Transcript Working Safely in Global Construction

Working Safely
in Global Construction
Tom Will
Rohm and Haas Company
No one person or single party can
create a safe jobsite. It requires a
collaborative effort with the owner
and contractors working together
from the top of their respective
organizations down to, and most
importantly with, the hourly
workers.
Case Study: Taloja, India
• Adhesives, sealants,
emulsions plant
• 3.6 million work-hours
• Two lost time incidents,
two recordable injuries
• Construction Users
Roundtable (CURT) Award
• President’s Health-Safety-Environmental Award (Jacobs)
• Joseph J. Jacobs Master Builder Award
• On time, on budget project that met business goals with
outstanding safety results
Project Execution Strategy
Joint partnership by:
Owner:
Rohm and Haas
EPCM Contractor/Alliance Partner:
Jacobs H&G
Numerous subcontractors
Safety Goals
• Zero injuries
• Everyone goes home in
the same condition they
went to work
• World-class safety
program
• Proactive safety tools
• Support worker needs
(on and off the job)
Work Force
Taloja, India
►
Safe workers
shown: 600
►
Project peak:
1,300
►
Total
employees
indoctrinated:
5,200
Safety Beliefs
• You can work safely anywhere ― all of the time.
• Owner, contractor, and subcontractors working
together make it happen.
• It all starts at the top.
• Safety management culture and systems drive results.
• Each and every individual must contribute.
• Injuries are produced by “at-risk behavior” that can be
changed.
• Changing behaviors requires systems, resources,
commitment, and hard work.
What Were the Keys to Safety Performance?
• Application of
Industry (CII) Best
Safety Practices
• “Owner’s Role in
Safety” research (CII
Project Team 190)
• Rohm and Haas/
Jacobs Alliance
18 Best Safety
Practices
Details in
Implementation Session
Tie-off / Fall Protection
Do Not Worry; If I Lose
Balance, My Harness
Would Save Me!
Use Protective Equipment
Properly. Safety Harness
Lanyard To Be Hooked On
Strong And Rigid Objects
Safety Statistics
Category
U.S.
India
9 Million
100 Million
1,800
50,000
Construction
deaths per day
5
150
Construction
deaths per year
1,250
40,000
Construction
workers
Injuries per day
Comparison to Similar Gulf Coast Project
Gulf Coast
Category
Typical CII
Equivalent
Taloja, India
Total Installed Cost (TIC)
$50MM
< $20MM
Work-Hours
800,000
3,600,000
Total Recordable Injuries
4
4
Lost Time Incidents (LTI)
1
2
1.0
0.2
Recordable Incident Rate (RIR)
CII Industrial RIR
1.0 – 1.1
U.S. Industrial RIR
5.0 – 7.0
Challenges & Risks: Taloja, India
• No real safety culture or legislation.
• Many owners and contractors don’t
support safety.
• High manual labor content and
worker density.
• Work force: poor, unskilled, migrant.
• Civil work during monsoon season.
• Several distinct languages.
• Minimal use of construction
equipment.
Key Program Elements
• Management commitment, involvement, accountability
• World-class health-safety-environmental program
• One common safety team
• New employee orientation and training
• Medical facilities — on and off site
• Pre-project planning
• Safety observations system and audits
• Recognition/reward and disciplinary system
• Incident investigation and feedback/learnings
Professional Safety Staffing
Rohm and Haas
2
Jacobs
4
Safety specialty sub
5
Contractors
12
Total
23
Additional support and auditing from management
at Rohm and Haas and Jacobs.
Why It Worked
• Management support and corporate alignment.
• The core project team and Jacobs’ local presence.
• Corporate alignment (Rohm and Haas/Jacobs).
• “Walked the talk.”
• Organized, staffed project with safety as key success factor.
• Made local practices safe, didn’t impose the unfamiliar.
• Supervisors were key and we won their hearts and minds.
• Work force felt that management cared about safety.
Summary of Injuries
Three million, six hundred thousand work-hours:
• ONE industrial injury
• Four recordable injuries
- Two lost time incidents
- Two recordables
- One was “slip and fall” resulting in laceration
(only true industrial accident)
• Forty-four first-aid cases
Frequently Asked Questions
How did you deal with poor
contractor safety culture?
Selection process, training,
zero tolerance.
Frequently Asked Questions
Only one industrial injury?
Do people not report injuries at the site?
Not normal in India.
Site nurse improved reporting.
Site procedures mandated reporting.
Frequently Asked Questions
Why 660 percent turnover?
Migrant farm workers, contract agency workers,
paid daily with no retention incentive, zero
tolerance to at-risk safety behavior.
Safety Management Beliefs and Principles
• All safety incidents are
preventable.
• All safety incidents are
caused by at-risk behavior.
• All behaviors can be changed.
• “If you’re not confronting at-
risk behavior, you’re
reinforcing it.”
• Leadership is required to institute change and improve safety.
• Attainment of zero injuries is possible.
Rigging
For “Long” Loads
Use Double Slings!
Conclusions
Success Factors
• True and highly visible management commitment.
• Local jobsite commitment (walk the talk).
• Key contractor culture and commitment.
• Implementation of a solid, detailed safety plan
utilizing CII Best Practices.
• Follow-through with elements of the plan.
• Winning hearts and minds of supervisors, making
believers out of them.
• Above all, uncompromising intolerance to “at-risk
behaviors.”
The Bottom Line
“You will achieve the level of
safety that you demonstrate you
want to achieve.”
Implementation Session
Working Safely in Global Construction
Moderator:
• Randy Arrington, Jacobs
Panelists:
• A. L. Benny, Construction Manager (Jacobs)
• Geoff Bell, Project Manager (Rohm and Haas)
• Tom Will, Capital Manager (Rohm and Haas)
Georgia B
3:15-4:15 pm and 4:30-5:30 pm