Tarmac SHE Report 2004
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safety health environment and social report 2004 In 2004 we, in Tarmac, made good progress in mean clear demonstration by management, terms of both our safety, health and from the top down, of the importance of environmental performance, and also our safety and health. As an example, my senior community engagement. This was marred by a team and I each commit to devote at least one fatal injury on one of our UK road surfacing day a month to task auditing. This involves us operations. It is totally unacceptable to me and personally verifying that conditions and my management team that anyone should die behaviours on a site are safe, taking corrective as a result of an accident at work. Our aim is action where appropriate. safety health environment and social report that no one should be harmed in any way while 2003 safety health they are working with Tarmac. Consequently Caring for the environment will remain an environment and social report we are striving to eradicate all injuries, and at important part of our commitment to ensuring 2004 the same time to focus particularly on the areas a sustainable future in the areas where we where the highest risks to life and limb may arise. operate. Having introduced effective environmental management systems, we have The first strand of our strategy on safety and successfully achieved ISO 14001 certification at health is to eliminate all lost time injuries, by 470 or 73% of our industrial sites and we are
safetyhealthenvironment social which we mean injuries giving rise to one lost aiming for 100% by the end of 2006. We have report2002 shift or more. Significant progress was made in also set targets for reducing energy and water 2004 with a reduction of 24% in the lost time consumption, minimising waste and promoting injury frequency rate. In 2000 we set the target biodiversity at a local level, with the of zero lost time injuries by 2005. All Tarmac implementation of local Biodiversity Action Plans. sites are therefore now working to a target of zero lost time injuries. 89% of our sites were In the community we will continue not only to This is the tenth report on Tarmac's safety, health, environmental free of such injuries in 2004. We are aiming to communicate openly but also to engage all get this as close as possible to 100% in 2005, interested groups and to support valuable and social performance. It represents the progress, achievements and to achieve at least 94%. I am convinced community initiatives. that setting and committing to ambitious and performance through 2004. This report covers all of the targets has been a material factor in our Tarmac is determined to offer the products achievements over the last four years. Since which society needs, in a manner that does wholly owned Tarmac operations worldwide. 2000 we have improved our lost time injury not prejudice future generations. We strive to frequency rate by a factor of five and in 2004 offer the best product quality, to be reliable, we were four fifths of the way to the zero understanding and responsive to our customers' target. This gives us encouragement, confidence needs, and to be straightforward to deal with. and determination to achieve the ultimate result. These same values guide our attitudes towards safety, health, the environment, and the The second strand of our strategy on safety communities in which we operate. and health is the Golden Rules. These Rules are aimed at guiding our behaviour and conditions I am determined that Tarmac's leading position in in the nine areas where our experience shows our industry is in all aspects of its performance, that the greatest risk arises. The fatal injury not least those which are the focus of this that occurred in 2004 involved breaches of the report. Equally I am determined that we strive Golden Rules, and it is our goal to achieve to match or exceed the best in industry 100% compliance of the Rules this year. generally, not just the construction materials industry. We look forward to the future with The third strand of our strategy on safety and confidence that the progress made to date is a health is to eliminate, by the end of 2005, sound foundation on which to build. conditions or behaviours that may give rise to industrial disease. I do not want to see our employees suffering from ill health caused by Robbie Robertson their employment, any more than suffering an Chief Executive Officer injury, and this will guide our focus on health. Tarmac Group
Binding together the three strands of our strategy is Visible Felt Leadership, by which we
about Tarmac 2 our growth strategy 3 safety 4 health 10 special report: benefits for all at Buxton 12 environment 14 social 22 special report: good neighbours at Nosterfield 26 contact us 28
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introduction and contents Tarmac Report 2004 About Tarmac Ready-mixed concrete Contracting services Our growth strategy
Tarmac is the UK's leading provider of Tarmac's range of conventional and Tarmac carries out and project manages a Tarmac is growing its business in the UK materials, products and services to the specialist ready-mixed concretes are wide range of construction contracts for and, especially, in continental Europe and construction industry and is growing these produced in bulk from the company's public and private sector customers, is also developing opportunities in the activities in continental Europe, the Middle nationwide network of plants and are including providing a bespoke service for Middle East, India and China. Our growth East and the Far East. delivered to major construction sites in major contracts from design through to will focus on both aggregates and more truck-mixers. fulfilment. Projects include the construction downstream activities. Having invented the modern road surface of footpaths and cycleways, road repair – 'tarmacadam' – more than 100 years Concrete products and construction, the development of Significant progress has been made in ago, Tarmac has evolved and diversified. industrial or business parks, multi-storey growing Tarmac's business in 2004, in Today, its materials and products can be Concrete products are produced from car parks and commercial driveways. In almost all areas of activity. The highlight in found all around us – in our road and rail extracted materials and are used in a addition, Tarmac provides fencing, signing, the UK was undoubtedly completion of infrastructure, homes, hospitals, schools variety of forms. Concrete blocks are used lighting and traffic management services. the new cement plant in Buxton, and commercial buildings and in a variety for walling, structural flooring and Derbyshire which is capable of producing of processed products too from animal decorative paving. Specialist pre-cast Recycling up to 800,000 tonnes a year of dry feed to toothpaste. products are used in a wide range of process cement. tunnel, rail and civil engineering projects. Tarmac has developed a wide range of Tarmac is owned by Anglo American plc, recycled products and services for the Other major milestones including the one of the world's largest mining and Mortar and screeds construction industry – recycling waste acquisition of Wisniowka, a well-located, natural resources companies and forms part materials, mixing them with quarry by- high quality sandstone quarry in central of the company's industrial minerals division. As the UK leader in the supply of mortar, products, to produce a range of recycled Poland. In Spain and France further Tarmac's strategically placed plants aggregates and blended materials. acquisitions were made in aggregates and provide a complete range of ready-to-use, concrete products, while in China the Products and services coloured and dry silo mortar. With the Yang Quarry, near Shanghai, was ability to deliver consistently mixed, completed. This new facility will go into Aggregates factory-produced products, Tarmac is able full production in 2005, operating to the to cater for a wide variety of applications highest standards of safety, health, Tarmac extracts aggregates from more from small-scale, brick-laying projects to environment, and community engagement. than 200 quarries producing crushed rock, major UK house building schemes. sand and gravel. These products are used Tarmac operates in the following countries in road construction and in the construction Lime and cement products in Europe and around the world: of other foundations, as well as in producing a wide range of concrete, Tarmac supplies lime and cement ■ UK products. Cement is typically used in the asphalt and other downstream products. ■ France A range of recycled aggregates and production of concrete and concrete ■ Belgium secondary aggregates such as slag, which products for the construction industry. is a by-product of iron and steel Lime is used in land remediation and ■ Germany water treatment projects and is also used production, also provide a sustainable ■ Spain alternative to newly-quarried materials. to make a diverse range of everyday products and materials including fibreglass, ■ Poland Asphalt toothpaste, sugar, glass, leather and iron ■ Czech Republic and steel. ■ United Arab Emirates Heavy duty and high performance ■ Oman asphalts are produced and supplied for a ■ India variety of applications from driveways and car parks to motorway road construction, ■ China. airport runways and sporting arenas.
about Tarmac our growth strategy
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Tarmac Report 2004 about tarmac our growth strategy Tarmac Report 2004 Our policy How we work Tarmac employees and contractors are The Golden Rules highlight safety risks encouraged to take action to ensure the associated with the following: Tarmac places a top priority on safety and safety of themselves and those around ■ Tarmac will strive to achieve and maintain the highest standards of safety health. This is integral to the way the them by stopping any activity which may Confined spaces ■ company carries out its business and its be unsafe. The principles of Zero Tolerance Working at height ■ and health for all employees, contractors and members of the public commitment to good citizenship. The Target Zero are: Energy and machinery isolation ■ and will seek to eliminate injury or ill health resulting from its activities. business is striving to eradicate all injuries Surface vehicles ■ ■ and unsafe behaviour through the Always take appropriate action if you Quarrying operations ■ development and widespread see an unsafe situation Lifting and material handling ■ Personal protective equipment implementation of the Golden Rules. ■ If you see someone behaving in an ■ National contracting operations. At Tarmac, safety and health are line management responsibilities of prime importance. The unsafe manner, ask them to stop management of each business is responsible for ensuring that appropriate arrangements are Zero tolerance target zero ■ Tarmac monitors and measures adherence made for the fulfilment of this policy and monitoring its implementation and effectiveness. Don’t allow a colleague to work in Tarmac operates a zero tolerance approach unsafe conditions. to the Golden Rules and is aiming to achieve 100% compliance in 2005. As part of its commitment to safety, Tarmac aims to: to workplace injuries, which is known as Zero Tolerance Target Zero. This policy has Putting safety first ■ Ensure the visible commitment of all ■ Ensure that all employees are fully set a target for the reduction of lost time line managers, carrying out regular aware of their responsibilities regarding injuries to zero by 2005, to be achieved Tarmac’s Golden Rules are fundamental safety audits safety, health and welfare by a 50% year on year reduction in lost safety principles, designed to eliminate time injuries. known safety risks associated with every ■ ■ Adopt a behavioural approach to the Identify hazards and assess risks and aspect of the business’s operations. These management of safety and health eliminate where practicable This zero tolerance policy has also set rules are communicated to all employees targets for the elimination of conditions ■ Seek to eliminate at-risk behaviour ■ Involve employees at all levels by and contractors and they have been a key which may give rise to occupational establishing local SHE Committees factor in improving the company’s safety ■ Achieve and maintain conditions of health disorders and diseases including performance. Employees are encouraged work, which are healthy and safe ■ Provide and maintain safe plant and noise induced hearing loss, hand arm to suggest how to improve safety on their equipment vibration syndrome, dermatitis and ■ site, so helping to ensure everyone stays Provide adequate welfare facilities for occupational lung disease. employees ■ Continuously review and revise alert to safety risks. company policies and guidance notes ■ Seek to eliminate dangerous occurrences ■ Provide adequate numbers of ■ Carry out regular health screening of competent persons to advise on all employees aspects of safety, health and welfare 2004 Target 2005 ■ Provide effective instruction, training ■ Allocate adequate resources to fulfil and supervision this policy. ■ Ensure that people employed are both physically and mentally fit and 100 100 100 100 100 100 100 100 100 100 96 competent for their duties 93 93 100 91 89 90 90 88 88 87
80
60 Percentage 40 safety 20 0 PPE hicles Lifting Spaces Height verage Ve A Isolation National Confined Quarrying
Golden Rule Contracting Fundamentals
Golden Rules Compliance 2004
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Tarmac Report 2004 safety safety Tarmac Report 2004 Reporting workplace injuries Our Performance Another indication of Tarmac's impressive On a smaller, but no less significant scale, Tarmac is also focussing efforts in order to safety performance is the reduction in individual sites are encouraged to monitor improve safety standards in those areas All employees and contractors are Our achievements – injuries reported to the Health and Safety and report their own safety performance. where it is most needed. For example, encouraged to report workplace injuries the facts and figures Executive. Tarmac reported 12 injuries in In 2004, Tarmac's concrete product plant operations in Spain continued to perform and this information is used to measure UK quarries to the Health and Safety at Henlade in Somerset has proudly poorly against safety performance targets, Executive in 2004, compared with 92 in reported its third successive year with zero particularly with regard to the lost time the safety performance of individual 2004 has been another year of achievement 2000. This is an 87% improvement and lost time injuries. injury frequency rate. In order to turn this plants, operations and businesses. and progress in terms of Tarmac's safety compares favourably with the 46% performance around, the management performance. The company has continued improvement reported by the industry as a As part of its commitment to safety, team will be gaining an insight into world- A key performance measure used by to report a significant reduction in lost whole to 31 March 2004. Tarmac carried out no fewer than 33,000 class health and safety best practice and Tarmac is the lost time injury, or any injury time injuries since the Zero Tolerance Target individual task audits during 2004, learning from the success of Tarmac France. which results in a person losing one or Zero initiative began in 2000 and reported Tarmac's business in France has made monitoring the application of safety They will be challenged to introduce these more full shifts from work. In order to a 24% reduction in the LTIFR in 2004. compare the safety performance of exemplary safety progress in 2004. The standards and in particular, the Golden standards and management approaches LTIFR reduced by more than half in 2004 Rules. In addition, more than 1,200 locally. In particular, managers will also be businesses or plants, a lost time injury In fact, 89% of Tarmac's sites were free (compared with 2003) and since 2000, a employees have now been trained to carry responsible for raising awareness of the frequency rate (LTIFR) is also calculated. from lost time injuries during 2004 and 94% overall improvement has been out safety task auditing. The data Golden Rules and ensuring they are Other key performance measures are also the business is aiming to get as close to achieved. This highly successful collected by these task audits is collated in adhered to in the year ahead. used to prevent and eradicate lost time 100% as possible during 2005, and to turnaround in safety performance has the Unsafe Act Index, which provides an injuries. These include monitoring non-lost achieve at least 94%. time injuries, near-hits and the Unsafe Act positioned Tarmac France, alongside other invaluable early-warning indicator of Index, which is designed to highlight Tarmac businesses, as a leader in safety. safety performance. A lower Unsafe Act Enforcement action where there are significant rises or falls in Index is a sign that unsafe practices are behaviour which may put employees at risk. being tackled and prevented at source. There were no prosecutions for breaches of health or safety during 2004. There Despite the successes, Tarmac recognises were four enforcement notices served by that there is always room for improvement. the Health and Safety Executive in 2004 Regrettably, in December 2004, Tarmac and these have been fully complied with. UK reported one workplace fatality. A detailed investigation has been carried out and learning points will be established and applied across the business as a whole.
3.57 95 11.20 12.0
3.5 90 10.0 3.0 80
70 2.31 2.5 8.0
54 60
2.0 50 6.0
5.12 LTIFR 4.83 TIFR 1.39 L 1.5 40
RIDDOR Injuries 4.0 26 0.88 30 1.0 22 0.67 20 1.51 12 2.0 0.5 ARGET ARGET 0.72 T T 10 0 0
0 0 0 2000 2001 2002 2003 2004 2000 2001 2002 2003 2004 2005 2000 2001 2002 2003 2004 2005
Tarmac Group LTIFR Injuries in UK Quarries Tarmac France LTIFR Tarmac Henlade 2000 – 2004 2000 – 2004 2000 – 2004
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Tarmac Report 2004 safety safety Tarmac Report 2004 Achieving recognition Some of the ideas generated by the SHE ■ There were four overall Innovation and Driver training and road safety The way forward Innovation and Best Practice Awards 2004 Best Practice Award winners in 2004. QPA Safety Awards include: Tarmac Southern's team at Westbury Safety on the road is just as important as achieved first place for the mixer chute safety within the workplace and for many ■ Looking ahead to 2005, Tarmac In recognition of Tarmac's contribution to A new lightweight safety barrier was safety handle and second place for the workers, driving is part of their day to day raising safety standards, the company developed for use with mobile drilling safety platform, designed to help drivers business activity. will continue to seek to eradicate machines at the Lausitzer Grauwacke access the drums of truck-mixers safely. won a number of top industry awards at all injuries, to focus on reducing the Quarry Product Association's Health, quarry in Germany as part of an Tarmac Central achieved an award for Tarmac introduced a new, comprehensive Safety and Best Practice Awards 2004. innovative solution to prevent falls. the technician working platform, to road safety policy in 2004, addressing risk and to set safety targets for Tarmac was winner in four out of the five prevent injuries caused by bending to everything from car selection to journey ■ categories which the business was eligible Employees at a concrete plant in compact concrete into moulds. Lausitzer times. achievement. to enter and also achieved the prestigious Westbury in Wiltshire developed a Grauwacke quarry in Germany achieved overall award for outstanding performance simple handle, allowing the driver to the best runners up award for their In implementing the new policy, Tarmac in health and safety. stand to the side when positioning the design of a drill rig safety barrier. requires all employees to present their The business is aiming to ensure chute to discharge concrete. The driving licence as part of their annual that 100% of sites report zero Spreading safety best practice device is to be fitted to all of Tarmac's appraisal and highlights driver safety risks, truck-mixers. including mobile phone use. In addition, injuries in 2005, and to achieve at To reward safety performance, Tarmac has Tarmac UK has appointed a specialist ■ also established its own Innovation and One of Tarmac Central's contract training provider to train all drivers, least 94%. Best Practice Awards scheme. The awards hauliers developed a frame and including delivery drivers, to avoid causing are made quarterly to employees who conveyor roller system for adjusting the or becoming involved in road traffic have identified a new way to improve easy sheet. The system is used to lift incidents. By setting and committing to the webbing strap and sheet over the safety performance and an overall award these ambitious targets, year on winner is nominated annually. load more safely. year, the business aims to build on ■ Many of the ideas produced by the Tarmac's asphalt plant in Hong Kong entrants are solutions to operational developed a simple, lightweight platform its reputation for excellence in used to access mobile plant. The problems and go on to be incorporated safety best practice in the into Tarmac’s safety, health and working platform is secure with rubber environment policies and standards. floor pads to prevent slipping and allows Tarmac Central – technician working platform construction industry and in other safe access at heights up to two metres. industry sectors.
As part of this endeavour, Tarmac will continue to strive to ensure that fundamental safety principles are adhered to by all employees and contractors and that everyone Lausitzer Grauwacke – drill rig safety barrier is responsible for ensuring unsafe practices are eliminated.
Tarmac Central – sheeting frame
Tarmac Southern – truck-mixer safety handle and access platform Tarmac Hong Kong – working platform Driver Training and Road Safety Instruction
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Tarmac Report 2004 safety safety Tarmac Report 2004 Our policy The way forward
Tarmac aims to ensure a workplace environment that is safe and poses Tarmac will implement the minimal risk to health for all employees and contractors, wherever occupational health they may be and whatever job they do. For this reason, the business management strategy during places a top priority on health issues. 2005 by setting a new occupational health benchmark for the business and initiating a campaign to promote the How we work safety, environment and social issues as Each business in the Tarmac Group will Managing stress and more well as regular reporting of health Key develop its own occupational health importance of health and well- Tarmac has made significant progress Performance Indicators. management action plan based on a As part of the new occupational health being in the workplace. during 2004 to strengthen its health policy, model designed to ensure continuous strategy, Tarmac is seeking to raise developing a new occupational health In implementing the new strategy, the first improvement. This model will start by awareness of the importance of mental as strategy for the benefit of all employees. stages will include establishing a new identifying possible health hazards before well as physical health issues and the All businesses will complete an occupational health benchmark for the establishing who is potentially at risk and impact these illnesses can have on The strategy is based on the Anglo business and an educational awareness assessing the extent of the risk. It will go individuals at work. occupational health risk campaign designed to highlight workplace on to carry out risk-based health monitoring American Occupational Health guidelines assessment to identify and, and sets out to eliminate the conditions related health issues along with more before recommending an action plan, Mental health problems can have many and behaviours that cause health risks. general health advice on matters such as which can be monitored and reviewed. causes, including stresses associated with where possible, eliminate the nutrition and exercise. both work and home life. While a level of risk for all employees. In For the following workplace related In particular, the strategy involves a more controllable level of stress is healthy and illnesses and disabilities, new performance targeted approach to employee health leads to improved motivation, job addition, regular reviews of targets have been set to eliminate, by the monitoring, identifying workers who are satisfaction and performance, excessive end of 2005, new cases or the at high, medium or low risk. stress can be harmful. Tarmac operates a occupational hygiene, risk and progression of any existing cases of: preventative policy designed to avoid health monitoring data will Employees are also encouraged to carry excessive stress and to encourage employees ■ Noise induced hearing loss out regular self-assessment and report to report stress at an early stage. create a new benchmark against health problems as soon as they arise and ■ Hand arm vibration syndrome the company has updated the Tarmac Guide To encourage employees and their families which improvement can be to Good Health – a publication introduced ■ Dermatitis to be open about stress, Tarmac is measured in the future. in 1994. extending its Employee Assistance ■ Occupational lung disease. Programme to include round-the-clock access to confidential counselling to help Once the risk exposure of each The strategy was launched in 2004 and employees manage work-related stress will be fully implemented in 2005. As part and to provide life management business has been assessed, of this process Tarmac is encouraging assistance in a range of legal, financial employees to take health matters more and other non-work related issues. targets will be set to eliminate seriously and senior level commitment is or, where elimination is not being used to help prioritise health issues, through an approach called Visible Felt possible, reduce the number of Leadership. This involves regular face to Identify workers exposed to high or face meetings between managers and possible health hazards employees to discuss health and other medium risk.
Monitor, Identify people Report and exposed Review
Action Plan Quantify to eliminate level of health or reduce exposure exposure
CCarry out risk based health surveillance Assess health risk
Occupational Health Continuous Improvement Cycle
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Tarmac Report 2004 health health Tarmac Report 2004 Buxton's New Cement Plant
Special Report – Benefits for all at Buxton
Recent changes at Tarmac’s site in Buxton in the Peak District show how investment and working in New Plant, Old Plant partnership with the local community have delivered a cleaner, greener, safer and more efficient cement 2004 full year equivalent plant, fit for the 21st century.
1,697 2,000 After 40 years of operation, Buxton's old In addition, the new cement plant has the site, the new plant has been cement plant, operating alongside been designed to produce zero process sensitively sited more centrally, 35 metres 1,600 Tunstead Quarry, could no longer meet waste and will also provide a beneficial below the rim of the quarry. The old modern energy consumption and emissions outlet for process wastes arising from the cement plant is to be demolished and the standards. To address this, Tarmac decided lime production operations on site. site will be fully restored during 2005. 1,200 to invest £115 million to create a new 663 Also, three new rail link depots in London, state-of-the-art cement plant on the same Clive James, managing director of Tarmac 499 538 800 Birmingham and Leeds will allow up to
site. The new plant would provide Central Ltd, comments on the success of onnes per annum increased production capacity, while the new plant: 300,000 tonnes per year of cement to be T delivering important environmental benefits. distributed to customers farther afield and 400 19 “We are delighted with the efficiency and will minimise the impact of road traffic on 2 The new plant would also bring benefits environmental benefits that have been the local communities in Derbyshire. 0 by securing up to 60 jobs and creating achieved in the construction of this new skills development opportunities, including plant and this has been made possible by Working with the community
an apprenticeship programme. In order to a combination of Tarmac’s investment- sulphur nitrogen achieve this, Tarmac needed to win the backed vision and community and Tunstead Quarry and its new cement plant Oxides of Oxides of Particulates support of and work closely with a wide regulatory support. The new plant will has an active, ongoing community range of local authority, regulatory and provide much-needed resources for the engagement programme, which ensures Emissions Comparison community stakeholders. construction industry as well securing jobs that all interested people are aware of and for local people.” consulted on developments at the site and Efficiency and the environment have the opportunity to contribute. Many As well as ensuring enhanced efficiency, local events and initiatives are supported 1,909 Tunstead Quarry is one of the largest Tarmac was also sensitive to the natural each year and a wide range of local 2,000 quarries in Europe with an output of six beauty of the site and its surroundings. groups are invited to visit Tunstead to million tonnes per year and is one of the Tunstead is situated in the High Peak area learn more about the processes on site. 1,247 1,600 UK's primary sources of limestone. The of Derbyshire, adjacent to the Peak new dry process cement plant produces District National Park. The area is 1,200 800,000 tonnes per year of cement and particularly noted for its rich flora and has brought significant efficiency benefits. fauna and is also a popular tourist spot. 800 Since starting operations in the spring of While developing plans for the new 400
2004, carbon dioxide emissions at the kWh/tonnes of cement plant have been reduced by 26% per cement plant, Tarmac consulted with tonne of cement. Emissions of oxides of relevant regulatory and statutory 0 nitrogen have decreased by 61% and authorities in order to ensure the new Energy Efficiency Improvements oxides of sulphur have decreased by 96%. plant was sited in a way that would Particulate emissions have reduced by minimise its visual impact on the 99.7% and have almost been eliminated. environment. While the old cement plant Energy consumption per tonne of cement had been visible at the northern edge of has also been reduced by 35%.
special report
Natural beauty of the site and its surroundings
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Tarmac Report 2004 special report special report Tarmac Report 2004 Our policy How we work Environmental management systems Environmental management Tarmac recognises that quarrying and in practice Tarmac aims to achieve world-class performance in environmental associated operations, by their very Tarmac is introducing effective nature, can have a significant impact on environmental management systems All of Tarmac's overseas operations have practice and minimise the environmental impact of all its operations, the environment and the company takes (EMS) across all its businesses, which meet now introduced environmental preventing pollution and striving for continual improvement in its all aspects of its environmental the recognised international standard of management systems. As a result there management seriously. ISO 14001. has been a notable increase in employees' environmental performance while working towards more sustainable awareness of environmental issues, operating practices. The environmental policy statement was These systems help Tarmac to manage its including improved waste management reviewed in 2004 and revised in order to impact on the environment in a responsible and oil and fuel storage. bring it up to date and in line with current and proactive way, ensuring a consistent At Tarmac, protection of the environment is a line management responsibility of prime issues facing the business. As part of this approach across a geographically diverse Our Hong Kong asphalt operations have importance. The management of each business is responsible for ensuring that appropriate process, the business has established new group. recently implemented an integrated safety, arrangements are made for the fulfilment of this policy and monitoring its implementation environmental performance targets to environment and quality management and effectiveness. reduce energy, potable water consumption During 2004 Tarmac has largely completed system, which has achieved certification to and waste and to implement local the implementation of its environmental the Occupational Health and Safety The following targets have been set: Biodiversity Action Plans. management systems business-wide and Assessment Series OHSAS 18001 in 2004. significant progress has been made in The system is already bringing benefits to ■ To complete ISO 14001 certification by ■ Identify, assess and manage achieving ISO 14001 certification. At the the business, ensuring resources are 2007 environmental risk end of 2004, more than 470 sites had effectively aligned, resulting in increased achieved third party certification. efficiency. ■ Reduce energy consumption by 15% ■ Make a positive contribution to by 2014 based on 2004 usage biodiversity by active stewardship of In the Middle East, Dhahira Quarry has ■ Reduce potable water consumption by land been nominated for a prestigious award 4.3% by 2010 for concrete and mortar ■ Contribute to people's culture and for the third consecutive year in the finals and concrete products based on 2002 heritage through archaeological of the Oman environmental awards scheme. usage exploration ■ Reduce waste sent for licensed disposal by 25% by 2010 based on 2004 ■ Work in partnership with local communities and be a responsible EMS EMS certified quantities Implemented to ISO 14001 neighbour ■ Implement Biodiversity Action Plans at all active mineral operations by 2008. ■ Work to improve the standards of the sectors in which the company operates In order to achieve these aims and targets the company will: ■ Enhancing environmental awareness of employees through structured training ■ 100 Meet and, where possible, exceed 98 applicable legal requirements, ■ Encourage the adoption of sound 94 100 regulations and standards of the environmental principles amongst 89 country of operation contractors, suppliers and customers 83 83 83 ■ Minimise adverse environmental alike 76 impacts on air, water, land and people, ■ Respond positively to the environmental arising from our operations and 80 developments in each business area by products throughout their life cycle working with all stakeholders ■ Identify, assess and manage 59 environmental risk ■ Report and review the environmental impact of the businesses operations 60 ■ Demonstrate efficient use of natural and progress in achieving targets resources, seeking opportunities to minimise waste and to re-use or ■ Allocate adequate resources to fulfil 41 recycle materials this policy. 40 Percentage of sites environment 20 0 Other Asphalt Products Concrete Concrete Aggregate and Mortar
Tarmac EMS ISO 14001 Implementation and Certification
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Tarmac Report 2004 environment environment Tarmac Report 2004 Our Performance Overall performance Energy Policy Introducing the SavE campaign Tarmac also supports the Carbon Trust's Saving energy, reducing Action Energy Programme in the UK, emissions Enforcement action There has been a significant increase in the Tarmac's materials are essential to our At the start of 2004, Tarmac UK which has been successful in helping sites number of reported minor Level 1 incidents daily life. Our products are used in a wide participated in Anglo American’s Energy to identify opportunities for saving energy Tarmac is seeking to reduce energy In terms of enforcement action, regrettably, during 2004. This is mainly due to better range of construction and some processing Technology Pilot Project, to produce an and reducing carbon emissions levels. consumption in order to conserve global reporting as a result of employee training overview of the current energy profile of fossil fuels and reduce greenhouse gas breaches in environmental best practice applications. Tarmac aims to provide these Saving energy in practice led to three prosecutions being brought and awareness-raising. Level 1 incidents essential products in a responsible the business, a review of current emissions. against the company in Spain and all of include minor oil leaks from machinery or manner, helping to ensure a sustainable technologies in use and an assessment of A number of significant energy reduction the offending sites have ceased operation spillages of dusty raw materials. Reporting resource base for future generations. energy saving opportunities. initiatives have already been successfully or will soon do so. The company is taking and reviewing incidents helps Tarmac to implemented by individual plants. For steps to improve its environmental identify persistent problem areas and better Target The findings of this project led to the example, at Hayes asphalt plant in Greater performance in Spain and elsewhere with manage the impacts of its operations in the launch of Tarmac's SavE campaign to drive London, a local energy saving audit the implementation of environmental future. There have been 7 Level 2 incidents, Our target is to reduce our specific energy energy efficiency improvements. A new identified how substantial energy savings management systems certified to the same as in 2003. Tarmac has never consumption by 15% by 2014. performance target has been set – to could be made by making changes to the ISO 14001. experienced a Level 3 incident. achieve a 15% saving in specific energy main extractor fan, an essential part of We are committed to: consumption over 10 years to 2014 (based on 2004 usage). the production process. Variable speed Incident Brief Description* drives were installed on the two motors Level ■ Increasing our energy efficiency 3 A new energy policy has been introduced used to operate the fan and this has ■ Investing in clean, energy efficient Level 1 Minor impact, short term along with an awareness-raising resulted in a 62% reduction in energy kWh/tonne kWh/m effect. technologies programme to encourage employees to consumption. 106.6 102.4 ■ Reducing the environmental impact think more about saving energy. To Level 2 Moderate impact, medium Reducing emissions in practice 100 term effect; enforcement arising from our consumption target. highlight the campaign and communicate action or prosecutions below its importance, Tarmac has developed a series of posters and booklets and each of As well as seeking to reduce greenhouse $100,000. In order to achieve this target, the 80 company will: the UK businesses has appointed its own gas emissions, Tarmac is investing in Level 3 Significant impact, extensive energy champion to help drive the initiative technology to enhance dust abatement or long term effect; ■ Establish formal energy saving targets locally, encouraging employees to identify and reduce particulate emissions to levels 60 prosecutions with fines more that are quantifiable and measurable and implement energy reduction measures. well below those specified by the than $100,000. Integrated Pollution Prevention and ■ Establish a measurement and targeting
Control (IPPC) regime. In 2004, the 3 40 system *Anglo American Group definition company invested £2.2 million to fit KWh/unit production ■ reverse jet filters at Tunstead Shaft Lime kWh/tonne Increase awareness of energy efficiency kWh/tonne Kilns, which have significantly reduced 10.4 kWh/m 20 amongst all employees 8.2 5.9 particulate emissions levels and brought ■ Ensure that all relevant employees thermal efficiency benefits too. receive training in energy awareness 0 and efficiency improvement techniques 251
■ Conduct site energy audits to identify Rock Gravel Asphalt
250 Crushed Products Concrete Concrete 226 opportunities for efficiency Sand and
improvements and Mortar
■ Implement all cost effective energy Specific Energy Consumption 2004 efficiency measures 200 ■ Ensure that energy efficiency and carbon emissions are considered in 796 business decisions 800 ■ Invest in cost effective, clean technology 150 663 126 ■ Use alternative fuels and renewable energy where cost effective. 600
100 Number of Incidents 400
230 50 200 onnes of Carbon Dioxide (000s)
12 T 7 7 4
0 0 Level 1 Level 2 Level 1 Level 2 Level 1 Level 2 Processes Electricity Fossil Fuel 2002 2003 2004 Purchased ethane Flared Consumption (landfill sites) M
Environmental Incidents Kiln Energy Usage CO2 Emissions from Tarmac 2004 2002 – 2004
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Tarmac Report 2004 environment environment Tarmac Report 2004 Waste management Waste reduction in practice Saving water Tarmac has recently re-prioritised its water conservation targets, gathering data on As part of its commitment to the Tarmac's businesses are encouraged to Most of the water used in Tarmac's potable water supplies that are actually environment, Tarmac is seeking to look for new ways to minimise waste. quarries is abstracted from untreated consumed and that leave the site in minimise waste in all areas of its operation ground or surface water sources and is concrete, mortar and concrete products. and in particular, reduce waste requiring In 2004, a Tarmac concrete plant teamed stored in lagoons, from where it is Tarmac set targets in 2002 to reduce off-site disposal. up with the company's waste management pumped and circulated on site for product potable water consumption in these areas contractor to trial a new way to reduce washing and dust suppression. Very little of production by 4.3% by 2010. Tarmac’s operations, whether quarrying, waste. At concrete plants, waste is water is lost from the environment and asphalt or concrete production, do not produced when washing out truck mixers the vast majority is returned to ground or By focusing on water consumption in produce large amounts of waste. Relatively and a new system has been introduced to surface water. these areas of production, Tarmac will be little waste is disposed of off-site and recover the waste concrete and return it able to measure its effectiveness in most is inert aggregate waste. Less than to the production process. Because of this, Tarmac has changed the conserving potable water supplies. 1% of the total waste produced is way it reports water usage. Total water hazardous and consists mainly of waste oil The system involves two stages: firstly consumed will be calculated as percentage from plant and machinery, which is sent coarse aggregate is recovered and moisture content of the end product that to recycling facilities. returned to the production process. leaves the site. Previously, all water that Secondly the remaining slurry is fed passed through the site was reported even Tarmac has set a new target for the through a plate press process that if it was returned to the same source. reduction of waste sent for licensed disposal separates out the clean water and of 25% by 2010 (based on 2004 usage). produces a cake of the fine aggregates Only very small amounts of water are and powders. Both the cake and water actually consumed – between 1.5 - 6% of can then be reused in the process. the Tarmac’s total water usage leaves the Recycling site in hard rock, sand and gravel It is hoped that the trial will significantly products. Approximately 18% leaves In order to make use of waste materials reduce the amount of waste requiring Tarmac's sites in concrete and mortar and produced by the construction industry, disposal to landfill and has reduced waste an average 12.5% is used to produce Tarmac has invested in its own recycling transportation and disposal costs too. concrete products. business, which produced more than one million tonnes of recycled aggregates in 2004. Most waste materials come from demolition projects or regeneration schemes. These recycled aggregates make Original data Restated data use of materials that would otherwise require disposal and can be used in place of primary aggregates in the construction 200 of roads. 28,245 30,000 177 ARGET T 154 25,000 150
20,000 3
100 3
15,000 m Litres/m
Total waste generated 10,000 in 2004 = 599,000 tonnes 50
4,077 4,230 5,000
% 0 0 63.6 Non-hazardous waste to landfill 0.2 Hazardous waste to landfill 2004 2010 1.0 Metal recycled 2003 2004 35.2 Non-hazardous waste sent for recycling/re-use
Tarmac Group Waste Generation – 2004 Concrete Waste Recycling Total Water Consumption Potable Water Consumption Against Target
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Tarmac Report 2004 environment environment Tarmac Report 2004 Promoting biodiversity Biodiversity Action Plan at The way forward Mancetter Quarry With more than 200 active quarries covering around 10,300 hectares, the land Mancetter Quarry is set within an area of Broad Bodied Chaser – Libellula compressa In 2005 Tarmac will be working towards its area operated by Tarmac encompasses a farmland and mixed woodland at Hartshill wide variety of wildlife species and habitats. Ridge in north Warwickshire. Parts of the new environmental performance targets: surrounding area have been designated as In order to ensure that Tarmac is managing Sites of Special Scientific Interest (SSSIs) in the land it occupies and protecting its rich recognition of its rich biodiversity, which ■ To complete ISO 14001 certification by biodiversity, the company is aiming to includes a wide range of plant, bird and 2007 introduce site-specific Biodiversity Action wildlife. Plans at all active mineral extraction sites ■ by 2008. These local action plans are The Biodiversity Action Plan for Mancetter To reduce specific energy consumption recommended as part of a UK-wide Quarry provides a framework of detailed by 15% by 2014 (based on 2004 usage) conservation initiative, supported by ecological information and analysis. This English Nature. analysis has enabled us to develop targets ■ To reduce potable water consumption and an action plan to protect and maintain In 2004, UK quarry managers completed the environment. in the production of mortar and the first stage of implementation of the local Biodiversity Action Plans, carrying out In particular, the action plan sets out a concrete products by 4.3% by 2010 detailed on-site audits. A series of specialist series of five-year programmes for the (based on 2002 usage) assessments will follow during 2005, progressive restoration of the quarry, drawing input from Tarmac's own estates which will include the development of ■ To reduce waste sent for licensed managers and relevant ecological surveys additional oak/hazel woodland, acidic of the land area. Where necessary, herb-rich grassland, alder carr, reed beds, disposal by 25% by 2010 (based on specialist independent ecological advice ponds, lowland heath and scrub. will be sought before priorities are 2004 quantities) identified and local action plans developed. The site regularly employs the British Trust for Conservation Volunteers to control ■ To implement Biodiversity Action Plans Once completed, the implementation of the scrub and to erect and maintain at all active mineral operations by 2008. site-specific Biodiversity Action Plans will amphibian fencing. Of particular note has be managed as part of Tarmac's ongoing been a project to grow cuttings from a environmental management system. single rare Wild Service Tree found within the quarry. Over fifty saplings have now Tarmac has already achieved a great deal been grown and planted out as part of Cowslip – Primula veris in terms of raising awareness of the Biodiversity Action Plan. environmental matters in all areas of its operations and will be building on this during 2005 and beyond. The company will STAGE 1 2004 Initial site self audit aim to minimise the environmental impact of its operations in a sustainable way.
STAGE 2 Detailed site assessment
STAGE 3 Prioritisation
STAGE 4 Further evaluation
STAGE 5 Produce BAPs 2008
Biodiversity Five-Stage Approach Biodiversity Action Plan Mancetter Quarry – Wetland Area Wild Service Tree – Sorbus terminalis
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Tarmac Report 2004 environment environment Tarmac Report 2004 Our policy
Tarmac seeks to promote and maintain open and constructive dialogue and good working relationships with employees, local communities, regulatory agencies, business organisations and other affected and interested groups.
Our performance Partners in local communities
Tarmac takes pride in its open and honest Wherever it operates, Tarmac works in communication with all stakeholder partnership with local communities and groups, not least the communities in believes that establishing and maintaining which it operates and its customer and open and honest communications with supplier relationships. local stakeholders brings benefits for everyone. Embracing Anglo American's policy, Tarmac has adopted a series of Business Prior to starting operations at Yang Quarry Principles based on good citizenship which in Eastern China in 2004, Tarmac sought include developing strong links with all to create an understanding of quarrying stakeholders, ensuring they know as much among the local community. A local as possible about all aspects of our employee training manager is helping to business operations. establish safety best practice and a community liaison officer is working in These Business Principles are part of the partnership with local stakeholders. company’s commitment to sustainable development and to achieving recognition Tarmac's quarries also support a as a good employer, a good supplier and programme of educational days and tours a good neighbour. for schoolchildren designed to introduce them to the world of quarrying and provide information about the earth and its minerals. During 2004, Tarmac launched a new educational resource for teachers based on a town called Quarryville which can be accessed through this website: www.tarmac.co.uk/quarryville
Visitors at Tarmac Open Days social
Our Business Principles
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Tarmac Report 2004 social social Tarmac Report 2004 Partners in people development Partners in industry Partners in supply Partners in archaeology Partners in charity The way forward Tarmac aims to develop its people to Tarmac takes a proactive approach to Tarmac aims to establish effective Archaeological finds, unearthed as a result As well as supporting the interests of the improve organisational, team and raising awareness of important safety, partnerships with suppliers, which support of quarrying activities, occur regularly. communities in which it operates, Tarmac individual performance, ensuring everyone health and environment issues at an the company's Business Principles. also supports a number of selected charities. Tarmac will continue to work has an opportunity to achieve professional industry level by hosting events to share Every time a new land area is to be closely with stakeholders to and personal growth. best practice. In this way, suppliers become active excavated, detailed assessments are carried Tarmac has renewed its sponsorship of a supporters of the company’s safety, health out, to meet the requirements of relevant three-year research fellowship in help raise awareness of the In 2004, the company established a new Colchester Quarry hosted a safety and environment targets and in some statutory authorities, and where necessary, environmental change at Jesus College, business’s activities and the Talent Management Forum focused on awareness day, organised by the Health cases can even develop new products and archaeologists are appointed to carry out Oxford. The research student sponsored enhancing the knowledge and performance and Safety Executive in partnership with services to help Tarmac to meet its goals. a thorough programme of investigations. under the former fellowship has been economic benefits they bring. of individual employees. The company the South East Quarries Liaison Group. leading research in the field of water also initiated a new Senior Management Foremen and quarry supervisors from When planning for the introduction of During 2004 a wide range of interesting management and is attached to the The business will continue to do Development programme, in conjunction different companies around the Anglia Tarmac's new occupational health archaeological artefacts has been College's Environmental Change Institute, this through proactive, open with Cranfield University, providing an region were able to share best practice at strategy, several suppliers of personal discovered: which is a world-class centre in the study insight into modern management practices. the event. Similarly, Clitheroe Quarry in protective equipment and other service of the environment. dialogue with all stakeholders Lancashire hosted a safety day with its providers, were invited to join Tarmac in ■ Excavations at Broom Quarry in and other interested groups. Building on its successful National neighbouring cement plant for operatives launching the strategy. The suppliers Bedfordshire have uncovered the upper Tarmac also supported the Prince of Wales Vocational Qualification (NVQ) from across the north of England. provided sponsorship and a number of skulls and horns of seven aurochs – a XL Programme – an initiative providing programme, 53 managers are currently training sessions for managers. predecessor of the modern domestic support to young people facing difficulties working towards an NVQ in safety, health cow. These creatures were thought to at school or at work to help with their and environment management and the have become extinct around the development and empower them to make future plan is that they will all obtain a beginning of the Bronze Age. positive decisions about their future. SHE NVQ by 2010. During 2005 the programme will be extended to include ■ Excavations at Planany Quarry in the In addition, Tarmac has provided wide- managers in non-quarrying operations. Czech Republic have discovered relics ranging support in terms of employee of ancient civilisations including resource, materials and fund-raising In 2000, the Quarry Products Association Paleolithic and Roman artefacts, nine activities to numerous regional charities set a target for the aggregates industry to graves and skeletal remains. and initiatives. get 50% of its employees to a minimum NVQ Level 2 (or equivalent) standard by the end of 2004. Overall, Tarmac's businesses have either met or exceeded this target.
Tarmac also operates its own online intranet learning system called T-Learn, which helps employees to continually develop their skills. Further enhancements are planned for this system in 2005.
Training at Yang Quarry, Eastern China
Safety Awareness Day at Colchester Quarry Excavations at Broom Quarry Prince of Wales XL Programme Logo
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Tarmac Report 2004 social social Tarmac Report 2004 Special Report – Good neighbours at Nosterfield Managing issues An integral part of the community While discussing initial plans to extend the Successful quarries need the support of the communities in which they operate. Nosterfield Quarry is quarry, some local people and interest As well as addressing concerns, the quarry groups raised concerns about the possible tries to provide tangible benefits for the demonstrating that being a good neighbour means using open and honest dialogue to help address impact on archaeology in the area. The local community. While making plans for quarry is some half a mile from the first the restoration of a small area of the misconceptions and to consider local issues, while securing future operations for the benefit of the region. series of three Neolithic structures known quarry that is no longer in use, it was as the Thornborough Henges – a established that local people would scheduled ancient monument that lies welcome access rights for a public within a protected zone. footpath. Tarmac was able to provide a Nosterfield Quarry has been operated by 1,500 metre footpath, which was Tarmac for 14 years. During that time it Since these concerns were raised, completed in spring 2004. has become an integral part of the local statutory agencies and local authorities community, excavating and producing have been leading a study to assess the Similarly, as part of the same restoration much-needed materials for use in the archaeological significance of the scheme, there are plans to open a new region's construction industry. The quarry Thornborough Moor site. Tarmac has information and education centre at the itself lies adjacent to North Yorkshire agreed not to go ahead with any planning quarry for use by the local community, moorland, close to the villages of application for Thornborough Moor until schoolchildren and other visitors. The new Nosterfield, Well, Thornborough and West the outcome of the study is known. centre will have a car parking area and a Tanfield. Since operations began, the screened wildlife viewing platform. quarry has placed much emphasis on In order to gain a better understanding of communicating with local people, schools, the archaeology in the area in and around Listening to local wildlife campaigners has interest groups and other organisations. the quarry, Tarmac has commissioned a also led Tarmac to take action to help specialist archaeologist to carry out an Liaising with local people replace the lost wetland landscape of the intensive archaeological investigation north of England. A major new reed bed including geophysical surveys, field has been developed at the quarry, to Like most of Tarmac's quarries, Nosterfield walking, test pitting and trial excavations. attract birds like the Bittern and other has established a local liaison committee, Any artefacts found by him are carbon species back to the area. made up of parish councillors, dated and recorded on a web site which representatives of local groups and can be accessed by the public. Recent Each of Tarmac's quarries has an important residents. This committee provides a regular finds include the skeletal remains of four role to play within the local community forum where Tarmac can meet with local Iron Age horses and flint arrowheads from and the wider region. Regular supplies of people to update them about any plans or the Neolithic period. For information visit: good quality aggregates are vital to the events at the quarry and involve them in www.archaeologicalplanning region's construction industry. But delivering any relevant decision-making. consultancy.co.uk/mga/projects/noster/ these supplies is just part of the story, by being a good neighbour and working After consulting with the local community closely with local communities, Tarmac can and the local authority in the 1990s, deliver lasting benefits in other ways too. Tarmac introduced a new haulage route to the quarry, ensuring hauliers use a specified route to minimise any potential disturbance in nearby villages.
Tarmac also produces a quarterly newsletter called Neighbourhood News, which is delivered to local homes.
special report
The New Hauliers Approved Route Public Footpath Information and Education Centre
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Tarmac Report 2004 social social Tarmac Report 2004 Tarmac Group Head Office Europe Operations
20 Carlton House Terrace Tarmac Central Europe GmbH London Goethestrasse 85 SW1Y 5AN 10623 Berlin Tel: 020 7968 8888 Germany Tel: 00 (49) 307 908 070
UK Main Offices Tarmac Matériaux de Construction S.A.S. Zone Industrielle Northern 62440 Harnes P O Box 5 France Fell Bank Tel: 00 (33) 321 793430 Birtley Chester-le-Street Tarmac Iberia S.A.U. County Durham Juan Esplandlu DH3 2ST 11-9–28007 Madrid Tel: 0191 492 4000 Spain Tel: 00 (34) 91 212 0600 Central Tunstead House Buxton Middle East and Asia Operations Derbyshire SK17 8TG Al Futtaim Tarmac Quarry Products LLC Tel: 01298 768 555 PO Box 87111 Dubai Western United Arab Emirates P O Box 1 Tel: 00 (971) 4 3331670 Kington Herefordshire Tarmac Zawawi LLC HR5 3LQ P O Box 314 Tel: 01544 230 711 Post Code 130 Azaiba, Sultanate of Oman Southern Tel: 00 (968) 24 694 166 Churchward House Kemble Drive Tarmac (India) Pvt Ltd Swindon 12-13 Sai Chambers Wiltshire 2nd Floor Plot 44 sector 11 SN2 2TA CBD Belapur Tel: 01793 698 600 Navi Mumbai 400 614 India Contracting Tel: 00 (91) 22 2757 5437 Blyth Road Maltby, Rotherham Tarmac China South Yorkshire Suite A, 11th Floor S66 8HX Jin An New Century Plaza Tel: 01709 817 665 188 Wujiang Road Shanghai Concrete Products 200041 Millfields Road People's Republic of China Ettingshall Tel: 00 (86) 21 6218 3131 Wolverhampton West Midlands WV4 6JP Tel: 01902 353 522 Please visit the Tarmac website for more information relating Recycling to the company: www.tarmac.co.uk Millfields Road Ettingshall Wolverhampton West Midlands WV4 6JP Tel: 01902 353 522
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Tarmac Report 2004 contact us If you have any comments on this report, please write to the safety, health and environment department at the address below. Or e-mail us at [email protected]
This report is also available on the Tarmac website: www.tarmac.co.uk
R
Tarmac Limited Millfields Road Ettingshall Wolverhampton WV4 6JP www.tarmac.co.uk
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