Working Safely Working Safely

in Global Constructionin Global Construction

Tom WillTom Will

Rohm and Haas CompanyRohm 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, IndiaCase Study: Taloja, India

• Adhesives, sealants, Adhesives, sealants, emulsions plantemulsions plant

• 3.6 million work-hours3.6 million work-hours

• Two lost time incidents, Two lost time incidents, two recordable injuries two recordable injuries

• Construction Users Construction Users Roundtable (CURT) AwardRoundtable (CURT) Award

• President’s Health-Safety-Environmental Award (Jacobs) President’s Health-Safety-Environmental Award (Jacobs)

• Joseph J. Jacobs Master Builder AwardJoseph J. Jacobs Master Builder Award

• On time, on budget project that met business goals with On time, on budget project that met business goals with outstanding safety resultsoutstanding safety results

Project Execution StrategyProject Execution Strategy

Joint partnership by:Joint partnership by:

Owner:Owner:

Rohm and HaasRohm and Haas

EPCM Contractor/Alliance Partner:EPCM Contractor/Alliance Partner:

Jacobs H&GJacobs H&G

Numerous subcontractorsNumerous subcontractors

Safety GoalsSafety Goals

• Zero injuries Zero injuries

• Everyone goes home in the Everyone goes home in the same condition they went same condition they went to workto work

• World-class safety programWorld-class safety program

• Proactive safety toolsProactive safety tools

• Support worker needs (on Support worker needs (on and off the job)and off the job)

► Safe workers Safe workers shown: 600shown: 600

► Project peak: Project peak: 1,3001,300

► Total Total employees employees indoctrinated: indoctrinated: 5,2005,200

► Safe workers Safe workers shown: 600shown: 600

► Project peak: Project peak: 1,3001,300

► Total Total employees employees indoctrinated: indoctrinated: 5,2005,200

Work ForceWork ForceTaloja, IndiaTaloja, India

► Safe workers Safe workers shown: 600shown: 600

► Project peak: Project peak: 1,3001,300

► Total Total employees employees indoctrinated: indoctrinated: 5,2005,200

► Safe workers Safe workers shown: 600shown: 600

► Project peak: Project peak: 1,3001,300

► Total Total employees employees indoctrinated: indoctrinated: 5,2005,200

Safety BeliefsSafety Beliefs

• You can work safely anywhere You can work safely anywhere ―― all of the time. all of the time.

• Owner, contractor, and subcontractors working together Owner, contractor, and subcontractors working together make it happen.make it happen.

• It all starts at the top.It all starts at the top.

• Safety management culture and systems drive results.Safety management culture and systems drive results.

• Each and every individual must contribute.Each and every individual must contribute.

• Injuries are produced by “at-risk behavior” that can be Injuries are produced by “at-risk behavior” that can be changed.changed.

• Changing behaviors requires systems, resources, Changing behaviors requires systems, resources, commitment, and hard work.commitment, and hard work.

What Were the Keys to Safety Performance?What Were the Keys to Safety Performance?

• Application of Industry Application of Industry (CII) Best Safety Practices(CII) Best Safety Practices

• ““Owner’s Role in Safety” Owner’s Role in Safety” research (CII Project research (CII Project Team 190)Team 190)

• Rohm and Haas/ Rohm and Haas/ Jacobs Alliance Jacobs Alliance 18 18 Best Safety Best Safety Practices 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

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 StatisticsSafety Statistics

CategoryCategory U.S.U.S. IndiaIndia

Construction Construction workersworkers 9 Million9 Million 100 Million100 Million

Injuries per dayInjuries per day 1,8001,800 50,00050,000

Construction Construction deaths per daydeaths per day 55 150150

Construction Construction deaths per yeardeaths per year 1,2501,250 40,00040,000

Comparison to Similar Gulf Coast ProjectComparison to Similar Gulf Coast Project

CategoryCategoryGulf CoastGulf Coast

Typical CII Typical CII EquivalentEquivalent

Taloja, IndiaTaloja, India

Total Installed Cost (TIC)Total Installed Cost (TIC) $50MM$50MM < $20MM< $20MM

Work-HoursWork-Hours 800,000800,000 3,600,0003,600,000

Total Recordable InjuriesTotal Recordable Injuries 44 44

Lost Time Incidents (LTI)Lost Time Incidents (LTI) 11 22

Recordable Incident Rate Recordable Incident Rate (RIR)(RIR)

1.01.0 0.20.2

CII Industrial RIRCII Industrial RIR 1.0 – 1.11.0 – 1.1

U.S. Industrial RIRU.S. Industrial RIR 5.0 – 7.05.0 – 7.0

Challenges & Risks: Taloja, IndiaChallenges & Risks: Taloja, India

• No real safety culture or legislation.No real safety culture or legislation.

• Many owners and contractors don’t Many owners and contractors don’t support safety.support safety.

• High manual labor content and High manual labor content and worker density.worker density.

• Work force: poor, unskilled, migrant.Work force: poor, unskilled, migrant.

• Civil work during monsoon season.Civil work during monsoon season.

• Several distinct languages.Several distinct languages.

• Minimal use of construction Minimal use of construction equipment.equipment.

• No real safety culture or legislation.No real safety culture or legislation.

• Many owners and contractors don’t Many owners and contractors don’t support safety.support safety.

• High manual labor content and High manual labor content and worker density.worker density.

• Work force: poor, unskilled, migrant.Work force: poor, unskilled, migrant.

• Civil work during monsoon season.Civil work during monsoon season.

• Several distinct languages.Several distinct languages.

• Minimal use of construction Minimal use of construction equipment.equipment.

Key Program ElementsKey Program Elements

• Management commitment, involvement, accountabilityManagement commitment, involvement, accountability

• World-class health-safety-environmental programWorld-class health-safety-environmental program

• One common safety teamOne common safety team

• New employee orientation and trainingNew employee orientation and training

• Medical facilities — on and off siteMedical facilities — on and off site

• Pre-project planningPre-project planning

• Safety observations system and auditsSafety observations system and audits

• Recognition/reward and disciplinary systemRecognition/reward and disciplinary system

• Incident investigation and feedback/learningsIncident investigation and feedback/learnings

Professional Safety StaffingProfessional Safety Staffing

Additional support and auditing from management at Rohm and Haas and Jacobs.

Rohm and HaasRohm and Haas 22

JacobsJacobs 44

Safety specialty subSafety specialty sub 55

ContractorsContractors 1212

TotalTotal 2323

Why It WorkedWhy It Worked

• Management support and corporate alignment.Management support and corporate alignment.

• The core project team and Jacobs’ local presence.The core project team and Jacobs’ local presence.

• Corporate alignment (Rohm and Haas/Jacobs).Corporate alignment (Rohm and Haas/Jacobs).

• ““Walked the talk.”Walked the talk.”

• Organized, staffed project with safety as key success factor.Organized, staffed project with safety as key success factor.

• Made local practices safe, didn’t impose the unfamiliar.Made local practices safe, didn’t impose the unfamiliar.

• Supervisors were key and we won their hearts and minds.Supervisors were key and we won their hearts and minds.

• Work force felt that management cared about safety.Work force felt that management cared about safety.

Summary of InjuriesSummary of Injuries

Three million, six hundred thousand work-hours: Three million, six hundred thousand work-hours:

• ONE industrial injuryONE industrial injury

• Four recordable injuriesFour recordable injuries

- Two lost time incidents- Two lost time incidents

- Two recordables- Two recordables

- - One was “slip and fall” resulting in laceration One was “slip and fall” resulting in laceration (only true industrial accident)(only true industrial accident)

• Forty-four first-aid casesForty-four first-aid cases

Frequently Asked QuestionsFrequently Asked Questions

How did you deal with poor How did you deal with poor contractor safety culture?contractor safety culture?

Selection process, training, Selection process, training, zero tolerance. zero tolerance.

Frequently Asked QuestionsFrequently Asked Questions

Only one industrial injury?Only one industrial injury?

Do people not report injuries at the site?Do people not report injuries at the site?

Not normal in India.Not normal in India.

Site nurse improved reporting.Site nurse improved reporting.

Site procedures mandated reporting.Site procedures mandated reporting.

Frequently Asked QuestionsFrequently Asked Questions

Why 660 percent turnover?Why 660 percent turnover?

Migrant farm workers, contract agency workers, Migrant farm workers, contract agency workers, paid daily with no retention incentive, zero paid daily with no retention incentive, zero

tolerance to at-risk safety behavior.tolerance to at-risk safety behavior.

Safety Management Beliefs and PrinciplesSafety Management Beliefs and Principles

• All safety incidents are All safety incidents are preventable.preventable.

• All safety incidents are All safety incidents are caused by at-risk behavior.caused by at-risk behavior.

• All behaviors can be changed.All behaviors can be changed.

• ““If you’re not confronting at-If you’re not confronting at-risk behavior, you’re risk behavior, you’re reinforcing it.”reinforcing it.”

• Leadership is required to institute change and improve safety.Leadership is required to institute change and improve safety.

• Attainment of Attainment of zero injurieszero injuries is possible. is possible.

Rigging

For “Long” Loads Use Double Slings!

Rigging

For “Long” Loads Use Double Slings!

ConclusionsConclusions

Success FactorsSuccess Factors

• True and highly visible management commitment.True and highly visible management commitment.

• Local jobsite commitment (walk the talk).Local jobsite commitment (walk the talk).

• Key contractor culture and commitment.Key contractor culture and commitment.

• Implementation of a solid, detailed safety plan utilizing Implementation of a solid, detailed safety plan utilizing CII Best Practices.CII Best Practices.

• Follow-through with elements of the plan.Follow-through with elements of the plan.

• Winning hearts and minds of supervisors, making Winning hearts and minds of supervisors, making believers out of them.believers out of them.

• Above all, uncompromising intolerance to “at-risk Above all, uncompromising intolerance to “at-risk behaviors.”behaviors.”

The Bottom LineThe Bottom Line

““You will achieve the level of You will achieve the level of

safety that you demonstrate you safety that you demonstrate you

want to achieve.”want to achieve.”

Implementation SessionImplementation Session

Working Safely in Global ConstructionWorking Safely in Global Construction

Moderator:Moderator:• Randy Arrington, JacobsRandy Arrington, Jacobs

Panelists:Panelists:• A. L. Benny, Construction Manager (Jacobs)A. L. Benny, Construction Manager (Jacobs)• Geoff Bell, Project Manager (Rohm and Haas)Geoff Bell, Project Manager (Rohm and Haas)• Tom Will, Capital Manager (Rohm and Haas)Tom Will, Capital Manager (Rohm and Haas)

Georgia BGeorgia B

3:15-4:15 pm and 4:30-5:30 pm3:15-4:15 pm and 4:30-5:30 pm