Sharing good practice 2014 / 15 Ideas on how to make your work place safer

entries from the MPA Health and safety awards

Occupational Health We Understand Quarrying

With 20 years’ experience in construction, quarrying and aggregates IDC provides long-term, robust Occupational Health Services to any client in this sector, irrespective of organisational size or complexity.

Providing advice specific to risk, OH professionals attend site in order to offer case management advice. We believe in engaging managers and the work place in our assessment approach as this provides more informed and engaged solutions. This leads to better health outcomes for employees and employers alike.

The quality of the Health Surveillance service provided by IDC is unrivalled. We believe we are the only OH company who achieve 100% against our SLA’s and KPI’s not only now but over the previous 20 years. Additionally the robustness of our approach is proven to significantly reduce occupational health issues and insurance liabilities.

Noise Dust / Respirable Crystalline Silica HAVS

Our Gold Standard hearing assessment Our Gold Standard program delivered Our Gold Standard program delivered by and hearing conservation program by our Clinical Physiologists will assess our Qualified HAVS Assessors will identify delivered by our Audiologists will identify employees’ respiratory function and, in and forward manage mild, moderate and and manage cases of Noise Induced full consideration of length and extent of severe cases of HAVS or CTS. By assessing Hearing Loss and reduce the risk of further exposure, determine if employees require the risk (including that from previous hearing damage. This service also advises further investigation for COPD or silicosis. employment) we will advise on the on PPE and risk management, is proven This service also advises on RPE suitability necessity for adjusted duties, prevention to protect employees hearing from noise and efficiency and risk management strategies to reduce cold provocation. damage and to significantly reduce our Where necessary we will obtain a diagnosis client’s exposure to hearing claims. from a HAVS Specialist Physician.

Other Services

• Manual Handling • Safety Critical Worker • Confined Space Working • Random Drug and Alcohol • Immunity and Vaccination Assessment Assessment Assessment Testing Programmes • DSE Assessment • Working at Heights • Visual Acuity and Colour • RPE Fit Testing • Fitness for Disciplinary / • COSHH Dermatology Assessment Perception Assessment • Wellness Programmes Tribunal Advice Surveillance • Night Working Assessment • Site and Quarry Vehicle • Lost Time Accident Services • Sickness Absence • Lone Working Assessment • Kiln Wreck Assessment Driver Fitness Assessment • Ill Health Retirement Advice • Specialised Risk Assessment

The Industrial Diagnostics Company Ltd T +44 (0) 845 0775512 Atherstone House, The Sidings, W www.industrial-diagnostics.com Merry Lees, Leicestershire. LE9 9FE E [email protected] Foreword

Achieving our goal of Zero Harm will only be possible if we are relentless in our efforts to identify ways in which we can make our activities safer in every sector in which we operate. This will only be possible if we share and learn from others. The innovations, new systems and initiatives highlighted in this publication in most cases can be applied or adapted to similar situations across the industry. This publication epitomises the MPA ‘Safer by Sharing’ ethos of communicating the best ideas so that all can benefit and hopefully be inspired to think of new ideas, which in turn may be shared. MPA members have championed a huge range of initiatives to improve the safety of drivers and other road users. A new section has been added this year to specifically reflect initiatives to Reduce Operational Road Risk. This compliments other driver related initiatives summarised in other sections. The importance of engaging with the wider community and campaigns that encourage employees to share key health and safety messages with their families are also highlighted in several other entries. The MPA Health and Safety Awards are open to all and attract entries from SMEs, the larger companies, suppliers and service providers to our industry. They are judged independently and celebrated annually at our Health and Safety Conference and Awards event. Whether an MPA member or not, please share your health and safety successes by entering the 2015 awards. The short listed entries summarised in this document can also be found online at Safequarry.com together with all the ideas from previous years and many more routes to best practice. For those who have downloaded the Safequarry App, the winning entries from 2014 and 2013 can be viewed together with the videos supporting these entries. Please share the App with your colleagues. We have already exceeded 500 users for the App, we want to grow this so that everyone is able to benefit from immediate and free access to key health and safety information when they need it. I do hope that you will find the 2014 contributions helpful and worthy of discussion with colleagues as we look forward to receiving new ideas for celebration and sharing in 2015. Nigel Jackson, Chief Executive

John Crabbe Memorial Trophy for Sir Frank Davies Trophy for companies with Outstanding Excellence in Health & less than 1000 employees – Kilwaughter Safety – Hope Construction Materials. Chemical Company. Trophy sponsored by Babcock Trophy sponsored by Industrial International Diagnostics Company

Contributors to H&S Awards in 2014

MPA Wales Regional Working Party Joint Entry EPC-UK Marshalls PLC Quarries Partnership Team (QPT) FM Conway Ltd Moreton C Cullimore Aggregate Industries UK Ltd Forticrete Myers Group Charcon Flooring Golder Associates (UK) Ltd Northstone (NI) Ltd Charcon Construction Solutions GRS Roadstone Sibelco UK BAM Ritchies Hanson Aggregates Singleton Birch Limited Bathgate Silica Sand Hanson Smith & Sons (Bletchington) Ltd Breedon Aggregates Ltd Harsco Stanton Bonna Brett Group Hills Quarry Products Ltd Steetley Dolomite Brett Landscaping Hope Construction Materials Transport for London CEMEX Kerneos United Asphalt Ltd Chepstow Plant International Limited Lafarge Tarmac Weinerberger Colas Ltd Lagan Cement CPI Euromix Whitemountain Quarries Limited 2 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 2014. Some of the entries are flagged to show that there is a video available – the videos can be viewed at www.safequarry.com. In addition to this year’s entries, awards from previous years can also be accessed. The website features a database of incident alerts, toolbox talks and the latest on the industry’s hot topics. By registering on the site, you will receive email alerts when new items are added and an ‘information basket’ where you can store those that most interest you. The resources are ideal for training purposes and for Continuing Professional Development (CPD). We hope that organisations of all sizes working within the mineral products industry will find them useful and accessible. To ensure that your browsing on www.safequarry.com is recorded for CPD purposes, you do need to log in every time that you access the website. The winning entries and related videos can also be viewed on the Safequarry App.

How to use this guide

This guide is a compilation of solutions that MPA companies have applied to minimise and, where possible, eliminate health and safety risks arising from their daily operations. The ideas and innovative approaches are often very simple and inexpensive and could readily be applied to a range of common industry problems. It is hoped that by reviewing this guide, particularly those sections relating to your main area of work, you will recognise solutions that could be applied within your own workplace or that 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 & safety in the work place. 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 that available via www.safequarry.com, please send an e-mail to [email protected] quoting the entry number which is located immediately to the left of the entry title. The sharing of best practice is crucial in helping the industry to achieve target zero.

Contents

Bitumen, Asphalt & Contract Surfacing 4 Transport Initiatives 27

Sponsored by the Refined Bitumen Association Sponsored by Brigade

Contractors Safety 10 Occupational Health and Well Being 30

Sponsored by Mentor Training Sponsored by Addax International Limited

Engineering Initiatives 14 Worker Involvement 32

Sponsored by Hycontrol Sponsored by Institute of Quarrying

Behavioural Safety, Safety Culture & Leadership 20

Sponsored by MPQC Mineral Products Qualification Council Index 35 Reducing Occupational Road Risk 24 Health & Safety working groups 36 Sponsored by TfL Transport for London

visit www.safequarry.com for more details or email: [email protected] 3 8 hour ON ON 3 VIDEO VIDEO UP AWARD RUNNER WINNER Improved traffic management on-site. traffic management Improved Reduced riskcollisions and other incidents when vehicles of manoeuvring are Reduced risks injury of banksmen to Visibility instructions of banksmen and significantly enhanced Total respirable dust reduced from 3.86 to 1.09 mg/m 3.86 to from dust reduced respirable Total Improved morale and sense of pride in what has been Improved achieved. Better control of risks of fire in the event control Better Improved dust control and housekeeping dust control standards Improved Safer environment for operators for environment Safer Respiratory is no longer required protection Visually, all fumes are evacuated within 2 minutes evacuated all fumes are Visually, Temperature reduction achieved within 7 minutes reduction achieved Temperature Air temperatures maintained below 24°C while the fan is 24°C while the fan maintained below Air temperatures operating. Respirable crystalline silica reduced TWA

BENEFITS BENEFITS l l l l l process of developing a solution. It of developing process install a blower to was decided contaminated purge the side of the building that would fan onto a fine mist of water produce that would add a system air and to creates new system The particulate suppress that would matter. work and will help maintenance working for a safer environment is activated priorto The system of a fire. the spread control to alarm. by the fire staff entering building or the maintenance l l l l l l l l l Bitumen, asphalt & contract asphalt Bitumen, surfacing sponsor DESCRIPTION DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Installing ‘Fire Fan’ on sealed asphaltInstalling ‘Fire Fan’ plant house Express Asphalt Aggregate Industries UK Ltd > Darwen Lafarge Tarmac was seeking an effective way to improve the to improve was seeking way an effective Tarmac Lafarge visibility of banksmen and the clarity of instructions they were was importantThis as surfacing drivers. work often takes to giving with delivery frequently highways vehicles place at night, on live area within a limited and manoeuvre reverse to being required with other plant workingproximity. in close a super bright, compact and lightweight traffic research Following 300 over at effective wand was developed, It base enabling it to meters. has a magnetic stationary to be mounted metallic objects/ function. LED torch and a useful white vehicles colour banksman can change the wand’s The the instruction being given. reinforcing has been of training sessions A programme supervisors, site involving implemented and deliverybanksmen, plant operators drivers Wand.’ ‘Traffic Safety on the use of the Traffic Safety Wand for banksmen Wand for Safety Traffic Contracting Tarmac > Syston Lafarge The Darwen Asphalt Plant is located within a sealed building. Darwen within a sealed building. The is located Plant Asphalt respirable in a build-up of both heat and fine results This a hazardous dust with a high concentration of silica creating undertaking Operators environment. maintenance and repair use respiratory to suits which were protection required work were of +40°C. Furthermore, at air temperatures uncomfortable wear to brigade recovery casualty had identified potential the fire to smoke due build-up. fire, event of a difficulties in the in the involved staff was the site identified these issues, Having 605 551

bitumen, asphalt & contract surfacing 4 bitumen, asphalt & contract surfacing 5 HIGHLY HIGHLY COMMENDED COMMENDED Simple, low cost safety system that can be installed in four that can be installed in four system cost safety low Simple, hours. Possibility of injuryPossibility reduced operators to Safer, cleaner and more efficient plant. cleaner and more Safer, Less material wastage through spillage material wastage through Less Energy consumption reduced by 25% by consumption reduced Energy Plant production rate increased from 88tph to 98tph 88tph to from increased rate production Plant Improved distribution skip of material into Improved capacity increases of the skip 2.1 tonnes to Manual handling involved in cleaning around skip in cleaning around removed Manual handling involved

BENEFITS BENEFITS l l running and continues to power work lights, beacons and other beacons and other work lights, power running and continues to particularly items essential safety working. during night-time A when is illuminated switches proximity of the small light at the rear closed. are the guards l l l l l l although the mixer could handle a 2.1 tonne mix, if a customer mix, if a customer could handle a 2.1 tonne although the mixer in two be completed of material this had to 2 tonnes required batches. drip door between the mixer a mixer for solution was a design The spillage whilst the skip any is not prevents This and the skip. box directly underneath of material with the ability direct the flow to capacity. the skip, thus improving into visit www.safequarry.com for more details or email: [email protected] Before (left) (above) and after Before

DESCRIPTION DESCRIPTION Following publication of the MPA chipper guidance, a plant fitter a plant fitter chipper guidance, publication of the MPA Following on guarding the trough was reviewing Aggregates at Breedon could He was concerned that the guards chipper. a hydrostatic this resolve To the machine. isolated without having be removed and at each end of the trough, fitted risk, were switches proximity the trough reason any If box. for the main control connected into the to the power opened when the machine is running, are guards remains engine The them turning. which stops augers is removed,

Installing interlock system on chipper guard Installing interlock - Ethiebeaton Breedon Aggregates Ltd > East Contracting

Mixer drip doorMixer Asphalt Tarmac > Cambridge Lafarge The design of the discharge system from the mixer box into a into box the mixer from system of the discharge design The in a maximum deliveryskip resulted below positioned of just be manually small spillages that had to and frequent 1.7 tonnes capacityThe limitation also meant that on a daily basis. cleared 583 536 HIGHLY HIGHLY COMMENDED COMMENDED Solution could easily be replicated on other plants. Solution be replicated could easily System is low cost and easy to install cost and easy to is low System Reduced maintenance time and improved visibility in control visibility in control time and improved Reduced maintenance room Cleaning of camera lens safely completed using control using control completed Cleaning of camera lens safely level at ground switch Eliminates risk of both injuryEliminates and damage in the future. A robust skip/winchA robust braking in place is now system

BENEFITS BENEFITS l l l l achieved by carefully positioning a copper pipe bent to shape to shape to copper pipe bent to positioning a carefully by achieved copper pipe is connectedThe the lens. direct the blast of air onto and is solenoid controlled. air system the to l l meant that when the gearbox failed, there was no means of there failed, gearbox meant that when the winch includes an electro/ replacement The the winch. stopping spring applied disc brake the drum. that activates onto directly the skip in the system, be a failure that should there ensures This held in position. and immediately will be immobilized DESCRIPTION Description Theale Asphalt Plant uses CCTV Plant Asphalt Theale enable the critical to parts of the the from manufacturing be monitored and loading to process room. control dust and exposed to are the site around cameras located The Cleaning basis. be cleaned on a regular the lens to fumes requiring use either a ladder or MEWP to with the the operator necessitated consequent risks with working associated at height. simplify the task, this issue and to a solution was resolve To on air system the existing compressed that utilised developed that enabled a burst of air was set up box the plant. A control was This camera. the lens of the appropriate applied onto be to visit www.safequarry.com for more details or email: [email protected] CCTV lens cleaning from ground level CCTV lens cleaning United Asphalt Ltd > Theale Industry first in skip winch braking systems braking skip winch first in Industry SteelPhalt Harsco > Following an incident in which a skip’s winch braking failed system in which a skip’s an incident Following plant the asphalt into the stops through fall’ ‘free causing it to damage and loss of business during in extensive repairs. resulting in conjunction Hall and Benninghoven, with Qualter Harsco, and installed a revolutionarydesigned secondary braking system incident could not be repeated. the ensure to the only braking modification, was located on the winch Before within the electric which of the gearbox) the input side (on motor 609 543

bitumen, asphalt & contract surfacing 6 bitumen, asphalt & contract surfacing 7 HIGHLY COMMENDED Process has enhanced safety culture on the site. culture has enhanced safety Process Safer environment for both drivers and operators and operators both drivers for environment Safer Tankers ideally positioned to complete deliveries complete ideally positioned to Tankers Avoids possibility the tanks into of tankers reversing Avoids Easier for drivers to complete unavoidable reversing reversing unavoidable complete drivers to Easier for manoeuvres Warning allows remedial action before system is shut down. system action before remedial allows Warning Drivers very about changes positive System in place to monitor critical parameter monitor safety in place to System Reduced risk of fire

BENEFITS BENEFITS l l l l l l l l parkingdesignated was marked area out in high visibility floor set up as sleepers were markings Painted assist the drivers. to point at the optimum distance stop a physical curbs provide to the tank,from taking account the delivery into hose lengths. restrictA chain barrier was also put in position to with signage access when bitumen was being delivered. l for some rudimentary investigation and repair, or if it rises a set to some rudimentary and repair, for investigation the fire removing is turnedpoint, the bitumen dosing system off risk. visit www.safequarry.com for more details or email: [email protected]

DESCRIPTION description

Designated off-loading area for bitumen tanker deliveries Designated off-loading area for bitumen CEMEX > Billingham Coating Plant

RAP chute monitor RAP Plant > Marini Asphalt Hanson Staff at Billingham Coating Plant decided to review and improve review and improve to Plant decided Coating Staff at Billingham Over a two their bitumen tanks. week to of deliveries the safety period with delivery they consulted drivers about what would A simple all on-site. for assist them and make the operation safer For each tank, a change was implemented: and cost effective At Hanson’s Marini Asphalt Plant, conditioning stone exiting the exiting the conditioning stone Marini Plant, Asphalt Hanson’s At It is added. bitumen found was dryer RAP before with is mixed of the stone the temperature of the RAP, that without the addition the dryer being the bitumen leaving ignite was high enough to feed risk. causing a fire RAP A consistent the mixer, into sprayed a means of of the plant and critical the safety to was therefore monitoring the RAP at the point of entry was required. that probe solution was the installation of a level The probe The the RAP at the point of entry. independently monitors and if it increases of RAP in the chute the percentage monitors an amber light has blocked, meaning the chute a set level, above be a problem may indicating there room comes on in the control allows This and a warning screen. alarm appears on the PC control 589 648 Maintenance can be and carried out safely efficiently at height.

Before (far left) (left) and after (far Before l BENEFITS and hand rails. and hand rails. Reduces the number of people carry to required out maintenance. Eliminates Eliminates possibility of strain injury More control over the whole delivery over control process. More Drivers no longer need to reverse Drivers no longer need to Delivery drivers segregated from other traffic Delivery from drivers segregated Housekeeping much improved Housekeeping improved much Mixer man is able to monitor drivers and deliveries safely drivers and deliveries monitor Mixer man is able to Trip hazards removed from site and pedestrians site protected from removed hazards Trip Positive feedback from delivery in from feel drivers who now feedback Positive of deliverycontrol process

BENEFITS BENEFITS l l l l l l l l l lighting and a camera were installed, traffic management was installed, lighting and a camera were adjusted. levels and ground reviewed working at height with associated risks. The solution was to replace replace solution was to The working risks. at height with associated that guard with a specially designed guard the existing tail drum working access steps with incorporated complete a safe platform, DESCRIPTION DESCRIPTION During routine maintenance of the burner maintenance on the asphalt plant During routine push the burner to back required two people were at Ettingshall, cause a strain to had the potential This cleaning. along its tracks for injury attach the solution was to The and was very impractical. pull the burner to burner a pneumatic ram specially designed to lever position via a control maintenance its safe back into slowly at source ram can be isolated The distance away. a safe mounted the burner being work is completed, whilst the maintenance its working to gently returned position via the ram. Hanson > Ettingshall Safer bitumen through effective visual and soundSafer bitumen through of delivery management at point Lafarge Tarmac > Santon Asphalt Burner ram for safer cleaning Following the introduction of new guidance for ‘Safe Bitumen Tank Tank Bitumen ‘Safe of new the introduction for guidance Following working asphalt plant set up a the staff at Santon Management’, Itparty was decided could be improved. deliveries how review to clear and be made following would that all tank/silo deliveries all drivers. to provided information easily understood installed alarm high-high level were and an ultimate A high level lamps and a klaxon.on each tank with indicator Each tank was also the driver light informing indicator green with an additional fitted the unit shows display accept 28t. A large that the tank is able to accept. the tank is able to ullage that and the safe tank contents of the delivery Barriers, layout improved The point was changed. DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Tail drum guard and platform guard Tail drum > Ettingshall Hanson Access to the dust feeder, hopper and vibrators at the asphalt hopper and vibrators the dust feeder, to Access a concernplant at Ettingshall was often required as maintenance 642 643 532

bitumen, asphalt & contract surfacing 8 bitumen, asphalt & contract surfacing 9 Significantly strengthened the fire safety position at the site. position at the site. safety fire the strengthened Significantly Enhanced compliance with the requirements of the Enhanced compliance with the requirements 2005 Order) Safety Regulatory (Fire Reform More robust site emergency response procedures emergency site response robust More Simplifies a complicated site promoting a rapid extrication promoting site Simplifies a complicated be put in danger life should any No manual handling or lifting since doors open outwards. Faster response in the event of a fire emergency of a fire in the event response Faster possibilityEliminates of splash backs and burns drivers to Hydrant location map, key Hydrant isolation points and fire location map, extinguisher location map guide Innovative bitumen tank fire

BENEFITS BENEFITS l l l l l l l 6. erected sign a large guide was also converted into fire The firefighting by quick reference for the bitumen tanks adjacent to servicereviewing and local fire The site, engaged with the teams. pack. information the safety improving 5. visit www.safequarry.com for more details or email: [email protected]

Key location map – schematics of the site and plant, ideal for Key and plant, ideal for location map – schematics of the site ‘Incident Pack’ Command an materials map and information Hazardous Innovative gantry casualty facilitate map – to layout extraction and brief in-going teams Key key – staff numbers and information site holders, locations

DESCRIPTION DESCRIPTION

Safety locking device CEMEX > Local Asphalt Carlisle

Fire box to house critical information critical to house Fire box Ltd > Darwen Industries UK Aggregate Staff at Local Asphalt Carlisle designed and built a safety locking and built a safety CarlisleAsphalt designed Local Staff at of the unit front The of bitumen. deliveries safer ensure device to to be enable the flange and bolts slides forward on runners to place and locked. is slid back into the cover before tightened of with the design Bitumen delivery involvement drivers had direct the device. 2. 3. 4. The manager at Darwen asphalt plant, a former firefighter, was manager at DarwenThe firefighter, a former asphalt plant, the emergency services from concerned that anyone unfamiliar needed if all the information not have would with the site this he liaised with address To in an emergency. the site attending format service of the information the ideal the local fire and agreed to the entrance, was installed close box fire A bright red required. relevant information: all the housing a file containing 1. 618 660 ON ONON VIDEO VIDEOVIDEO UP AWARD RUNNER WINNER Approach can be used to develop new modules for new develop modules for can be used to Approach other areas. Compliments the PICs database Compliments Information on contractors’ performance and Information on contractors’ competency is shared interrogate to and easy is easily updated System this approach contractors to from feedback Positive

l l l l l process Ensures language is not a barrier to an effective induction language is not a barrier an effective Ensures to Consistent approach to induction across sites and avoiding and avoiding sites induction to across approach Consistent duplication System helps identify an individual’s needs that can then be needs that can then helps identify an individual’s System addressed Inductees learn more by reading the materialInductees themselves reading by learn more Induction process reduced from 2.5 hours to 30 minutes 2.5 hours to Induction from reduced process Workshops were well received by collect by customers received well were Workshops support to committed are Collect campaign customers with their staff packages employers used by were Training to approach A consistent applied procedures safety the region across Scheme is on-going and monitored. results

BENEFITS BENEFITS l l l l questions at the end of each. Contractors work through the work through each. Contractors questions at the end of at booths equipped with computer based induction process eight of the major into translated Each module has been terminals. cam a web is issued using ID card A photo languages. European book. standards and a site the PICs and compliments CEMEX sites across is shared system The system. l l l l l l Contractors safety sponsor safety Contractors DESCRIPTION DESCRIPTION CEMEX UK’s Rugby Cement Works wanted to improve their improve to wanted Works Cement Rugby CEMEX UK’s It contractor 2.5 hour site that the induction was felt process. did not address induction based on videos and PowerPoint experience and the contractor’s sufficiently the individual was also system The the job. for particular required competencies contractors. abuse by open to potentially web-based management a comprehensive, CEMEX developed that the ensured This package on the individual worker. focused and job specific issues. the site It induction for was appropriate be to for the task competencyhelped confirm the contractor’s including personal history, carried the individual’s out through experience task and site-specific training, performance monitoring. and poor-performance feedback tracking enabled Positive supervisors issues. identify and address to is based on 11 short system The with pass or fail modules visit www.safequarry.com for more details or email: [email protected] Asphalt collect customer safety initiative Asphalt collect customer Wales Regional Working Party joint entry > CEMEX, Hanson, Aggregate Industries, Lafarge Tarmac, G.D. Harries and Sons Web based computer induction system induction based computer Web Works Rugby Cement CEMEX > Members of the MPA Wales Regional committee were concerned were committee Regional Wales Members of the MPA with collect of safety at their customers the standards by improvements, achieve that to They recognized asphalt plants. need would operating procedures of safe standard a consistent to It that the best way all sites. was agreed be applied across to workto in partnershipinfluence change was by and use the Safer Sharing approach. A working party a policy all the where was established and agreed operating procedures. safe implement consistent would operators in a set of rules held resulting Several meetings were card. safety and don’ts and the publication of a do’s part formed induction.This of the collect customer’s of the employers held for A number of workshops were practices examples of unsafe workshops, At the drivers. and the new policy highlighted was explained. were Training along with consequences of non-compliance. their staff. to give them to for packages provided were 636 592

contractors safety 10 contractors 555 HIGHLY Reducing contractor risk COMMENDED EPC-UK > Rough Close - Alfreton

DESCRIPTION Experience of contractor failures identified a need to improve performance of contractor control. EPC therefore revised their selection process, site induction and contractor control processes, categorising work as high or low risk and assigning an appropriate safet y level of supervision. The approach conforms to HSE guidance and uses behavioural safety audits as part of the monitoring process. All contractors l DuPont Behavioural Safety STOP audits are often carried were invited to a briefing prior to the launch of the new process out with senior managers along with discussions relating to and senior management’s commitment to this initiative was safety with contractors employed at their point of work. emphasised. Key elements included: l A written acknowledgement is provided by the contractor l Pre-screening of contractors including a review of their when the task is complete and, after a final inspection, the training and competence assessment of employees, risk process is returned to production control assessments and method statements l Each job undertaken by a contractor is assessed against l All contractors on-site to undergo a site induction, repeated criteria and a total score allocated. When the score falls below annually or earlier an agreed level, a meeting is arranged with the contractor to l A method statement and risk assessment is required prior to advise them of the unacceptable standard of work. commencing work of a hazardous nature BENEFITS l Revised contractor control procedures based on the level of risk. High risk tasks to require in-depth review of all key l No contractor-related incidents in last 12 months elements relating to the task plus the control measures. l On-going review of contractor performance The procedures are documented and signed including an l Contractors helped to enhance their performance agreement from the contractor that they understand and will l Incentive for contractors to be high performing follow them l A safer working environment for all.

637 HIGHLY Contractor safety COMMENDED Chepstow Plant International Ltd > Company wide

DESCRIPTION pressurised equipment is also checked and copies of certificates Following an incident where a contractor working for Chepstow for these items must be shown before the Permit is issued. International Plant received a RIDDOR reportable injury, a decision Once the contractor has met the standards set, they are allowed was made to improve contractor controls. to proceed with the task, but are subject to regular supervisory All contractors must complete a detailed pre-qualification checks by the supervisor or manager. The checks are recorded, questionnaire. The information supplied is recorded, and where including the time, date, and a description of the progress of the necessary, checked against databases on the HSE website. The task. information is reviewed and updated on a monthly basis. The number of Permits to Work issued across all sites is one of the All site supervisors and managers conduct checks on the key health and safety performance indicators. The standard of the contractors coming on-site, recording the information on a Permits is subject to the audit and site inspection programme General Permit to Work. This ensures that the contractors’ risk conducted by the health and safety managers. assessments and method statements are correctly completed, BENEFITS up-to-date and relevant to the task; that they hold the correct l Clear standards and procedures in place to manage safety qualifications to attend the site and that they have copies of contractors their cards or certificates available, such as Safety Passport Alliance, l A safer working environment Essential Minimum Safety Standard or other standard as dictated by the company’s clients. l Performance is being measured. Any specialist lifting equipment, electrical equipment or visit www.safequarry.com for more details or email: [email protected] 11 System has been adopted in over 30 other sites. 30 in over has been adopted System Operatives have all the appropriate PPE and information PPE and information all the appropriate have Operatives Complies with COSHH emergency procedures with COSHH Complies Significantly reduced risk of incident involving washing down reduced risk of incident involving Significantly Easy access to all emergency equipment and faster response all emergency response Easy access to equipment and faster in an emergency. Fitters operate more efficiently more operate Fitters environment in a clean, safe administered aid can be First Positive feedback from contract fitters from feedback Positive Safer and controlled working environment for fitters working for and controlled environment Safer site around to travel no longer need Contract fitters

BENEFITS BENEFITS l l l l l l l l l l DESCRIPTION DESCRIPTION Following an incident where a driver’s eye was contaminated with was contaminated eye a driver’s where an incident Following at Hope Construction manager a production acid, hydrochloric to wash station’ ‘acid Materialsthe concept of an developed kitThe is the possibilityeliminate of a similar incident occurring. required elements self-contained and includes all the different using a 14% and plant washing of vehicles safe complete to acid solution. hydrochloric risk acid’ ‘using a kitThe container, contains a sealable storage of work, data sheet and risk system COSHH assessment, safe a set in and out sheet, an extendable broom, assessment, a sign an apron, glasses, a set of wrap-around safety of gauntlet gloves, wash FFP3 RPE and eye acid, putting on container for stickers for station. visit www.safequarry.com for more details or email: [email protected] Fitters’ safe working area, first aid room and emergencyFitters’ safe working equipment store Breedon Aggregates > Beauly Quarry Acid wash station Acid > Greater London Materials Hope Construction At Beauly QuarryAt close located were and oil storage the container fitters exposed the maintenance This plant. busy processing a to these reduce To movements. and vehicle dust noise, excessive to to service contract working fitters for a safe area mobile hazards, is bunded on three The new area plant was created. and fixed spill kits containers, waste and sides with the quarry oil store, store, fitter’s The all held within the area. burning equipment etc. welder, which is then closed off with a chain link van parks within this area fence. In room and emergency addition, a new equipment store first aid within this area. also created were 586 542

contractors safety 12 593 Combined permit office and isolation station contractors CEMEX > Rugby Cement Works

DESCRIPTION At Rugby Cement works, the permit station was small and separated from the isolation station. Following consultation with employees and contractors, it was decided to increase the size of the existing isolation station and incorporate the permit station to safet y allow co-ordination of both activities. Each job is now allocated a pin reference number. The pin is placed on the plant schematic layout board and the relevant numbered permit rack is used to store all the job information (risk assessment, method statement, any additional special permits etc.). All personnel lock-off on a multi isolation box, cross referencing with the permit. For the winter shutdown, a larger isolation box is provided so that whole sections of the plant can be isolated and locked-off at any one time, avoiding numerous individual isolations.

BENEFITS l One-stop-shop for permit issue and isolation l Easy cross referencing of permit and isolation l Management can see where all the works are at a glance, allowing targeted inspections l Ideal venue for important safety information to be shared l Allows all relevant information for each job to be stored in one place l Any overlapping works can easily be seen and accommodated.

674 Contractor induction assessment Hills Quarry Products Ltd > Company wide > Swindon

DESCRIPTION the site-specific issues and relevant control measures. It is linked Hills were concerned that although they had well-established to a Permit to Work procedure which forms part of the Induction systems for the management and control of contractors on-site, Assessment record. there were occasions when contractors were showing their BENEFITS staff generic documentation produced by health and safety l Raises the profile of health and safety with contractors professionals and using these rather than Hills’ own system. The l Contractors understand exactly what Hills requires and contractor would not have the benefit of the site and task specific avoids working to a generic SSOW information or understand the standards and controls that Hills’ l Both Hills’ staff and contractors think more about the health required, to maintain their safety and that of employees. and safety requirements of the specific job. To address this issue, a ‘streamlined induction assessment’ for contract workers was issued. The contractor is taken through a Contractor Induction Assessment which is recorded, to identify

visit www.safequarry.com for more details or email: [email protected] 13 ON ON VIDEO VIDEO UP AWARD RUNNER WINNER Can be installed at various depending upon the Can levels application. Relatively quick and easy to install quick and easy to Relatively Tested by the Building Research Establishment and each the Building Research by Tested 9m height capable of withstanding at least 400 kg from Can be manufactured to any size application size any be manufactured to Can Rugged construction Re-usable system Bracket can be easily and to cheaply fitted relatively existing conveyors. Halved the maintenance the maintenance Halved replace to time required rollers Eliminates risk of the return rollers falling during installation risk rollers of the return Eliminates or failure Eliminates need to use mobile elevated work platforms on work platforms use mobile elevated need to Eliminates with one-sidedconveyors walkways

BENEFITS l l l l l l l l l l Engineering InitiativesEngineering sponsor Reduces risk for maintenance fitters who no longer struggle fitters maintenance Reduces risk for installation for holding rollers with only a area catchment the onto Roller can be slotted 30mm spanner required

DESCRIPTION DESCRIPTION BENEFITS visit www.safequarry.com for more details or email: [email protected] Installation of airbags for additionalInstallation of airbags overhead protection CEMEX UK > Rugby Cement Works Return roller bracket for conveyors for roller bracket Return Quarry Tarmac > Mountsorrel Lafarge During the annual winter shutdown two tasks were identified, identified, two tasks were During shutdown the annual winter both on the same critical path, and which impacted upon each Back be carried was needed to out on the Hog’s Work other. refractory lining and at the same time was needed on the flash connected the drier, is 92m above Back Hog’s The drier liners. the be needed for would Protection ducting. diameter large by falling material. against any personnel working below, to the nets fitted protection roof In the standard addition to Back, trialled, a series airbags of were refractory lining in the Hog’s were and three installed at different in the ducting. levels They sat on steel and were beams, cushion to designed and absorb the impact falling from of anything The above. airbags sealed tight up were against the side of the ducting. downcomer A maintenance engineer at Mountsorrel Quarry engineer A maintenance a designed a range of issues that traditionally bracket address to roller return difficult and rollers the return made the task of replacing the de-weighting bracketThe removes hazardous. potentially normal points with a locating roller’s the return replacing issue by permanent purpose-built the weight Instead of removing cradle. pivoting by is removed raising the belt, the weight of the belt by ‘cage’ a into down the roller and dropping the cradle downward then be to the roller cradle allows The the active conveyor. below accidently without risk of the roller or replaced, easily removed enable the to the cradle has been designed When in place, falling. position. be lifted easily back into to roller l l 590 548

Engineering initiatives 14 Engineering initiatives 15 ON ON VIDEO VIDEO UP HIGHLY RUNNER COMMENDED Cutting is quicker, less arduous and undertaken less arduous at ground is quicker, Cutting level. Reduced manual handling is easier. process Cleaning and maintenance Reduced risk of pneumatic high pressure injectionsReduced injuries risk of pneumatic high pressure easier with the wider access be significantly would A rescue Elimination of hazards of hazards Elimination with associated trailing cables (415 volt) comfortable when entering and more feel much safer Staff screen the bottom onto Reduced risks from working at height for and the potential muscular and skeletal injuries

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

Reduced risks associated with noise, dust, HAVs, slips trips dust, HAVs, Reduced risks with noise, associated and falls

Confined space improved access Confined space improved Scaur Quarry Aggregate Industries UK Ltd > Ghyll DESCRIPTION BENEFITS DESCRIPTION

Plasma cutting trolley cutting Plasma Flooring > Morpeth Charcon Ghyll Scaur Quarry has a vibrating twin deck screen. To access the To Scaur QuarryGhyll twin has a vibrating deck screen. deck,bottom styletop it is necessary the linatex remove to first Due to grid. a section of the metal screening mat and then remove supportthe narrow is very steelwork, manhole created the narrow. of the deal with blinding to regularly quite is required Access gear required safety the amount of Due to screen. bottom of silica in the gneiss the presence including dust masks due to importantly More process. it was an unpleasant and difficult stone, prove or ill colleague would an injured of rescuing the process very difficult. section and out one cross cut was to solution developed The The bolted section. it with a suitably flanged bolted replace section has performed satisfactorily of high vibration in this area deck has the bottom access to when the section is removed, and, doubled in size. effectively l Charcon Construction Solutions introduced plasma cutting Construction Solutions introduced Charcon T beam manufacturing at their Morpeth process the into held, hand the use of heavy, replaced This manufacturing site. T beam. used whilst standing on the which were saws petrol trailing electrical that and it was realized During commissioning, of the plasma the manual movement pneumatic cables and travel to was developed A trolley hazards. were cutting devices, with suspended cables on a small integrated of the beams, on top It the monorail. incorporated which allowed a set of side wheels ‘crabbing’. the side of the beam without be guided by to trolley 606 666 ON ON VIDEO VIDEO HIGHLY HIGHLY COMMENDED COMMENDED Eliminated the need to work in confined space the need to Eliminated reduced risk of muscular and skeletal Significantly injury process. effective reliable and cost efficient, More

BENEFITS l l l out maintenance as the plant needed to be isolated. Spillages be isolated. needed to as the plant out maintenance A difficult and be manually cleared. had to and frequent were task working constant to the physical Due in a confined space. very were costs repair with bearings high and conveyor flooding, conditions. in the damp frames suffering whole enable the to the feeder redesign solution was to The replacement The carried be ground. to out above process purpose-built easy maintenance, allow and work area platform and inspection and clearing much easier. of spillage is now distance guarding. The interior The distance guarding. for allow tight to space was too This caused specific guarding. major difficulties when carrying Reduced manual handling and confined space workingReduced manual handling and confined space and maintenance for required Reduced time and manpower inspection.

DESCRIPTION Reduction of confined space at the quarry at the space of confined Reduction > Rainham Quarry Brett Group The feed hopper at Rainham hopper Quarry feed The level was built at ground in a very situated and feeders with the majority of conveyors flooding. to prone which was ground below area hard-to-access by was in a confined space and protected area designated The DESCRIPTION BENEFITS visit www.safequarry.com for more details or email: [email protected] Removable working platformRemovable working Lafarge Tarmac > Barrasford Quarry At Barrasford Quarry, the access to the conveyor head drum that the conveyor Quarry, the access to Barrasford At carried the primary material from required secondary to crusher, or inspection maintenance was carried each time any a scaffold hopper feeding is a reception the conveyor below out. Directly a confined the secondarymaterial into crusher and therefore when working was required on the space management approach this task how reviewed of employees drum. A team head conveyor and quicker. could be made safer and raised that could be lowered solution was a platform The visual inspection of safe for it allows When raised, using a winch. When lowered scaffolding. the head drum without the need for can be maintenance suitably isolated, and with the conveyor the crusher hopper for and the feed carried out on the head roller, of the the grid through ‘rodded’ if appropriate, and, can be viewed platform. l l 608 581

Engineering initiatives 16 Engineering initiatives 17 ON VIDEO HIGHLY COMMENDED Task is more easily completed and the blowbar is guaranteed is guaranteed and the blowbar completed easily is more Task release. to operators. working for Improved environment Fitter can stand at a distance during vibratory process Fitter temporary from risk crusher bowl of falls into Eliminated ladders Manual handling eliminated by use of the crane Manual by handling eliminated maintenance from risk has been eliminated Significant operation Vibrator framework has eliminated whole body vibration framework has eliminated Vibrator working when maintaining crusher. Safer environment

BENEFITS BENEFITS BENEFITS l l l l l With has been removed. plates barrier wear between the concave a purpose built from in place the men can work safely ‘top hat’ this against concaves protection behind a barrierplatform providing the use of has eliminated This procedure off. falling or pinging ladders with harness. l l l visit www.safequarry.com for more details or email: [email protected] Hanson > Cliffe Hill

DESCRIPTION DESCRIPTION DESCRIPTION

equipment ‘Top Hat’ rotary crusher concave replacement safety‘Top Hat’ rotary crusher concave replacement

Access platform for changing primary crusher jaw Access platform for Quarry Breedon Aggregates Ltd > Leaton

Blowbar vibrator unit vibrator Blowbar Quarry Aggregates > Whatley Hanson Cliffe Hill operates a large gyratory crusher. The bowl is lined with The bowl gyratory a large Hill operates Cliffe crusher. out at the edges. thinner and splay which can wear plates wear ‘squashing’ since the the adjacent plates to energy transfers This together building up stored neighbouring plates forces effect to need plates when worn Thermal lancing is employed energy. the for is a potential and during this operation, there be replaced, concave large pinging suddenly, be released to energy stored attach to have operators where the crusher bowl into plates wear extract to lifting the heavy plates chains to them. this risk, eliminate that and built a structure has been designed To workplace, and a a safer form to the crusher bowl can be lifted into Quarry QuarryLeaton at the fitters struggled when changing primary while to stand place find a safe both to crusher jaws the avoid and bolting it in place and to locating the jaw of a crush injurypotential balanced. if it over making was designed, solution this A fully in-house engineered been cleared Once the crusher has safer. considerably exercise The position. into is lowered an access platform of material, working with its both a safe location and, provides platform possibility falling back any of the jaw from barriers, protection The platform located. it has been securely before a fitter onto lift and the hoist can still be used to sits on the crusher feedbox in and out. the jaw Changing blowbars on the primaryWhatley blowbars QuarryChanging crusher at it in position. hold to stand on the vibrator someone to required so designed are a tonne, approximately weighing each bars, The be When the bars need to position. into self-wedged that they are a sledge hammer before be loosened using to they have changed, out sideways. they can be drawn the hold unit frameworkA new to has been installed vibrator dust Once the in position and shake the blowbars. vibrator down is the vibrator under the blowbar, from away has been blown cradle vibrator The crane. the overhead position by into lowered It is switched that it is correctly positioned on the blowbar. ensures it becomes loose enough to so is vibrated on and the blowbar so that its has been designed vibrator The enable its removal. blowbar. the hold itself onto enables it to weight 670 647 560 System is being deployed at other sites. at other is being deployed System More efficient operation More Units no longer exposed to weather damage weather Units no longer exposed to Removes slip, trip and fall hazards slip, Removes Safer workingSafer all. for environment Bund wall heights’ Bund wall heights’ easily checked and maintained at correct levels Low cost tool, easily adapted for use with other industries. for easily adapted cost tool, Low Increases the longevity their of coupling clamps and reduces replacement costly premature Enables incompatible hose tails on delivery haulier tankers to be managed out Encourages the inspection and reporting of non-compliant systems Reduces potential for manual handling injuries forcing handling injuries manual forcing for Reduces potential incompatible hose coupling Reduces emissions of product to atmosphere Reduces emissions of product to Increases personal safety through fewer incidents fewer through Increases personal safety A quick and easy check to apply before delivery commences before apply to A quick and easy check

BENEFITS BENEFITS BENEFITS l l l retaining units can be fitted by one units can be fitted retaining one side of the bed. from operator It is portable so it can be stored The when not in use. under cover width mechanism accommodates in the various beam differences type moulds. l l l l l l l l l l achieves correct seating of seals and effective clamping. clamping. correctachieves of seals and effective seating l DESCRIPTION DESCRIPTION DESCRIPTION visit www.safequarry.com for more details or email: [email protected] T beam wire retaining bars Aggregate Industries UK Ltd > Lound Maintaining minimum bund heights Maintaining minimum Brett Groups > Waldringfield Quarry Charcon Construction Solution’s site at Lound manufactures T manufactures at Lound site Construction Solution’s Charcon outside. moulding beds located beams using long production laid in cables are long reinforcement the beams, casting to Prior placed across chains were Safety the moulds and pre-tensioned. in the event protection provide the moulds at every to metres few the beds to welded which were chains, safety .The of a cable break were prior and during to stressing, the wires and connected over contamination. Operators concrete rain and being damaged by with the connect the beds to the chains, clamber over had to trip or fall. a slip, for potential solution was a purpose-built,The spring loaded retaining rigid, flange at each end which allows unit has a locating The bar. The be clipped quickly it to casting beds. position on the into At Waldringfield Quarry, a simple but effective means has been Quarry, a simple but effective Waldringfield At This help maintain the correctdevised to minimum bund height. is particularly at this quarry relevant as it has a very mineral shallow with the the move’, ‘on deposit and hence the quarry is continually consequent re-alignment of access and haul roads. marked bund levels mudguards loaders have front on their All front use for been produced and hand held aluminium poles have Other pedestrians. by staff can also view the bund height in loader as it works in the comparison the mark to on the front quarry. Unicone tail compliance tool tail compliance Unicone and Lime Tarmac > Cement Lafarge customers’ to transferred materials as cement are such Powder delivery tankers road conveyor silos using pneumatic from had experienced a number of company The and rail wagons. the deliveryincidents where silo inlet pipe couplings hose to In the most serious incidents, had disconnected under pressure. been have been hospitalised and there have and drivers operators to the atmosphere. emissions environmental significant the use of due to were failures that these show Investigations deliveryincompatible or badly worn poor hose couplings and/or angle of flare, Inhousekeeping addition, the coupling’s routines. be out of to or metal thickness found diameter its outer were specification. A simple lightweight and easy to-use measuring was tool tool can quicklyThe check the check fittings. to developed interfacing the coupling connections ensure to coupling’s 537 667 627

Engineering initiatives 18 Engineering initiatives 19 26 Customers are now using excavators with specialist lifting using excavators now are Customers some utilise pipe and manhole lifters and some attachments, product loads. handle mixed able to now are Customers understand better the options and benefits understand better Customers available Reduced working at height when off-loading concrete products Supplying pipe lifter as an additional service attachment with deliveryoffer Providing a pre-slinging service customers to Providing Producing documentation that could be used to engage documentation that could be used to Producing with customers Providing on-site assistance to customers trying customers assistance to on-site out Providing unfamiliar equipment Educating customers about the safety, financial and about the safety, customers Educating productivity benefits

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

Identifying what offloading methods were available on the were Identifying what offloading methods market and ranking of safety them in order Reduction in manual handling and working at height risk other personnel on adjacent Considerable to reduction production lines Reduced activity crane overhead 50% by efficiency unit qualityImproved and increased Reduced maintenance morale. Improved

DESCRIPTION BENEFITS DESCRIPTION offloading Stanton Bonna > company wide Helping customers to avoid working at height duringHelping customers

New concrete sleeper de-moulderconcrete New Washwood Heath Rail Solutions > CEMEX > Stanton Bonna were concerned that many of their customers of their customers concerned that many Bonna were Stanton height when to the exposing their staff risk of a fall from were request It to customers unloading deliveries. was not unusual for might that there realising without with edge protection vehicles an operator the need for avoid that would be an option available might not In edge protection some cases, mount the vehicle. to be unloaded. to of the products the nature be suitable due to manhole covers unload piping, specialist equipment to Historically, impractical not easily or had been expensive, and similar products in equipment, customers developments recent With available. missing an opportunity of employees, the safety were improve to taking costs by productivity and reduce increase advantage of methods of off-loading. new or different involved: off-load safely help customers to A pro-active approach l l l l l l l CEMEX UK’s factory at Washwood Heath manufactures pre- Heath manufactures Washwood factory at CEMEX UK’s de-mouldingThe operation, sleepers. railway concrete stressed both a high involved a two-stage cranes, using several process with working together operator, the of manual handling by level On occasion, at height at various line. points along the production falling out of the de- in sleepers either resulted the process to cause with the potential platform moulder or off the storage serious injury the the sleepers and/or to damage to personnel, to equipment. self contained de- a new, consultation with the operators, After ‘hands on’ out the engineered new process The moulder was built. via a control and operated guarded machine is fully The element. panel. 665 591 Behavioural Safety, Safety Culture & Leadership sponsor

B ehavioural 530 AWARD ON ‘The Switch Programme’ – Mobile phone WINNER VIDEO campaign Lafarge Tarmac > Company wide

DESCRIPTION

S afet y, S afet y C ulture Lafarge Tarmac‘s senior management set a target to eradicate the use of mobile phones in hands-free mode whilst driving. The new mobile phone standard was applied to all employees, employed drivers and contractors working on behalf of Lafarge Tarmac on 1 January 2014. This standard was based on evidence which showed that the reaction times for drivers using a mobile phone are around 50% slower than normal and they are four times more likely to have an accident. To help communicate and embed this standard across the business, a working group, represented by all parts of the operational business and functions, was established. The working group was sponsored by a member of the senior leadership team. & L eadership A campaign was created called ‘The Switch Programme’, to help engagement with employees. It had two key objectives l To raise awareness of the Standard l To provide support to employees so they can comply with it. The latter included developing new ways of working to manage the operational challenges of implementing the standard. Teams across the whole business participated in a toolbox talk which had a particular emphasis on how to make changes to working practices, both individually and as a team, to ensure compliance with the standard. A variety of communications materials were developed to support ‘The Switch Programme’ which included posters, articles in employee newsletters, an intranet discussion forum, branded promotional items, a New Year postcard reinforcing the new standard’s launch and a competition for the best idea to help with implementation.

BENEFITS l Reduced risk of employees or contractors being involved in driving accidents l Inclusive campaign involving all levels of the company l Employees encouraged to introduce this to their family and friends l Sharing of best practice across the company.

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

B ehavioural 577 RUNNER ON BLBP Cliffe Team – Site Safety Transformation UP VIDEO – a Team Effort Brett Landscaping > Cliffe

DESCRIPTION BLBP Cliffe consists of three separate factories. Since 2010, the management team has led significant improvements, S afet y, S afet y C ulture implementing a programme to make Cliffe a model of best practice. The programme involved the implementation of a wide range of initiatives that included new health and safety systems; investing l Implementation of HAVs monitoring systems in a wide range of site improvements to improve housekeeping l Face Fit testing completed and poster campaigns introduced and employee safety; improved communications and sharing of across the site health and safety issues; team work in identifying and developing the solutions to address them. The actions included: l New COSHH assessment system. l Introducing SHE Committee system BENEFITS l Improving near-miss reporting l All staff engaged and the development of an ‘open culture’ l Completion of BrettSafes (mini risk assessments) l Excellent housekeeping standards and improved work flows l Clearly marked walkways and new barriers l Significantly improved awareness and standards of health l Upgrade of aggregates tower and safety & L eadership l Installing flooring platforms for mixer tower l RIDDOR reduced from 3 to 0 over 4 year period l Building workshop facilities to include adequate facilities for l Reported near misses increased from 560 to 1017 within 4 lifting operations year period l Improved machine layout l Sign-off completion of near misses raised to 99% l Improved traffic management system l Very positive feedback from staff, suppliers and customers. l Improved site welfare facilities

596 HIGHLY Health and Safety days COMMENDED CEMEX > National

DESCRIPTION his story to try and In 2013, CEMEX held 18 health and safety days across the UK influence safe behaviour with over 1,500 employees attending in addition to contractors, in the workplace. He told customers, competitors and the enforcing authorities. (16 events his personal story and were originally planned with extra demanded due to their the impact it had on his family, friends and colleagues. success). Most were stunned by the appearance of Ken and the realisation The health and safety days focussed on ‘Look after yourself and that they had just been shown scenes from a real event with each other’ the number one Safety Essential in CEMEX. severe consequences. The events differed to previous health and safety days in focussing The events were attended by all - from the UK President to the on behaviours. A series of real life scenes were re-enacted by shop floor, across all parts of the business with a member of the professional actors to show actions and behaviours of individuals senior management team opening and closing each event. in the workplace. Actors related the story of a factory based BENEFITS incident, using scenes to illustrate the run-up to an injury. In l Described by many as “the best health and training they had the intervals, the audience discussed what they had seen and ever received” how they related to their workplace. The audience was invited l Reaffirmed safety essentials to suggest how certain events should have been handled to influence the right result. l Aided change in culture to interdependence Towards the end of the event the real life victim of the incident l 2013 saw the lowest Lost Time Injury Frequency rate ever for was revealed. Mr Ken Woodward OBE was blinded in an industrial CEMEX. accident many years ago and has since travelled the world telling visit www.safequarry.com for more details or email: [email protected] 21 B ehavioural 635 HIGHLY ON Developing a HOPE Safety Culture COMMENDED VIDEO Hope Construction Materials > Company wide

DESCRIPTION ‘sharing and learning’ briefing notes were issued so all could learn Formed in January 2013, Hope Construction Materials has over and act to prevent repeats. 850 colleagues (direct employees) and several hundred service During 2013 colleagues were actively encouraged to get involved S afet y, S afet y C ulture partners (contractors) working on a daily basis. in health and safety improvement initiatives and a group of The first challenge was to mobilise and stabilise the business colleagues developed a ‘Welcome Intervention’ initiative and and bring together two different cultures, whilst at the same strategy for 2014. All are encouraged to intervene on safety time maintaining a clear focus on health and safety throughout a matters with the message ‘We welcome your Intervention’. As part period of massive change. of this initiative, a group of colleagues produced a short film, uploaded to YouTube to enable service partners and others, as The Executive team recognised the importance of safety as one well as colleagues, to view it. aspect of the business which all could get behind. The CEO delivered a series of one day visible felt leadership workshops to BENEFITS all directors and senior managers. Over 50 members of the senior l Clear understanding of senior management’s commitment management team made monthly site visits, supporting the to safety safety effort of colleagues and service partners. Between April and l Safety culture enhanced as two organisations merged December 2013 over 1163 hours of safety visits were logged (10% l more than planned). Plus, every site received at least one visit from Continued active engagement with colleagues and service & L eadership either a director or member of the senior executive team. partners l Every effort was made to keep the focus on safety, with regular In August 2013 – 200 days serious injury-free days achieved communications, briefings and face-to-face sessions. When l A full-year combined lost-time injury frequency rate of 0.64. incidents occurred colleagues were involved in investigations and

554 Behavioural safety – safety culture leadership EPC-UK > Rough Close > Alfreton

DESCRIPTION and trust. Behavioural Safety is a journey that EPC-UK embarked upon a few In 2014 a second safety culture survey was undertaken, years ago. With the number of incidents having been reduced benchmarking the original survey against the company’s through proven safety management, it became difficult to reduce performance and the wider industry. In addition, a formal initiative these further and consistently. The road to full behavioural safety is being introduced by ADSL from Houston, Texas to develop began with clear commitments to the workforce by way of actions Safety Leaders; create greater employee engagement and improve from senior management seeking an injury-free workplace. performance further.

To demonstrate the commitment of senior management, EPC- BENEFITS UK became one of the pioneers in introducing the Health & l DuPont STOP audits help senior managers to engage Safety Laboratories Safety Climate Tool. This survey conducted in regularly with individuals 2011 aimed to gain feedback from the entire workforce on the l Discussions take place at all levels on safety related matters importance they placed on safety in management and how it could be improved. An action plan was created from the feedback l Workforce actively encouraged to recognize hazards through which was enhanced in 2012 to include greater focus on drivers; point-of-work risk assessments a safety suggestion recognition system and the introduction of l Ongoing education on importance of reporting and leaning Safety Days. All have increased the level of workforce engagement from near-misses.

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

B ehavioural 673 Implementing health and safety improvements Hills Quarry Products > Swindon

DESCRIPTION The senior management has implemented a number of new initiatives in the last 13 months to help improve the health and

safety culture within the company. S afet y, S afet y C ulture Near miss reporting booklet and updated procedure – Staff were given training plus a copy of a booklet designed to encourage and record near misses. The near miss procedure has also been updated. The revised procedure allows employees to report near misses directly to site managers, who record the preventative action and feedback to the employee. Details of all near misses are collated and included in a report to operational directors who review actions taken and follow up if required. forum to discuss and raise health and safety issues, the committee The company sees this as a key tool in reducing accidents and has clear objectives and targets to improve health and safety maintaining zero reportable incidents. awareness within the company. The chair reports on each meeting Haulier site rules and traffic management maps – Sheets to directors to identify concerns and make suggestions for covering site rules and site-specific traffic management plans have improvements to be effectively escalated and discussed at senior been issued to all contract hauliers and drivers, as part of the site level. Feedback is given to the committee on decisions taken. & L eadership induction. The sheets supplement site signage already in place. BENEFITS Employee health and safety committee – The company l Improved health and safety culture within company re-launched its employee health and safety committee. It meets quarterly and is made up of a cross section of the workforce, with l Improved reporting of near misses plant operators, site managers and administrative staff. Directors l Improved sheeting of vehicles. are excluded to ensure free discussion. In addition to acting as a

584 Interactive behavioural safety training roadshow Breedon Aggregates > Company wide > Ethiebeaton

DESCRIPTION Towards the end of 2012, the company wished to further influence their health and safety culture, to demonstrate management’s commitment to improving safety with everyone looking out for each other, with a sustainable, interdependent approach. There was a need to complement the Visible Felt Leadership process having found that over 90% of incidents were caused by human error. In January 2013 a health and safety roadshow visited all parts of the business, using an external training company. The Near message to contractor partners. Miss Reporting theme used, resulted in an increase of 200% and reporting has stayed at a consistently high level since. A full Over the course of the week, nine half-day presentations were analysis is produced monthly, with a quarterly report send to the carried out across Scotland and the Western Isles. The scenario was homes of all colleagues. based on two ground workers from a fictitious company, tasked with inspecting manholes. The actors engaged with the audience Following on from this success, drama led, tailor-made training who ultimately influenced the final outcome. was delivered on ‘The Willing Worker’ – highlighting a worker taking risks and cutting corners. All company employees attended BENEFITS the training day with a presentation from the Chief Executive l Effects from the presentation had a lasting impression and and the Health and Safety Manager. All sub contractors were also effect invited to further engage them and push the behavioural safety l Made individuals question their behavioural decisions. visit www.safequarry.com for more details or email: [email protected] 23 ON ON VIDEO VIDEO UP AWARD RUNNER WINNER Positive feedback from drivers to the initiative. drivers to from feedback Positive Raising awareness of issues with other road users of issues with other road Raising awareness Near miss system identifying where changes need to be changes need to identifying where Near miss system safety improve made to Improved traffic management on-site Improved Positive feedback from cycling groups and other key cycling from groups feedback Positive stakeholders. the business across of safety standard Common Helped raise awareness of issue nationally Helped raise awareness users other road Reduced risk of incidents involving Reduced risks of road accidents involving VRUs Reduced involving accidents risks of road a quarterly issues. safety on road Newsletter Drive Produced Removed barriers to independent hauliers reaching barriersRemoved hauliers reaching independent to standards the reinforce to A fully reportable near miss programme traffic management system First operator to be awarded a Certificate of Whole Fleet Fleet Whole a Certificate of be awarded to operator First FORS programme TfL’s by Compliance A significant input to development of common industryto development input A significant standards

BENEFITS BENEFITS l l l l l l l l l l l l l l Reducing Occupational Road Risk sponsor Fitting all vehicles to fully conform to the MPA Cycle Safe Safe Cycle the MPA to fully conform to all vehicles Fitting be specified on with forward facing cameras to standard, new vehicles. to and franchisee drivers employed both company Training Road User standard. Vulnerable the MPA help raise to at public events of attendance A programme issues safety of road awareness which all traffic management system drivers An updated up to sign entering site Supported the MPA development and subsequent development Supported the MPA standards Safety of Cycle promotion understand the complex variety to Helped customers of and equipment standards Construction London for Transport with the Engaging working building a groups (CLOCS) Safety and Cycle Logistics single standard Scheme Recognition (FORS) Operator Working with the Fleet contract for process audit an internal vehicle develop to with the FORS standard hauliers aligned trade Engagement and active communications through Police, the Metropolitan media, cycling groups, campaign increase to CBI, Select and other groups Committees awareness. nationally of all contract side under vehicles with A retro-fit run bars and side sensor equipment independent contract employed everyWorking towards LT accreditation. haulier meeting a minimum Bronze LT delivery is made be first in industry to every where Target equipment and the driver with safety fitted a vehicle by accreditation. a minimum FORS Bronze trained to

DESCRIPTION DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Road safety campaign Hills Quarry Products Ltd > Company wide Vulnerable Road Users – driving the standard – driving Users Road Vulnerable Tarmac > National Lafarge Hills Quarry embarked safety Ltd on a major road Products initiatives: the following involving campaign l l l l The frequency and severity of incidents between Vulnerable Vulnerable frequencyThe and severity between of incidents Road Users (VRU) and construction is unacceptably vehicles has both campaigned Tarmac Lafarge high, especially in London. of this issue and made a number of specific raise awareness to and contract their fleet commitments to hauliers. Campaigning l l l l l Commitments l l l 541 671

Reducing Occupational Road Risk 24 26 R educing 623 RUNNER ON Raising the industry profile in road safety UP VIDEO CEMEX > Logistics Cement and Aggregates

DESCRIPTION l EU parliament cycle safety lobby provided vehicle and expert CEMEX has been pro-active in driving a wide range of road support O ccupational safety initiatives particularly with regard to cyclist safety. With an l Provided keynote speakers for Boris Johnson cycle safety increasing number of fatalities involving cyclists, CEMEX decided campaign and at Met Police events to organise a round table event to provide a platform to debate l Supporting several national TV productions including the and discuss workable industry solutions. BBC’s ‘One Show’ The London round table event - ‘Making LGVs safer for cyclists’ l FTA – Transport manager – UK wide seminars – Provided featured Dr Stephen Summerskill and Dr Russell Marshall of resources on cycle safety Loughborough University discussing the latest scientific research BENEFITS

into blind areas around large vehicles. CEMEX presented the R oad results of trials into different cyclist safety features. The event was l Provided leadership to the construction sector on cyclist well attended by industry, experts and pressure groups. safety This event was in addition to the continuation of cyclist awareness l Shared key research enabling informed debate on key issues R isk ‘Exchanging places’ campaigns and other key events such as: l Improved understanding of key issues from different l Department of Transport – Evidence to advisory panel on perspectives vehicle safety technologies l Helped influence a consistent approach amongst customers l Transport for London Construction Logistics and Cycle Safety and authorities to conform to necessary safety requirements group and standards l Institute of Traffic Accident Investigators – supported a crash l Demonstration of CEMEX vision of ‘Being the Best’ for families test day event l Demonstration of MPA’s ‘Safer by Sharing’ scheme.

559 HIGHLY Setting industry standard for road safety COMMENDED FM Conway Ltd > Dartford

DESCRIPTION The system has been recognised by high-profile industry awards A key recommendation in a Transport Research Laboratory report and the company was awarded Gold status in the Fleet Operator commissioned in February 2013 was “adherence to a nationally Recognition Scheme (FORS). recognised standard on work-related road safety such as the BENEFITS ISO39001 standard on road traffic safety management”. l 60% decrease in accidents FM Conway began implementing the standard which was formally in the first three months the certified in January 2014 - the first UK company to achieve the system was operational standard. l The awards endorse the benefit ISO39001 is a management system that enables the company to of the scheme to all, both within identify the risks of its interactions with the road traffic network; and outside the company. evaluate control measures and improvement opportunities and monitor and measure the improvements realised. It provides a quantifiable system that informs the company how best to improve the safety of its operations. A cross-departmental working group identified the hazards its activities pose to other road users and defined nine risk categories with practical improvements to mitigate them. The findings were codified and developed into a formal road safety manual and system. These were ratified by BSI during December’s 12-day audit. The company’s teams constantly review and update its management processes and the working group meets quarterly to ensure that all new and evolving aspects of road safety are embraced by the system. visit www.safequarry.com for more details or email: [email protected] 2517 HIGHLY COMMENDED Drivers recognise the benefit to them and to other road to other to them and the benefit Drivers recognise users. Images can be used in the even of an RTA - to prove fault prove - to Images of an RTA can be used in the even The recordings can be used for driver assessment can be used for recordings The

BENEFITS l l l sign in the cab serves the driver. sign to as a reminder a through the drivers back to can be played footage Recorded or via a laptop. computer Raise awareness of general road safety at a young and at a young safety of general road Raise awareness age impressionable in traffic Reduce the likelihood being involved of children incidents related of parents hopefully raise awareness the children, Through these issues the local to Demonstrate commitment of the company community.

DESCRIPTION BENEFITS DESCRIPTION visit www.safequarry.com for more details or email: [email protected] Ensuring the safety of children within our community Ensuring the safety Myers Group > Huddersfield Black box recorders fitted to vehicle fleet to vehicle fitted box recorders Black > Whitminster Department C Cullimore > Transport Moreton Since September 2014, the Myers Group has presented to around around to has presented 2014, the MyersSince September Group 11 schools in the betweenages of 8-10 from the 1000 children Kirklees working specialist area, who deliver with an organisation servicesAs part schools including cycling of this, to proficiency. of the risks asked assist in raising awareness to were Myers Group on our roads. children to uses cartoons, serious and some presentation The film, photos issues and covers attention shock tactics children’s gain the to and code the highway points raised from blind spots, to relating the importance clothing etc. hi-viz of helmets, training ends with a practicalThe session with two trucks on-site. the cab and four go into children four vest, a hi-viz One child wears they can how showing of the vehicle in front stand immediately demonstrating the forward facing mirror, only be seen through visible than the others. more is so much the child in hi-viz how from far away how show blind spot mat is used to standard The be seen. to stand, the cab they need to camera, again using with a near-side is fitted second vehicle The the blind spot mat, with a parked bike which cannot be seen but is clearly visible on the camera of the mirrors, any through monitor. l l l l Most of the company’s fleet of tipper trucks has been fitted with trucks has been fitted fleet of tipper Most of the company’s road of drivers and other the safety improve to cameras ‘black box’ view a the camera shows windscreen, the truck’s to Fitted users. Whilst the drivers’ the driver. and towards the road both towards is now the feedback watching, ‘big brother’ was of initial reaction as much for that they are demonstrated the cameras having good, sign tailboard-fixed A road users. for other benefit as the drivers’ of the camera and a further users of the existence road reminds 535 656

Reducing Occupational Road Risk 26 26 Transport initiatives sponsor T ransport 579 AWARD ON Improved traffic management system WINNER VIDEO Brett Group > Cliffe

DESCRIPTION l Permit system for pedestrians needing to deviate from BLBP Cliffe is a complex of three concrete block paving factories walkways initiatives located on the same site. Historically the site was heavily l Designated HGV loading bays congested with queues of HGVs outside the site on narrow lanes l Improved signage creating hazards for other road users. On-site, there were problems l Creation of new exit point with barrier with stock management that led to long waiting times and to l HGVs having to make multiple pickups across the site. Additionally, Installation of a sheeting/load checking platform prior to final the route for HGVs on the site crossed over key pedestrian routes exit point with the need for two way traffic in a confined space. BENEFITS In consultation with the site team, changes were made to l The site is safer and more efficient the yard system by examining and improving stock holding l Traffic and personnel principles, changing entrance and exit points, re-routing traffic and are segregated pedestrian routes and enhancing pedestrian protection measures. l Fewer interactions Specific improvements included: between FLT and HGV l New entrance with barrier eliminating both queuing on l Safe access to loads blind bend and cars mixing with HGVs entering site. l Reduced FLT travel l Creating a vehicle-free pedestrian route from car park. distances l Pager system to call in HGV drivers – minimizing pedestrians l Reduced loading errors in waiting areas l FLT fuel use down by l Revised stock locations minimising FLT 12% travel distances when stocking/loading l Vehicle turnaround l One way system for HGVs with full time improved by 28% width roadways l Positive feedback from l Designated walkways creating staff and customers pedestrian segregation throughout site

545 RUNNER ON Automatic Tyre Inflation System (ATIS) UP VIDEO Lafarge Tarmac > Cement and Lime

DESCRIPTION the compressor maintains the tyre pressure enabling the driver Semi-trailer tyres are the most neglected wheel position on a to complete his journey. If more serious, the driver can stop safely vehicle, particularly those on the near-side rear. Research shows and seek attention. that damaged tyres account for over 50% of all roadside service BENEFITS calls. A puncture often has to be attended to in an unsafe situation l Safer vehicle and improved performance placing the tyre fitter and others at risk. Tyre blow-outs and l punctures will also impact on customer service. Less potentially unsafe repairs at roadside for tyres fitters l Lafarge Tarmac has developed an Automatic Tyre Inflation System Fewer blow-outs and consequent reduction in vehicle (ATIS) which maintains correct tyre pressure levels. This works damage by providing high-pressure air to each tyre from an on-board l Even tread wear, less tread damage, better grip, longer tyre compressor fed from life the truck’s existing l Improves tyre safety performance and traction during driving high-pressure air l Driver awareness of tyre pressure status, visually and audibly system. l Improved fuel efficiency, reducing CO emissions When the ATIS 2 l Improved reliability and service to customers registers a low tyre pressure, the system l Fewer emergency roadside assistance incidents informs the driver. l Reduced costs of operation With a slow puncture, l Easy to install system - can be retro-fitted to most LGVs visit www.safequarry.com for more details or email: [email protected] 2717 HIGHLY COMMENDED A safer workingA safer all on- for environment especially in poor site weather positive Stimulates thinking rules health and safety to in relation at minimal to produce easy visual aid, Simple but effective cost works in darknessSystem on daylight and is not reliant of drivers remind to vehicles approach the need to Avoids rule site Drivers receive reminder reminder Drivers receive at crucial point of entering working site Correct alignment of mirrors Correct alignment use Quick and easy to Minimises risk of blind spots on lorries Reduces likelihood of collisions Reduces likelihood PL claims. of expensive

BENEFITS BENEFITS l l l l l l initiative was rolled out via a safety alert out via a safety An was rolled initiative training. and driver use on all dispatch adaptation of the rubber mat is planned for the to painting thermoplasticlocations by ground lines on the ratio is cost-v-risk The same dimensions as those of the mat. minimal. l l l l l Designated for route for LGVs minimises risk of near hits/ LGVs for route for Designated accidents/incidents

visit www.safequarry.com for more details or email: [email protected] DESCRIPTION DESCRIPTION BENEFITS DESCRIPTION Site staff reported, via the quarry staff Site alert near miss hazard system, certain that on a number of occasions, road-going were vehicles activating not always their amber warning when on-site. beacons and usually not a forgetfulness to In it was down most cases, rules. violation of site deliberate placed at the approach solution was a conspicuous sign, The main quarry the to pick up the with a sensor to weighbridge set off the amber flashing which automatically movement vehicle the quarry approach When vehicles itself. beacons on the sign is alerted the driver area, weighbridge activate the vehicle to beacons. reminder of a triedtested and visual simple but effective This quarrystandard has worked with much measure well control instances being reported operating without of vehicles fewer activating their beacons. l reminder Amber warning beacon CEMEX > Hyndford Quarry Small vehicle route vehicle Small Quarry > Holmehall Materials Hope Construction After a number of safety near hits regarding traffic management traffic management near hits regarding a number of safety After and heavy and the mobile plant issues between small vehicles and design the decision was made to fatal accident at Pennyvenie, for allows which route vehicle small build a specially designated the Primary to Quarry safely fully travel to area, processing LGVs all heavy plant on-site. from segregated Mirror configuration mats Northstone (NI) Ltd > Coleraine At a regular employee involvement meeting, several drivers voiced voiced drivers several meeting, involvement employee a regular At for blind spots when using their mirrors concerns regarding procedures. normal driving and reversing method of and a sourced were edging Rubber mats with hi-vis blind checking based on the location of mirror developed, mirrors cycle junctions, With tracks, spots as reported lorry by drivers. front and the zone across atwo metre and traffic lights in mind, the side of the lorrydown was identified as a major blind spot. quickly could be adjusted mirrors and easily - a Furthermore, simple one-man task. carried out with very and the were feedback positive Trials 587 640 612

Transport initiatives 28 26 T ransport 540 ‘Driving Safety’ initiative Lafarge Tarmac > National

DESCRIPTION The roadmap has led to 154 individual ‘pledges’ of commitment, ‘Driving Safety’ is a cross-business transport safety initiative, each assigned against one of the six key areas to ensure balance initiatives established following a CEO incident review which identified that is maintained, covering the entire delivery journey. Actions a more holistic approach to transport safety was needed. The have identified areas of improvement from hauliers’ and drivers’ approach considered all the parties involved in a safe delivery involvement, to skills refreshers for operations teams. The larger including operations (loading the vehicle), vehicle owners and national actions focus on common goals such as driver inductions, drivers and customers. cyclist safety, mobile phone policy and incident reporting/ recording. The initiative brings together the wide range of skills and experience of all transport professionals within a framework that Outputs of the project are measured through KPIs that monitor makes it easy to identify, target and drive for results. leading indicators which should lead to improvement in standards (such as FORS compliance of hauliers). Lagging indicators such The ‘Driving Safety’ framework breaks down the delivery of product as overall transport incident frequency rates help to identify and to customers into six key areas: monitor transport safety performance. l Owner BENEFITS l Driver l Improved collaboration from transport teams with a pooling l Vehicle of expertise l Loading l Initiative works both locally and nationally to cover whole l Journey transport community l Customer l National actions help deliver a powerful message - transport Against each of these, transport professionals have identified safety is at the top of the agenda. a vision of ‘what good looks like’ and how it can be measured. Launched across the business in September 2013, each transport team identified the roadmap of actions that would lead to excellence in each of the six key areas.

659 Securing loads – ‘Secure it right, first time, every time!’ Wienerberger > Sandtoft

DESCRIPTION l Packs should be reached using a simple extendable fork Sandtoft use contract hauliers with the responsibility to secure positioned under the edge protector under loose straps loads safely, left with the driver. which are then tensioned. The company questioned its hauliers and other distribution The requirements are strongly enforced and drivers know that depots on the practice of safe loading using various methods and failure to comply may result in disciplinary action with the developed a set of minimum requirements for load security for potential to be banned from all sites. both on-site and off-site and on the public highway. BENEFITS A document was produced with the various scenarios of different l Drivers understand the reason for the guidelines types of securing loads clearly illustrated. The guidelines apply to l Minimises the risk to themselves and the public all drivers and are applicable to both Sandtoft’s own and customer l collection vehicles. Random checks are carried out to ensure All drivers use the same proven methods of securing loads compliance. The guidelines state: l The dispatch safety log used to confirm the driver has l Nets are disallowed unless they can be put in place from the secured load safely ground l Visible proof of the company’s adherence to good health and l Climbing on the trailer is banned from site safety practices. l Straps are to be used along with pack edging protectors to secure pallets

visit www.safequarry.com for more details or email: [email protected] 2917 Occupational Health and Well Being sponsor O ccupational 626 AWARD ON ‘Stop dust before it stops you’ WINNER VIDEO – Animated training video Quarries Partnership Team (QPT) > National

DESCRIPTION The video can be The Quarries Partnership Team (QPT) comprises members drawn viewed via the Safequarry website H ealth from across the quarrying industry including quarry operators, TUC, trade associations and training bodies, and is co-ordinated via the video library. by the Health and Safety Executive. Its primary role is to raise BENEFITS awareness of the risks associated with dust and respirable l Short, simple crystalline silica with measures for its reduction.

and and clear QPT commissioned a short training film to help raise awareness messages of the issue of dust and potential ill health effects. Comprising a l Reinforces

W ell series of quarry-based activities, the video features an animated other training quarryman who does everything wrong. The exploits of this l hapless character are interspersed with high quality real-life Easily sequences of how it should be done. accessible via B eing safequarry.com The video emphasises how to avoid both the immediate and l long-term adverse health effects of uncontrolled dust in the Evidence workplace and the consequences for a worker’s life. It is aimed for shows that it use on-site by those with the responsibility for health and safety has already in the quarrying industry, with the target group to include quarry been used operatives, maintenance personnel and contractors. It provides extensively by an accessible and engaging way to demonstrate how the correct operators behaviours can reduce exposure of workers to silica dust within l The use of humour, the tone and structure help effective the quarrying industry. communication.

549 RUNNER ON Protective film on driver’s cab window UP VIDEO Smith & Son (Bletchington) Ltd > Transport Department

DESCRIPTION occurrences of skin cancer on the side of their body nearest the Following one of the company’s drivers being diagnosed with side window. skin cancer on his neck, Smiths Bletchington considered whether The company found that standard vehicle glass provides little this might be connected to the driver’s exposure to sunlight protection against the strongest UV light on side windows, and no whilst driving. Following research, they found reports from the vehicle manufacturer or supplier offered alternatives. Working with US and Australia that made a link between full-time drivers and a local vehicle window repairer, a clear laminate film that provides UV protection was identified - Johnson’s Window Film Museum UV clear. So far, a third of the vehicle fleet has been fitted with the laminate. This work is undertaken when a vehicle is in the workshop for MOT or other work. In addition, awareness of skin cancer has been increased and sunscreens made available.

BENEFITS l Driver’s risk of skin damage from UVA exposure reduced l Laminate is totally clear so does not impair vision l Laminate does not contravene any vehicle manufacturing standards or window tinting laws l Easily fitted at cost of circa £80 per vehicle l Staff pleased by the company’s response to this issue.

30 visit www.safequarry.com for more details or email: [email protected] 26 O ccupational 619 HIGHLY RPE programme to prevent exposure to airborne COMMENDED silica dust Marshalls PLC > Cromwell – Natural Stone Processing

DESCRIPTION Marshalls processes Yorkshire Sandstone for building materials,

paving and masonry products. Large sandstone blocks are cut H ealth to size and finished within the saw shed using a number of different types of mechanised saws. Water suppression is used as the primary exposure control strategy for airborne silica. The sandstone is fine grained with a silica content in the range 70- and 90%. Personal exposure monitoring has yielded concentrations in excess of the RCS Workplace Exposure Limit (WEL 0.1mg/m3).

Initial improvements did not reduce personal exposure of RCS to W ell below the WEL. With approximately 70 people routinely working within the saw

shed moving between different machines, we needed to urgently B eing address the issue of airborne silica. A meeting was organised and the following actions were agreed and all signed up to the programme: l All employees received information and training on hazards associated with Respirable Crystalline Silica and the use/ wearing of RPE and chose equipment to suit, based on the type of work undertaken, facial hair and general comfort l For full or half face respirators a face-fit test was carried out l All the equipment has a monthly maintenance schedule to include cleaning and filter replacement. Monthly reports will be generated and filed. l Routine dust monitoring measures airborne contaminants within the saw shed. Findings are discussed and any actions implemented l Mandatory wearing of RPE where the WEL for Respirable Crystalline Silica is exceeded l All employees attend annual health surveillance as per the group policy l RPE programme endorsed by the HSE whose DVD ‘Introducing and managing RPE in the workplace’ follows the implementation.

BENEFITS l All employees co-operate fully with the wearing of RPE from the outset l Exposure levels of employees is now controlled l Employees take responsibility for cleaning and inspecting their mask before use l Clear ground rules (RPE Policy) cover when/where masks should be worn l Rules applied to all employees, contractors and visitors.

visit www.safequarry.com for more details or email: [email protected] 31 The Institute of Quarrying Worker Involvement sponsor W orker 649 AWARD ON Tablet solution for the contracting industry WINNER VIDEO Hanson Contracting > National

involvement DESCRIPTION Using feedback from the trial, iPave was further developed and 123 Contract surfacing is a transient operation with the workforce improved before rolling out across the country. The roll out was regularly changing sites, placing high demands on the business supported with iPave training sessions which were delivered with to achieve health and safety excellence. Numerous health and the assistance of foreman and safety representatives. safety paper-based procedures used by Hanson Contracting were The iPave project was led, developed and championed by the becoming more of a barrier than an enabler. Working in integrated workforce. teams with a wide range of challenging targets to achieve it was BENEFITS recognised that the use of electronic data and sharing information l using modern technology was essential. Replaced a highly paper-based health and safety culture l Discussions with the workforce, initiated by Hanson’s Safety A safer, better informed and more efficient work force Behavioural Programme, highlighted these areas for improvement. l A 50% increase in Near Hit Reporting since its introduction A project team including foremen and safety representatives, l The ability to make real-time recordings of dynamic risk identified the use of an adapted tablet as a means of addressing assessments these issues which would enhance workforce and contractor l £28K savings in photocopying, pre-printed stationery and safety on-site. process efficiencies The iPave tablet was developed as an on-site solution for capturing l Facilitated the implementation of techniques such as Visual photographic, video, audio and GPS location records of incidents Management and 5S’s and activities on-site, in real-time. Additionally, iPave records l Improved the identification of risks and hazards on-site plant inspections, near hits, dynamic risk assessments, COSHH assessments, method statements and daily site walkthroughs. l Provided access to real-time photo/video plant failure information The iPave tablets were rolled out to selected sites, on a trial basis, and feedback was encouraged from the surfacing operatives. l Workforce engagement in the process enhanced the safety culture.

655 RUNNER ON Health and safety week UP VIDEO Hanson > National

DESCRIPTION Importantly, the programme was designed to go beyond the Hanson ran a highly successful health and safety week involving workplace and reach out to employees’ families. Particular efforts employees across all parts of its business. Activities were designed were made to involve all the company’s drivers - including hauliers to be engaging, thought-provoking and encourage participation and franchisees. – while also enhancing the skills of the workforce. Importantly, the The aims of the health and safety week included: event also led to action – both throughout the week and beyond. l To empower employees to put safety first Each day was based around a specific theme and supported with l To develop a link between safety at work and at home resources such as toolbox talks, podcasts, a home safety website l To encourage employees to consider a healthier approach to and posters. This approach ensured that a consistent set of key life. messages was delivered across the business. The main themes were: In addition there were some specific goals: 1. ‘Be safe at Hanson’ included training on the importance of l isolation and machine guarding To tackle an increasing trend of LTIs relating to drivers at customer sites and, 2. ‘All be healthy’ looked at personal health issues such as l adopting a healthier lifestyle and how to deal with work- Ensure the safe use of mobile phones on-site. related stress BENEFITS 3. ‘Be safe at home’ introduced a range of important home safety l High levels of participation achieved concepts l Excellent feedback 4. ‘Take a minute – Save a lifetime’ introduced a new risk l Declining LTIs assessment system for drivers to use when loading or l On-going internal conversation on health and safety unloading l Involving the family reinforces a safety culture at work. 5. ‘Friday and beyond’ a recap of the week and the launch of mobile phone procedures. 32 visit www.safequarry.com for more details or email: [email protected] 26 W orker 568 RUNNER ON Creation of a European guide for Pedestrian UP VIDEO and Traffic Safety Sibelco UK > Brookside Hall involvement

DESCRIPTION The completed project was refined from the initial brief following the consultation within the working group and wider business Sibelco Europe established a working group with representatives audience. The completed guide focused on: planning of walkways, from across the European business to develop a Good Practice identification of walkways, crossing points, loading points, visibility Guide on the management of the interaction between mobile aids and housekeeping. The guide also included a self-assessment plant and pedestrians. The working group drew on experience toll and action plan for sites to prioritize improvements based upon from colleagues within Russia, Belgium, Spain, Netherlands, Norway risk. and United Kingdom. Job functions ranged from operators, site managers, safety specialists and senior managers. BENEFITS Social media was used to canvas opinion of the work of the group l Common set of standards applied across the business and to capture opportunities for inclusion of good practice ideas l Action plans leading to safer working environment at all sites from a wider audience. The team functioned through postings l Approach gave credibility to outputs across group on the My Sibelco platform (social media), conventional email l and WebEx communications which allow the sharing of real time Best practice shared across group information in a virtual meeting environment.

616 HIGHLY Emotional and mental health awareness campaign COMMENDED Colas Ltd > National > Rowfant

DESCRIPTION In June, Colas’ Mental Health Newsletter was distributed across the Worker involvement often focuses on the safety side of the businesses via the Colas SA Global Safety week and employees industry and important issues surrounding employee health and were invited to discuss the topics raised in small groups and give wellbeing are put in the ‘too hard to deal with’ box. The company feedback. Subjects included ’Men’s Health Week; stress and coping investigated the stresses employees are exposed to and decided methods; talking about your problems; mental health workshops; to concentrate efforts in 2013 on emotional and mental wellbeing. stories from employees who bravely shared their experiences and Colas has supported and promoted Men’s Health for a number of information of where to seek help. years, however this campaign focused on issues that could affect The newsletter was also delivered to employees’ homes, published all Colas employees – both male and female. on Connex and the external website. In June 2013 the company Feedback was gathered from employees who attended the piloted Emotional and Mental Health Workshops in its Newcastle company’s emotional wellbeing workshops and a business case Depot. These were developed and delivered by ‘If U Care Share was put to the board to secure funding to develop the campaign Foundation’ a family run charity who focus their efforts on and develop workshops across all company locations. breaking down the barriers and stigmas attached to mental health and encouraging positive attitudes. The pilot workshops were The focus of the campaign was to raise general awareness of extremely successful and feedback was excellent - further were emotional and mental health issues which can affect 1 in 4 of run later in the year. Plans are in place to cascade these workshops us in our lifetime. Early in 2013 a communication programme to other company locations during 2014. was developed. Posters were distributed to all Colas locations produced by the mental health charity Mind, under the banner BENEFITS ‘Time to Talk’. The aim was to spark early interest in the subject. l Improvements will be measured in general wellbeing Social media was used to raise interest among both employees through the employee survey and the wider community by publishing short articles on work l Changes in employee sickness records will be assessed to carried out throughout the campaign. gauge success of the campaign.

visit www.safequarry.com for more details or email: [email protected] 33 W orker 558 HIGHLY Remote worker conference calls EPC-UK > Rough Close > Alfreton COMMENDED

DESCRIPTION l Operational issues past/forthcoming EPC-UK Services operate explosive depots, explosive trucks, drilling l Customer issues/leads involvement and blasting across the UK and often working in the most remote l Company news/performance (Supervisors/managers) quarries. Sharing of good ideas and best practice as well as keeping The responsible manager chairs the call and ensures that a relevant employees informed is extremely challenging since employees are safety topic is discussed and good ideas are shared by all. Minutes often away from home for weeks at a time. are posted on the company intranet, with actions being approved Following an internal ‘employee good ideas promotion’ a shotfirer and sanctioned by the management team. suggested a fortnightly conference call involving all employees BENEFITS within each operational area. This has been implemented. A l Faster solutions provided from operatives simple agenda was introduced to capture all aspects of the l Employees helped to keep engaged business: l Safety environment and security concerns reach all staff more l Safety contact (pressing issue of the day) frequently l Other Health, safety, security and environment issues l Improved safety performance and industry goal of Zero Harm.

598 HIGHLY ‘Please Look After Me’ campaign CEMEX > National COMMENDED

DESCRIPTION together to ensure workplaces Most people do not understand the consequences of an accident are safe. The conclusion was that if until it happens to them! So part of educating the workforce is someone had intervened in their situation then they may not have to get them to understand the potential effect of an injury, not ended up suffering the consequences they did. just on the injured party but on those around them - their family, The letters were distributed to their colleagues together with a friends and colleagues. It is part of the motivation to stay safe if sticker which they were encouraged to put on their safety helmet people truly understand the impact an incident can have. to show they had read the letter. Others were challenged if they CEMEX culture is built around being best for employees and their were doing something unsafe and all were committed to look families, the number 1 Safety Essential is ‘Look After Yourself and after their own safety and those around them. The sticker ‘Please Each Other’. Look After Me!’ emphasised the key message. In 2013 the company worked with several injured employees BENEFITS asking them to put into words the consequences of incidents. l Campaign has helped to reinforce the Being Best for They were tasked to write a letter to their colleagues describing Employees and Families Strategy not just the injury and treatment, but the knock on effect on those l Led to increased positive interventions and improvements in around them. health and safety The purpose of the letters was to implore colleagues to look after l Lowest recorded Lost Time Injury frequency and reductions each other, to intervene if someone behaves unsafely and to work in minor incidents in 2013.

650 Foreman’s inspection of hired-in mobile plant Hanson > Criggion Quarry

DESCRIPTION tie bar bushes as well as the obvious blown lights, broken horn Prior to allowing any new item of mobile plant to be used on-site, and cracked and missing mirrors. a thorough examination, not dissimilar to an MOT test, is carried By checking that all hired-in mobile plant is fully compliant with out by the mobile plant fitter. This applies to plant brought in by our high standards and that the company supplying or operating a contractor; bringing in a machine for his own work; or a hired the plant is aware of the checks carried prior to work commencing, machine for our own use. we can be confident that we have the safest and efficient plant This examination goes far further than the requirements of the operating at the quarry. daily inspection carried out at operator level, since the company BENEFITS has no way of knowing if there are any underlying faults from this l Confirms all hired-in mobile plant is fully compliant with the initial type of inspection. Whilst the daily inspection is acceptable company’s standards for an operator checking his regular machine, it is considered l Supplier or operator is made aware of checks carried prior to inadequate for a machine our company has no knowledge of. work commencing Over the past three years serious faults have been discovered that l Ensures maximum safety and efficiency for plant operating at have been repaired before the machine is allowed to work, such the quarry. as worn suspension bushes, faults in power steering systems, worn 34 visit www.safequarry.com for more details or email: [email protected] Index Incident alertsIncident processing Safer Title number Page Entry number Asphalt Quarry products Concrete & lime Cement wide Company Contracts Dust Maintenance Mobile plant & deliveryTransport Traffic Safety Wand for banksmen 4 551 • • • • Installing Fire Fan on sealed asphalt plant 4 605 • • • • • Mixer drip door 5 536 • • Installing interlock system on chipper guard 5 583 • • Industry first in skip winch braking systems 6 543 • • CCTV lens cleaning from ground level 6 609 • • • RAP chute monitor 7 648 • • • Designated off-loading area for bitumen tanker deliveries 7 589 • • • Tail drum guard and platform 8 643 • • Bitumen, asphalt & & asphalt Bitumen, contract surfacing contract Safer bitumen through effective visual and sound management at point of delivery 8 532 • • Burner ram for safer cleaning 8 642 • • Fire box to house critical information 9 660 • Safety locking device 9 618 • • Web based computer induction system 10 592 • • Asphalt collect customer safety initiative 10 636 • • • Reducing contractor risk 11 555 • • Contractor safety 11 637 • • Acid wash station 12 542 • • • • Fitters’ safe working area, first aid room and emergency equipment store 12 586 • • • Combined permit office and isolation station 13 593 ontractors safetyontractors • • • C Contractor induction assessment 13 674 • • Return roller bracket for conveyors 14 548 • • Installation of airbags for additional overhead protection 14 590 • • Plasma cutting trolley 15 666 • • • Confined space improved access 15 606 • • Reduction of confined space at the quarry 16 581 • • • Removable working platform 16 608 • • Blowbar vibrator unit 17 647 • • Access platform for changing primary crusher jaw 17 560 • • Top Hat’ rotary crusher concave replacement safety equipment 17 670 • • Unicone tail compliance tool 18 537 • • • Maintaining minimum bund heights 18 627 • • V ES ENGINEERING INITIATI T beam wire retaining bars 18 667 • • New concrete sleeper de-moulder 19 591 • • Helping customers to avoid working at height during offloading 19 665 • •

, The Switch Programme – Mobile phone campaign 20 530 • Site Safety Transformation – a team effort 21 577 • • • Health and safety days 21 596 • • Developing a HOPE Safety Culture 22 635 • Behavioural safety – safety culture leadership 22 554 • V IOURAL SAFETY LEA D ERSHIP Implementing health and safety improvements 23 673 • • • & SAFETY CULTURE

B EHA Interactive behavioural safety training roadshow 23 584 • • Vulnerable Road Users – driving the standard 24 541 • • Road safety campaign 24 671 • • Raising the industry profile in road safety 25 623 • • • Setting industry standard for road safety 25 559 • • RE D UCING D RIS K ROA Black box recorders fitted to vehicle fleet 26 656 • • OCCUPATIONAL Ensuring the safety of children within our community 26 535 • • Improved traffic management system 27 579 • • Automatic Tyre Inflation System (ATIS) 27 545 • • Small vehicle route 28 612 • • • Amber warning beacon reminder 28 587 • • • Mirror configuration mats 28 640 • V ES INITIATI TRANSPORT ‘Driving Safety’ initiative 29 540 • Securing loads – ‘Secure it right, first time, every time!’ 29 659 • • ‘Stop dust before it stops you’ - Animated training video 30 626 • • Protective film on driver’s cab window 30 549 • • • . OCC b eing & well well & HEALTH RPE programme to prevent exposure to airborne silica dust 31 619 • • Tablet solution for the contracting industry 32 649 • • • • • Health and safety week 32 655 • • • Creation of a European guide for Pedestrian and Traffic Safety 33 568 • • •

V EMENT Emotional and mental health awareness campaign 33 616 •

WOR K ER Remote worker conference calls 34 558 •

IN V OL ‘Please Look After Me’ campaign 34 598 • Foreman’s inspection of hired-in mobile plant 34 650 • • • 35 Health & Safety working groups

Lime Plant and Processes David Brown Lhoist (Steetley Dolomite) Ltd David Brown Lhoist (Steetley Dolomite) Ltd Kye Brown Singleton Birch Ltd Paul Denby Aggregate Industries Julian Clayton Lhoist (Steetley Dolomite) Ltd Martin Lever CEMEX UK Materials Paul Geaney Lhoist UK Ltd Bob Robinson Hope Construction Materials Andrew Jones Lafarge Tarmac Kevan Shovlar Hanson UK Viv Russell Lafarge Tarmac Andy Smith Lafarge Tarmac Ian Gibson Mineral Products Association Richard Solly Rema Tip Top Industry Ltd Ian Gibson Mineral Products Association Safer by Partnership Kye Brown Singleton Birch Ltd Bitumen Ian Gibson Mineral Products Association Matt Avery Aggregate Industries Roseanne Hayward MPQC (Awarding Body) Jason Barker CEMEX UK Materials Cedric Hollinsworth MPQC Ian Burrows OEurovia Roadstone David Jones Response Engineering Gary Dowell Hanson UK Peter Luxmore CEMEX UK Operations Mike Linley Mineral Products Association Bob Robinson Hope Construction Materials Arnold Marsden Lafarge Tarmac Rosamund Seal Aggregate Industries Andrew Williams Nynas Bitumen Andy Smith Lafarge Tarmac Richard Solly Rema Tip Top Industry Ltd Transport Working Group Andrew Taylor CEMEX UK Operations Nick Elliott Hope Construction Materials Mark Tyrer Hanson Aggregates Jeff Stobbart Aggregate Industries John Anderson Hanson Occupational Health Sean McGrae Lafarge Tarmac Craig Buttenshaw CPI Mortars Ltd Ben Street mqp Peter Luxmore CEMEX UK Operations Dominic Day Day Group Rosamund Seal Aggregate Industries Paul Needle Smiths Bletchington Kevin Stevens Mineral Products Association John Dargie Myers Group Steve Ford Sibelco Europe Robert Wilkinson CEMEX Peter Parle FM Conway Cement Tom Clubb Brett Group Mike Cowell Hope Construction Materials Trish Jagger MP Skills Graham Dunwell Hanson UK Kevin Stevens Mineral Products Association Jody Guilfoyle Lagan Cement Company Miguel Lara CEMEX UK Cement Leadership and Workforce Engagement Alison Shenton Hope Construction Materials Chris Leese CEMEX Mark Underwood Lafarge Tarmac Lesley Hall Brett Group Meirion Webber Kerneos Limited Mike Cowley United Asphalt Ian Gibson Mineral Products Association Nigel Clamp Hanson Andrew Cox FM Conway Contract Surfacing Andy Price Sibelco Stephen Barker CEMEX UK Materials Ian Scott Aggregate Industries Phill Beaumont Colas Limited Tyrone Partridge Day Group Ian Darroch Hanson Asphalt & Contracting Kevin Stevens Mineral Products Association Paul Kidd RIS National Ltd (Eurovia) Keith Merrie Aggregate Industries Performance Statistics Geoff Shearn J Wainwright & Co Ltd Paul Lacey Hanson Pat Sheehan Colas Limited Tyrone Partridge Day Group Darren Stokes Tripod Crest Ltd Andrew Taylor CEMEX UK Operations Dean Watkin CRH Plant Carl Wignell Aggregate Industries Glyn Williams Lafarge Tarmac National Contracting 36 Ian Gibson Mineral Products Association advert to follow Working with you towards Target Zero

Babcock International Group employs over 28,000 people across the globe - within sectors that can be inherently dangerous.

In everything we do, our priority is on the health and correct risk management system processes and putting safety of our employees and those working alongside effective safety reporting mechanisms in place. them. Best practice, innovative programmes and We focus on tackling safety issues at source, carrying out experiences are shared across the Group and with risk assessments to minimise risks and reduce the potential our customers and suppliers. of safety incidents. Within the mining & construction sector, safety Partnering with Babcock is so much more than transforming intervention is one of the most critical aspects of your fl eet performance – it’s about working with you to Babcock’s unique approach to fl eet management from ensure everybody returns safely to their home every night. ensuring a safe environment through to carrying out the

For more information on Babcock’s approach and services within the mining and construction sector, please email: [email protected] or call +44 (0) 121 227 7400 www.babcockmining.com The App to access the AM health & safety hub for the mineral products industry Register now for FREE Instant access wherever you are to: Safequarry App l Incident alerts l Industry guidance l Safety videos l Latest safety innovations l Toolbox talks

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For info call MPA +44 (0)20 7963 8000

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

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

Printed on paper and board which is totally chlorine-free and © Mineral Products Association 2015 produced from pulp from sustainable forests.