Displaying items by tag: UK

Lafarge UK has scored a notable success recently at its Cookstown Works reaching 10 years without a lost-time injury (LTI). It has emerged that this is the longest a Lafarge Group plant anywhere in the world has gone without a LTI. Cookstown also set the record the previous year in 2011, showing how far ahead it is of the rest of the group.

LTIs are generally defined as any work related injury or illness which prevents a worker from doing any work the day after the accident. Another similar measure is Lost Time Injury Frequency Rate (LTIFR), which takes into account hours worked by staff.

For example, in April 2011 Global Cement Magazine interviewed the safety manager at the Ste. Genevieve plant in Missouri, USA. He revealed a rate of zero lost-time incidents rate over the last 1.2 million-man hours and no LTIs over the last 700 days. Through construction the plant employed 2300 personnel and then 200 operational employees when it went live. By comparison Cookstown employs only 80 workers. Its LTIFR will be much lower.

The Mineral Products Association recorded a 81% reduction in LTIs between 2004 and 2009 for the UK cement industry. It has since set itself the further target to halve the LTIFR between 2009 and 2014. As of 2009 the UK LTIFR for direct employees was 3.59 per million hours worked. The MPAs target LTIFR for 2014 is 1.79 or lower.

Regardless of how you present the figures the Cookstown Plant LTI achievement is impressive. The challenge, as ever, lies in bettering it.

UK: Lafarge UK is celebrating the achievement of one of its UK cement production sites, which has reached the milestone of 10 years without a lost-time injury (LTI). Workers at the Cookstown Works in County Tyrone, Northern Ireland, have not suffered any injury that prevents an employee or contractor returning to work the next day since 2002.

Thanks to a strong team commitment to safety, the achievement has put Cookstown Works in the Lafarge Group's record books. Of the company's 170 cement production sites across the world, this is the longest any site has gone without a LTI.

Commenting on the major achievement, Cookstown Works manager William McGuckne said, "This is a proud moment for the team. Through continued hard work and constant vigilance on safety in all aspects of our operation, we have managed to maintain our safety performance and achieve this fantastic record. A culture of assessing risks, proceeding with care and looking out for each other has helped us contribute to the Lafarge Group's ultimate goal of zero harm to any of our employees or contractors."

Lafarge UK president Dyfrig James added, "My congratulations go to the whole Cookstown Works team of employees and contractors for achieving this world first for Lafarge's cement business."

UK: The UK Competition Commission has decided provisionally that the proposed joint venture between Anglo American plc and Lafarge SA in the UK could damage competition in certain markets for construction materials.

In February 2011 Anglo American, through its UK subsidiary Tarmac Ltd, and Lafarge announced a proposal to establish a 50:50 joint venture, to which each of them would contribute the bulk of their construction materials businesses in the UK. The two parties' main overlapping activities in relation to the joint venture are in the production and supply of cement, aggregates, asphalt and ready-mixed concrete. The Office of Fair Trading referred the case to the Competition Commission on 2 September 2011.

Now the Competition Commission has reported that the joint venture could lead to a substantial lessening of competition in the markets for the supply of bulk cement, rail ballast, high-purity limestone (when used for flue-gas desulphurisation), primary aggregates for construction applications in 23 local markets, asphalt in two local markets and ready-mixed concrete in seven local markets.

"We have a number of concerns about this joint venture," said Roger Witcomb, chairman of the Anglo/Lafarge Inquiry Group. "In bulk cement there are currently only four UK producers and there is evidence that the market is not as competitive as it could be. Prices and profit margins haven't been affected in the way we would have expected following the big falls in the demand for cement in the past few years."

Although the Commission has not reached a view on whether or not there has been coordination in the bulk cement market, Witcomb said there were concerns that the proposed tie-up would increase the susceptibility of this market to co-ordination. "Some of the reasons for this arise from the proposed combination of the cement businesses and some from the increased vertical integration that would result from the combination of their ready-mixed concrete businesses," he said. "Lafarge currently have a relatively small ready-mixed concrete business, while Tarmac have a relatively large one."

Witcomb continued, "We are now consulting on the possible actions we could take in response to the reductions in competition we have found, bearing in mind the close links that exist between the different product markets."

As well as the summary of provisional findings, the Competition Commission has published a notice of possible remedies, outlining ways that the potential anti-competitive effects of the joint venture could be prevented. It will issue a final report no later than 1 May 2012.

UK: A report by Markit/CIPS has shown that the UK construction industry as a whole experienced a slow down in January 2012. Jason Heath, a construction specialist at Bibby Financial Services said, "The latest Markit/CIPS survey highlighted that the construction sector slowed down in January 2012. Although the numbers indicate a fall in productivity, the survey also revealed that construction managers and owners are feeling optimistic for the first time in eight months."

"This optimism is perhaps down to construction firms having a particularly successful December 2011, potentially due to milder weather conditions and infrastructure projects commencing, which surprised economists who had predicted a decline towards the end of 2011," he continued. "In order to retain this positive outlook, the government needs to make funding the construction industry a priority by making it more accessible to firms so this sector can continue to provide a vital contribution to the UK economy," concluded Heath.

UK: A worker was killed in an industrial accident at the Cemex plant in Rugby in the early hours of this morning.

A spokesman for the plant confirmed that a man working for a sub-contractor was killed at the plant and emergency services attended the scene. Police officers and the Health and Safety Executive are currently at the site investigating what happened. Another man suffered a broken arm in the incident and had to be taken to hospital for treatment.

Cemex community affairs manager Ian Southcott said, "Regrettably one person has died and our thoughts and sympathies are with their family and friends. Cemex is cooperating fully with all of the investigations taking place." Southcott refused to reveal any more details about the accident while investigations are on-going.

The cement plant is currently in its annual shutdown period for regular maintenance. There are a number of contractors working on the site as a result. In December 2011 Cemex was fined for a worker's death in 2008 at the same plant.

UK: The Mineral Products Association (MPA), which covers the cement and lime industries in the UK, has released its 3rd Sustainable Development Report, which shows the continued progress of its members in the realms of health and safety, carbon emissions, biodiversity, nature conservation and resource efficiency. It highlighted that, while growth prospects are uncertain and markets remain 20% to 40% below pre-recession levels, its members continue to be committed to stringent sustainability targets.

Highlights from the report include the planting of 1 million trees in the UK by MPA member since 2005 and a drop in direct carbon dioxide emission from cement production in 2010. The ratio of land prepared for quarrying to that which was restored to nature was 0.8:1. The report also showed the extent of the slump in UK cement demand. The UK consumed just 158kg/capita of cement in 2010 against the European average of 404kg/capita.

Nigel Jackson, Chief Executive MPA, said, "Our third Sustainable Development Report shows where we have gained considerable ground. For example, there is a growing awareness of the contribution that good building design can make to sustainability and how the use of concrete can significantly reduce the whole life energy performance of buildings through thermal mass benefits."

However, the MPA used the report to reiterate its stance on certain government policies. It believes that the government should not impose excessive costs on energy intensive industries, such cement and lime, which could drive the supply of essential and indigenously available resources overseas. "The MPA believes that genuine sustainable development demands that UK industries and supply chains are both resource efficient, where our industry is best in class in Europe, and also financially sustainable."

UK: Hanson UK has announced that it is preparing for a 'tough' 2012. Jon Morrish, managing director, said "We informed employees two weeks ago that we were carrying out a detailed review of the cement business to prepare us for what we expect to be a very tough market in 2012 and beyond."

Morrish's comments arose is the wake of rumours that jobs may be cut at the company's Castle Cement plant in Lancashire. The site currently meets 25% of the UK demand for cement and employs around 300 people. Hanson, a subsidiary of the HeidelbergCement Group, currently runs three plants in the UK including plants in Lincolnshire and Wales, with a workforce of over 1000.

Morrish added, "This review, which includes an assessment of recent changes to the European carbon trading rules, encompasses all three of our cement plants and covers all functions from production and sales to technical and distribution. The three plants are all vitally important to the long term future of the business and there is no intention to close any of them."

"However, it is likely that production levels will change, which will have an impact on jobs. We plan to table outline proposals to employee representatives and recognised trade unions early next week and begin a proper and effective consultation process."

UK: The head of the UK Mineral Products Association (MPA), Nigel Jackson, has backed a 3 October 2011 announcement by the Chancellor of the Exchequer, George Osborne, in which he said that environmental laws and regulations were 'piling costs' on to the energy bills of homeowners and business and that "we're not going to save the planet by putting our country out of business."

Commenting ahead of Osborne's Autumn Statement, which is expected to be on 29 November 2011, Jackson said, "I could not agree more with the sentiment and look forward to seeing how that welcome statement translates into positive action to reduce the complexity and plethora of energy related legislation that exists, as well as the actual amount of additional cost that this industry now faces."

Jackson additionally stressed the importance of keeping strategically important energy-intensive industries, such as cement and lime, in the UK. He warned against over-regulation of such industries, saying that it would not only threaten the UK's security of supply but would also export jobs and carbon for no environmental gain. Jackson said, "When the Chancellor announces the government's proposed package of help with energy costs for those energy-intensive industries at risk of 'carbon leakage' we need to see the cement and lime industries included. Government must act decisively to signal that it wants to retain viable domestic cement and lime industries in the UK." Jackson stressed, "This is the Chancellor's opportunity to put his words into practice and help protect British jobs, British manufacturing and British business. We need this Government to be the most enterprising ever."

UK: Cemex UK has been fined Euro230,000 following the death of a worker in an explosion at its Rugby cement plant. The UK Health and Safety Executive (HSE) prosecuted Cemex after the death of 28-year-old Peter Reynolds on 15 January 2008.

Leamington Spa Crown Court heard that Reynolds was treating waste cement dust in the bypass dust plant at the company's Rugby Cement Works. While he was clearing a blockage in the lower mixer, there was a violent explosion of steam and dust from inside the machine. The force of the explosion blew Reynolds out through the side of the building onto the road ten metres below. He was pronounced dead at the scene.

HSE's investigation into the incident found that Cemex had recognised the potential for blockages to cause explosions as steam pressure built up within the mixer but it took no action to prevent them. The court also heard the company had failed to review its risk assessment following a previous incident in May 2006, when another man was injured using the same machine. This explosion bent a metal-cladded external wall, pushing it out by 50cm.

Speaking after the hearing, HSE Principal Inspector Neil Craig said, "This was an entirely avoidable tragedy, which has left a young family without a husband and a father. If Cemex had investigated the previous incident properly, Mr Reynolds would still be alive today."

"Cemex's protection against the build up of pressure was for the plant to be continuously vented when processing waste cement dust, but it frequently blocked. These blockages then caused steam to build up to a high pressure."

"The company could have made a number of changes to the mixer to reduce the flow of dust and improve the venting and cooling systems, or devised a new system of work. However, no action was taken and employees were expected to operate this dangerous piece of machinery."

Cemex UK pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc Act 1974. The company was fined Euro230,000 and ordered to pay Euro200,000 costs.

UK: Lafarge Cement's vision for the future is starting to take shape at the company's former cement works at Northfleet in Kent, UK, where it is conducting a major investment to reconnect rail freight facilities to the main north Kent line. Lafarge expects the rail sidings to be operational by mid February 2012.

The first main user of the restored line will be the cross-London rail project, Crossrail, which will transport excavated material from a tunnel bore near Paddington, London by train to Northfleet for onward transportation by ship.

Balfour Beatty Rail is carrying out all the design and construction of the new sidings and connection to the main line, whilst Chunnel Group has carried out the siding preparation works within the main site. The overall length of the rail link is around 2.25km and in total 4.75km of new track will be provided.

The 104-acre site is undergoing redevelopment by Lafarge in association with the Councils of Kent and Gravesham. The linkage of the site to the main line represents another important step in the regeneration of Northfleet embankment.