WINNER

Stanton Bonna - Eliminating Dust, Noise & Vibration Through Product Design   

The judges felt that this entry showed an Innovative, cost effective design solution which not only benefits Health and Safety by eliminating exposures to noise, dust and vibration, it also contributes to the efficiency of the operation.

Stanton Bonna has manufactured machine made Jacking pipes for the previous 10 years. These are a concrete pipe with a steel collar into which the pipe is jointed using a rubber gasket to seal the joint. The steel collars are fabricated from a piece of flat plate rolled to the required diameter and therefore are subject to the normal tolerances that could be expected for this method of manufacture. As a consequence during the moulding of the pipes grout is lost between the collar and the steel pallet on which the product is made. This grout has to be removed during the dressing of the pipe, usually by grinder which results in not only noise and vibration, but more importantly dust, not only at the workstation where the dressing is being carried out but also in the rest of the workshop if blown by the wind.

Runner-up

C R Longley - Occupational Health Initiative      

CR Longley faced mounting trouble with skin irritation but now have an ongoing plan of Occupational Health checks for their employees who work in the factory and intend to roll it out to all staff. The number of insurance claims against the company in 2010 was nil and their insurers have been able to offer a competitive renewal premium.

COMMENDED

Aggregate Industries- Behavioural Safety Challenging Our Standards     

As part of the site evaluation at a newly purchased site it became apparent that the site had not developed its Health and Safety culture to required levels. It was clear that the operatives were not reluctant to change, they just required the correct guidance; training and investment.
A “back to basics” approach was undertaken. A training matrix was generated and during week 1 of 2011 all manufacturing was stopped to initiate this training; this is planned to be on-going throughout the year and will be updated and refreshed annually. In short it was trained that Health and Safety was the number 1 priority. It was also made abundantly clear through Tool Box Talks and regular communication that Health and Safety was not a stick to beat people up with but was a requirement by law to adhere to. Standards were clearly communicated.

COMMENDED

Brett Landscaping- Control of Contractors

During 2009-2010, the Brett group, while analysing their accident data, realized that based on hours worked, visitors & contractors were having significantly more accidents than their own staff. This lead the group wide SHE strategy group to review how it handled contractors, and a project was set up to look at reducing the accidents they were having. Since the review of Contractors was carried out, there has been a marked decline in the number of contractors being injured, and while the rolling annual figures are higher, they are decreasing month on month.

COMMENDED

Brett Landscaping- Setting the Standard     

Brett Landscaping Ltd was formed just over 10 years ago. One of the issues that has developed over the years, is that each site tended to bring its own rules, customs and procedures. Much work has been done merging systems and integrating one management system to all sites (Brett’s management system is QHEST – Quality, health, environment, safety together), but it was felt there was still work to be done.
A project was set up called “setting the standard”. This focused on two issues, PPE & overalls and staff behaviour and rules. The site managers helped develop these rules and drew up a toolbox talk that could be delivered with the rules. When each member of staff went through them, they were each given a personal copy of the rules as a reminder to take away with them. Both projects, were followed up with poster campaigns to keep the initiatives in the fore front of peoples minds

COMMENDED

Marshalls Plc- Control of Vibratory Cleaning Equipment    

The usage of zip guns (CP7) is not controlled, meaning operators would possibly be over exposed to vibration given off of the zip gun due to poor maintenance and no control over the location of the guns.
A procedure was put in place for the issuing of zip guns. A lockable cabinet put in place for the zip guns to be stored, with limited persons having keys. The air tool register checked against the ID numbers of active zip guns and updated. An issue and inspection sheet put in place to cover pre and post use checks with an area for defects and comments on the tool. This ensures regular maintenance on the tools. All operators trained on the risks, correct use and maintenance of the zip guns. Each operator issued with a zip gun which is in good working order. Exposure value is now 15.3m/s2 from 36.43. A reduction of 21.13m/s.

COMMENDED

Marshalls Plc- Near Miss Reporting

Marshalls Near Miss Reporting is based on the Accident Triangle. a new system has been implemented to address a number of issues.

From looking at the statistics from previous years for Near Miss reports showed an imbalance. It was also noted the meaning and understanding of a Near Miss was not understood in the same way by all on site, which could allow for Near Miss incidents to go undetected and reported.
Due to the paperwork design, only Near Miss Reports were potentially reported for safety incidents, and environment and quality Near Misses, were going unreported.

COMMENDED

Sandtoft Roof Tiles- Forklift Truck Access Ramp

The gearbox and motor on the tile packaging machine was located approx 10 meters from the ground, preventative maintenance requires an annual change of these parts. Recent risk assessments identified that the current method of using a cherry picker and lifting tackle resulted in the risk rating being in the not acceptable range required a rethink. A full access gantry was built allowing easy access not only for the gearbox and motor but allowing electrical checks to be made easier.

Sustainability Award – sponsored by Hanson UK

Corporate category

WINNER

Aggregate Industries- A+ GRI Sustainability Report

The judges commented that the ‘A+ GRI’ report submitted by Aggregate Industries set a new benchmark for the sector and contained an exceptional range of highly effective sustainability activities, initiatives and achievements. They felt that many companies, both in the precast sector and outside, would not only be impressed by the quality and breadth of the work reported, but they would also learn from reading about it.

Aggregate Industries has long had a record for outstanding achievement in sustainability. The company sees part of its goal to protect these environments not only through working closely with its customers, clients and others in the supply chain to find the best solution but also through the manufacture and supply of the highest quality and most sustainable materials.

Aggregate Industries is also a Gold Leaf founding member of the UK Green Building Council in the UK. The company also sponsors the Wildlife Trusts and has committed to supporting the environmental organisation’s involvement in the BBC Breathing Places campaign. In recognising this continuous achievement, the company was also placed 24th in The Sunday Times Best Green Companies 2009, rising from 28th last year.

Aggregate Industries has shown great leadership in being the first company to adopt BES 6001 for Responsible Sourcing across all product groups. This has been in part due to another industry first; an externally verified A+ GRI Sustainability Report.

RUNNER-UP

Marshalls - Sustainability at Marshalls

The judges noted that Marshalls continue to take a positive stand on sustainability and appreciated the many examples of good practice submitted in their entry. The company has a clear sustainable business model that was being put into practice on a daily basis; the judges felt this would act as an inspiration to others in the precast sector.

Sustainability at Marshalls is based on three elements – economic, environmental and social. Whilst they operate a successful and profitable business, Marshalls also try to minimise our impact to the environment and look after the communities they work with in the UK and overseas.
Within each of the economic, environmental and social elements, Marshalls sets Key Performance Indicators (KPIs) designed to set a commitment and strive for the achievement of ambitious targets. Marshalls works in partnership with accredited organisations such as the Carbon Trust and nef (the new economics foundation) to validate and verify its work. Setting objectives and targets is just one part of the journey – it’s also about monitoring impact and watching the progress of its initiatives on real lives.

WINNER

Brett Landscaping - Energy Reduction in Curing Chambers

The judges were pleased to see how the employees at Poole had worked together to develop a very straightforward, yet highly successful solution to reduce curing energy by diverting hot air at the roof of the factory down to the curing chambers. The judges were impressed by the employee involvement and the fact that such a good idea could easily be replicated across the sector.

The Poole plant is one of the oldest block plants in the Brett group, and is now more than 20 years old. Unlike the other plants, this plant does not have a purpose build automated curing chamber that is temperature and humidity controlled. The plant has suffered from poor curing in the winter and high heating bills to try and cure this problem. To help reduce energy bills, the site team devised in-house fan system, that re-circulated the hot air, dragging it down from the roof space to the lower levels helping cure the blocks quicker and better. This allowed the site, to use the heaters less frequently, and to stick with a “summer mix design” rather than the “Winter mix design” which was cement richer, to ensure curing. The total project potentially will save the company approximately £10,000 per annum moving forward.

HIGHLY COMMENDED

Hanson Building Products - Recycling & Water use Reduction

By reducing water use and increasing recycling at their factory in Hoveringham, the judges noted that Hanson had been able to achieve 50% saving in water use and a substantial cost saving too.

Due to the nature of the manufacturing process particularly as a result of cutting concrete flooring components (Dust suppression) and the cleaning of concrete batching plants and casting machinery. The Hoveringham business unit generates high volumes of waste water that contains a percentage of cementitious particles; this by-product is commonly referred to as slurry.

The Hoveringham site “Recycling and Water Reduction Initiative” was conceived in 2009 as a Continuous Improvement project. After the installation and commissioning of the dewatering system; the waste disposal costs were significantly reduced (Savings of £48000 per annum). More importantly the benefits allowed the Hoveringham site to assist in achieving Hanson UK’s wide objectives set for both the Environment Management System (14001) and Sustainability.

The mandatory reduction of borehole abstraction set by the Environment Agency becomes effective in 2015 where the sites current water extraction limit would be reduced by 60%. The installation of this dewatering finally system prepared us to use an alternative source for water without the need for applying for an increase in borehole extracted volumes.

HIGHLY COMMENDED

Marshalls - Biomass Trial

Working with the University of Leeds, wood-pellet heaters were trialled at Marshalls’ West Lane Works to see how much energy and waste could be saved from changing to a biomass heating system, with support from CO2Sense. The judges praised the idea and hoped that other manufacturers would consider this in their own factories.

Marshalls’ West Lane works use gas oil to provide heating for product curing and general building heating for a good, compliant working environment. As a company, Marshalls has a target to move from a reliance on fossil fuels thus reducing its carbon footprint. In 2010, Marshalls West Lane Works partnered with CO2sense (Yorkshire) and Leeds University to trial the use of wood pellet heaters instead of oil heaters in order to reduce its carbon impact.

The Trial

• This was an innovative trial and had not been done before, hence part funding was available
• Marshalls has worked in partnership with the regional organisation CO2sense.
  
• One heater has been retrofitted with a biomass burner, which consumes wood fuel pellets.
  
• The purpose of the trial was to assess whether the wood pellet heater had an equivalent performance to the oil heater and whether there were any adverse regulated emissions.
  
• Leeds University conducted a detailed trial on emissions from the burner and different types of fuel so that detailed data could be used to assess emission differences between gas oil and wood pellets.

HIGHLY COMMENDED

Marshalls - Tegula

The judges were pleased to see that a change to the manufacturing process of these popular paving blocks had halved energy use, saved water and created a safer environment for factory staff, all of which was good evidence of another praiseworthy sustainability achievement for Marshalls.

An innovation in the manufacturing of artificially ‘aged’ block paving (Tegula) has led to a number of benefits for Marshalls including reductions in energy (carbon), water, packaging, noise and injury related issues (H&S) as well as improving lean manufacture and just-in-time period from production to customer – all of this without compromising the quality of the product and even improving laying rates.

The new Dancing Weight method is a simple concept. As the block paving is pushed forward from the Inlet Table to the Outlet Table, an electrical vibrator motor rotates which in turn oscillates a Vibration Table. Whilst the table oscillates the block paving impacts onto hanging metal weights which causes the weights to dance up and down.  As the block impacts the weight, it causes distressing of the top face and top corners of the block which gives it the desired aged appearance.

COMMENDED

Aggregate Industries - Taunton Park and Ride

Bardon Contracting successfully completed the Taunton Park and Ride project during 2010. There was a real desire and commitment from the team on site to make the project as sustainable as possible. This meant reducing the amount of material sent to landfill, reusing existing structures on site, the creation of habitats, working with the local community and most importantly learning from the experience to take to the next job.

To further confirm the sustainability credentials of this project the team decided to go for a Ceequal Construction only award something they had never done before. Due to the hard work from all the whole project team the project was awarded a Ceequal Excellent award. The award sits well with Aggregate Industries’ wider sustainability strategy and will hopefully help give the business the edge in tendering for future contracts.

Ceequal is the assessment and awards scheme for improving sustainability in civil engineering and public realm projects.

COMMENDED

Brett Lanscaping - Cliffe Lake Water Project

During 2010, Brett Landscaping’s management team, realised that water was one of the key elements that needed to be tackled to achieve our British Precast Sustainability Charter targets. Several small projects were done, on leaks, and water saving projects such as push taps, smaller cisterns etc. But the main use of water on the site is in the production of Concrete. Historically it has been a major problem on site, as the site is at the end of the mains line, in summer months, often the plants stand still when pressure drops and no water is available, costs up to £500 per plant per hour.

During the 2010, the Cliffe site produced 220,000 tonnes of concrete products, using around 5,866,640 litres of water to produce it. This is taken from mains water at a cost of around £5500 per annum (94.4p per m3). It was decided that to be more green, and to help reach our sustainability targets, this water could be taken from a local lake, rather than mains water.

COMMENDED

Brett Landscaping - Waste Minimisation and Review

Within the Brett group, data is collected monthly on Brett’s sustainability performance, which makes up the majority of the data submitted as part of it’s membership of the British Precast's Sustainability Charter. The data is known within the business as “measuring up”.

When this data was reviewed in 2010, waste was targeted at the Cliffe site as an opportunity for improvement. A project was set up, with the view to trying to reduce the amount of waste generated, the cost of waste disposal and with the aim of achieving “Zero to Landfill”. This project was communicated to the site SHE committee, who were all on board in improving the site’s waste management performance.

A toolbox talk was designed and issued to the staff to raise awareness, this highlighted the need to reduce, reuse and recycle wherever possible.

The waste streams on the site were mapped, and all the existing suppliers were contacted to confirm where the material was going and what the outcome of the material was (burnt, recycled, land filled etc)
The site is supplied with many of it’s waste removal facilities, from Viridor Waste Management. Neil O’Mallon the local sales manager, came on board with the project and helped the site manager Neil Frost, set up recycling facilities for plastic, paper and aluminium drink cans for all offices, and factories. Neil established bins in each area which made this recycling project highly visible in the all areas.