Pilot Study to Reduce Worker Exposure to RCS Kathy O’Leary BAM Ireland

Pilot Study Carried out on 2 No. Dublin 8 Projects Aloft Hotel Mill Street Student Accommodation

Hierarchy of Controls We used the hierarchy of controls as a guide to best practice

Areas of Concern Traditional Blockwork- Designs involving blockwork that produce RCS dust. Coring and Cutting of openings in concrete slabs- producing RCS dust. Tiling and Cutting of tiles- large amounts of RCS dust in enclosed areas. Suppression or extraction of RCS dust. RPE- not used correctly

Substitution to Reduce RCS D&B Contract Designers for Mill Street SA: Shay Cleary Architects Designers for Aloft Hotel: Plus Architects Civil & Structural Design on both projects: Donnacha O’Brien and Associates Early engagement with designers and design development Workshop held with various design teams to seek alternatives to RCS producing materials

Substitution: Blockwork Metsec Walls instead of blockwork RCS dust eliminated by not drilling into blockwork. The system had significant programme benefits. Significantly less requirement for scaffolding Metsec=light gauge metal infill walling

Substitution: Pre-Cast Units Early co-ordination of openings for services. Casting in of containment meant no requirement for cutting on site. Pre-formed opes. The original design was in-situ formed concrete. Workshop held with the structural engineer and architect for solutions to avoid RCS producing materials in the structure

Substitution: Shot Fixing Workshop held with M&E Service Designers Shot fixing instead of drilling for services was agreed where possible

Substitution: Plasterboard The only blockwork used was for an ESB sub-station as they would not deviate from their design. However, we engaged with them after the project and they were interested in investigating using materials other than blockwork for sub-stations Workshop held with design engineers and architects All blockwork was removed from the job and alternative plasterboard/pre-cast/shaft walls solutions were substituted.

Substitution : Flooring We sought without success a floor sealant to prevent dust We couldn’t find one that did not affect the adhesion of the floors. Ger floor (composite plastic) was used to eliminate MDF product cutting and associated dust.

Substitution: Facade Cast in Anchors Anchors used to prevent drilling. Jura Beige Limestone could not be changed as it was a planning requirement. In conjunction with the engineers we co-ordinated the stone package early in the project and allowed for all supporting bracketry to be cast in to the pre-cast elements.

Substitution: Bathroom Pods Pre-finished bathroom pods Tile install and associated works that create RCS were carried out in a controlled factory environment.

Design to Reduce RCS Ethos were the M&E designers LMC Mechanical and O’Neill Electrical were electrical Early engagement with design team and all specialist suppliers Commitment to implementing a fully BIM designed project. Project completed with no concrete cores or concrete chasing for services.

Project Controls Outline your requirements Use of extraction for tools to be included in the pre-start minutes of commercial/safety meetings for sub- contractors Method Statements and Risk Assessments must specifically include for prevention/minimisation of RCS dust.

Project Controls Control of Sources Extraction for tools. Partnering with Hilti & HSS Hire for discounted price on extraction units. Water suppression on tools

Project Controls Control of Sources Bulk clean up-remove large waste to allow for floor cleaning. Vacuum the dust- no sweeping! Lorries covered and loads of stone sprayed with water Bulk clean up includes plasterboard offcuts, timber offcuts, cardboard boxes, excess materials. Wheelie bins in corridors to remove bulk waste. Ensure lids are kept on the wheelie bins

Project Controls Communication Emphasis at induction Talk about it: Toolbox Talks, Whiteboard meetings, Weekly health and safety meetings with all contractors on site Noticeboards/Posters

Project Controls Communication Information and awareness included in our behavioural safety workshops Prizes awarded for best “Good Catch” card on RCS dust Ensure Risk Assessment: Safe Work Plans and Method Statements SWP updated to include for Silica dust-safe system in place

Project Controls Communication RCS dust information boards on all levels of the projects FFP3 masks provided at PPE stations

Project Controls Monitoring Dust monitors located internally in the site and along the site boundaries. No breaches occurred. Audit Compliance No requirement to monitor internally.

Respiratory protective equipment Full Face Mask FFP3 Standard mask where training must be provided to fit and use Glasses fogged up on FFP3. SC’s bought full face masks for their operatives. HSS gave discounts. Also no need to be clean shaven

Findings Buy in early is required from designers, sub-contractors and site management The use of BIM eliminated all issues with coring holes and associated dust. Programme advantage by using offsite construction and by using products which were quicker to install. Productivity increased, labour costs reduced by 35% and cleaning costs at project hand-over were 18% below average

Findings Regular communication and enforcement improved compliance Highlight awareness at induction stage to operatives and supervisors. Keep awareness high by pro-actively keeping RCS dust prevention to the fore. 95% of Sub-Contractors on site purchased dust extraction units for their tools Zero complaints from neighbours about dust Feedback from the workforce was positive that the work environment was more pleasant. Not working in dusty environments and not bringing dust home on their clothes

Recommendations Early consultation with the design team to plan for elimination or substitution. Use BIM for design. Include a requirement for tool dust extraction as part of commercial/safety pre-start meetings Liaise with tool suppliers to do deals for extraction units Stress the importance at induction and ensure ongoing awareness training

Recommendations Develop an e-learning module on RCS for management Full face masks to be used to improve compliance Measure compliance and give feedback to the management and workers Encourage employee feedback and engagement.

‘The pilot was a success because all involved realised that by partaking we are protecting our futures’ Design team, contractors and sub-contractors.