace Lhoist UK Ltd Darren Stokes Tripod Crest Lindsey 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 Bitumen Ian Gibson Mineral Products Association Richard Porter Aggregate Industries Communications & One Card Jason Barker CEMEX UK MATERIALS Matt Avery Aggregate Industries Mike Taylor Colas Mike Belson Aggregate Industries Andrew Cox FM Conway Chris Hudson Aggregate Industries Craig Chadwick Tarmac Ltd Nigel Clamp Breedon Gary Schofield Total Andy Taylor CEMEX UK Transport Working Group Robert Wilkinson CEMEX UK Matt Avery Aggregate Industries Dominic Day Day Group Robert Wilkinson CEMEX UK Tyrone Partridge Day Group Dominic Day Day Group Nick Elliott Hanson Nick Elliott Day Group Marian Garfield Hanson Mick Stovin LKAB John Wilkinson MPQC John Wilkinson MPQC Andy Cox MP Skills Paul Needle Smiths of Bletchington Russell Hunter Russell Hunter Sean McGrae Tarmac Ltd John Anderson Tarmac Lee Downer TJ Transport Sean McGrae Tarmac George Kendall Wincanton Phil Ramsden Tarmac Robert McIlveen Mineral Products Association Kathy Willcox CEMEX UK Marine Chris Leese Mineral Products Association Rachel Burton Aggregate Industries Cement Steve Davis Aggregate Industries Tim Billingham Breedon Group Nigel Reeve Britannia Aggregates David Stead Breedon Group Odd Wroldson Britannia Aggregates Mary-Ann MacInnes CEMEX UK Cement Matt Bland CEMEX UK Marine Steve Mansfield Hanson UK Kurt Cowdrey CEMEX UK Marine Meirion Webber Kerneos Limited Ken Hunter CEMEX UK Marine Andy Jones LafargeHolcim Ben Manfield CEMEX UK Marine Karen Farr Tarmac Ltd Mark Williams CEMEX UK Marine Ian Gibson Mineral Products Association Rod Lafargue Hanson Aggregates Marine Contract Surfacing & Asphalt Sam Phillips Hanson Aggregates Marine Mark Mercer Aggregate Industries David Thomas Hanson Aggregates Marine Malcolm Wheeler Aggregate Industries Bruce Bradley Tarmac Marine Brett Coupland Eurovia Stuart Browne Tarmac Marine Stephen Chapple FM Conway Gordon Tuck Tarmac Marine Gavin Kinson Hanson Mark Russell Mineral Products Association Ian Tomlinson Hanson 36 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

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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: Tony Entwistle, MPA silica sand industries.

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