Working Safely in Global Construction

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Working Safely in Global Construction

• Tom Will
• Rohm and Haas Company

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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.
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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

• Presidents Health-Safety-Environmental Award
  (Jacobs)
• Joseph J. Jacobs Master Builder Award
• On time, on budget project that met business
  goals with outstanding safety results

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Project Execution Strategy

• Joint partnership by
• Owner
• Rohm and Haas
• EPCM Contractor/Alliance Partner
• Jacobs HG
• Numerous subcontractors

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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)

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Work Force
Taloja, India

• Safe workers shown 600
• Project peak 1,300
• Total employees indoctrinated 5,200

• Safe workers shown 600
• Project peak 1,300
• Total employees indoctrinated 5,200

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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.

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What Were the Keys to Safety Performance?

• Application of Industry (CII) Best Safety
  Practices
• Owners Role in Safety research (CII Project
  Team 190)
• Rohm and Haas/
  Jacobs Alliance
  18 Best Safety
  
  Practices

Details in Implementation Session
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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
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Safety Statistics
Category U.S. India
Construction workers 9 Million 100 Million
Injuries per day 1,800 50,000
Construction deaths per day 5 150
Construction deaths per year 1,250 40,000
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Comparison to Similar Gulf Coast Project
Category Gulf Coast Typical CII Equivalent Taloja, India
Total Installed Cost (TIC) 50MM lt 20MM
Work-Hours 800,000 3,600,000
Total Recordable Injuries 4 4
Lost Time Incidents (LTI) 1 2
Recordable Incident Rate (RIR) 1.0 0.2
CII Industrial RIR 1.0 1.1 1.0 1.1
U.S. Industrial RIR 5.0 7.0 5.0 7.0
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Challenges Risks Taloja, India

• No real safety culture or legislation.
• Many owners and contractors dont 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.

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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

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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.
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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, didnt impose the
  unfamiliar.
• Supervisors were key and we won their hearts and
  minds.
• Work force felt that management cared about
  safety.

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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

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Frequently Asked Questions

• How did you deal with poor contractor safety
  culture?
• Selection process, training,
  zero tolerance.

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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.

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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.

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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 youre not confronting at-risk behavior,
  youre reinforcing it.

• Leadership is required to institute change and
  improve safety.
• Attainment of zero injuries is possible.

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Rigging For Long Loads Use Double Slings!
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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.

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The Bottom Line

• You will achieve the level of safety that you
  demonstrate you want to achieve.

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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 315-415 pm and 430-530 pm