Restart Project Summary Safety Report 2

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Comprehensive Overhaul Covering 4 areas Comprehensive Overhaul Covering 4 areas Involving 1,230 Contractors at Peak Involving 1,230 Contractors at Peak

Over 1 Over 1 ½½ million man hoursmillion man hoursBlast FurnaceBlast Furnace

SteelmakingSteelmaking

Sinter PlantSinter Plant

Power & EnergyPower & Energy

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�Scaffolding

Confined Space

Heavy Lifting Heavy Lifting ActivitiesActivities

Traffic / Pedestrian SegregationTraffic / Pedestrian Segregation

Work Work At HeightAt Height

Asbestos Asbestos Joint removalJoint removal

Multi LevelWorking

Manual Handling

Heavy VehiclesVehicles Contractor / commissioninginterface

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The blast furnace is the 2nd largest in Europe and has a 14 metre hearth. It is capable of producing in excess of 10,000 tonnes a day of iron. The blast furnace has 36 tuyeres which allows air to be blown into the furnace, and 4 tap holes for removing the iron out of the furnace. Works included but not limited to;

-Partial carbon hearth replacement -Copper stave replacement-Cast iron stave replacement -Stove burners & refractory's repair -Replacement top hoppers & valve chest -Clean slag pits & repair-Replacement gas cleaning plant cones -Upgrade of PLCs / automationOutrigger crane repairs & recommissioning -Various casthouse worksPreparation of plant for future coal injectionMechanical, hydraulic, electrical & instrumentation re-commissioning

850 Men at Peak850 Men at PeakLost time Frequency Rate Lost time Frequency Rate –– 0.40.4All Injury Frequency Rate All Injury Frequency Rate –– 5.45.4

121 Near Miss / hazard observations121 Near Miss / hazard observationsOver 1,400 AuditsOver 1,400 Audits

541 Signed Toolbox Talk sheets returned541 Signed Toolbox Talk sheets returned

1,000,000 Man Hours1,000,000 Man Hours

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The steelmaking facility is made up of the Basic Oxygen Steelmaking plant (BOS) where the steel is made by three basic oxygen convertors, and the Continuous Casting plant (Concast) where the liquid steel takes shape and is made into slabs.Works included but not limited to;

-Vessel relines - LMF Cooling tower remedial works-Vessel distortion works -Vessel bearing replacement -Slag splashing reinstatement -Refurbishment of moveable assets-Strand guide segment refurbishment -Straightener segment refurbishment -Exhaust fan ducting -All cranes to be recertified and made available-Mechanical, hydraulic, electrical & instrumentation re-commissioning

280,000 Man Hours280,000 Man Hours300 men at Peak300 men at Peak

Lost time Frequency Rate Lost time Frequency Rate –– 0.350.35All Injury Frequency Rate All Injury Frequency Rate –– 4.64.6

44 Near Miss / hazard observations44 Near Miss / hazard observationsOver 1,500 AuditsOver 1,500 Audits

254 Signed Toolbox Talk sheets returned254 Signed Toolbox Talk sheets returned

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The Power Station has three package boilers and two turbine blowers that provides the wind to the furnace. Works included but not limited to;

- RPS Blower Overhaul- Heavy Fuel Oil Supply routes (Pipelines & Tanks)- Turbine Alternator 3 Overhaul- Estuary Cooling Water works- Oxygen Storage System requires inspection and verification- Nitrogen Storage System requires inspection and verification- HV Electrical supplies require fault calculation analysis and reinstatement

130,000 Man Hours130,000 Man Hours

180 men at Peak180 men at PeakLost time Frequency Rate Lost time Frequency Rate –– 0.760.76All Injury Frequency Rate All Injury Frequency Rate –– 4.64.6

25 Near Miss / hazard observations25 Near Miss / hazard observationsOver 400 AuditsOver 400 Audits

220 Signed Toolbox Talk sheets returned 220 Signed Toolbox Talk sheets returned

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The Sinter plant has a 4 million tonne output and converts a mixture of iron ore fines, fluxes, waste materials and fine coke into an agglomerate, which makes up the majority of the blast furnace burden. Works included but not limited to;

-Crane re-commissioning-New R6 pan conveyor-De-dust system overhaul-Sinter Plant process fans-Replacement of ROSOV valve PST14-Serck Visco cooling tower replacement-Sinter machine lowering wheel replacement-Mechanical, hydraulic, electrical & instrumentation recommissioning

135 men at Peak135 men at PeakLost time Frequency Rate Lost time Frequency Rate –– 00

All Injury Frequency Rate All Injury Frequency Rate –– 4.54.527 Near Miss / hazard observations27 Near Miss / hazard observations

Over 185 AuditsOver 185 Audits

110,000 Man Hours110,000 Man Hours

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Site Induction Steel House

CDM Project Plant induction

SSI UK Senior Management Monthly

audits

Auditing Schedule

SSI UK Mgrs/Eng/superWeekly Advansa audits

SSI UK Mgrs/Eng/superWeekly Hazard

specific audits / BOPs

ContractorMgrs/Eng/superWeekly audits

Toolbox talksMinimum 1 per week

Take TwoRisk assessment

Daily before each task

Safety concerns sheetsFor workforce

Near Miss Incident / Investigation Reports

AccidentInvestigation Reports

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5W

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All Injuries Lost Time Injuries Medical Treatments

Project Lost time Frequency Rate Project Lost time Frequency Rate –– 0.38 All Injury Frequency Rate 0.38 All Injury Frequency Rate –– 5.65.6

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Restart Injuries Body

1%Back 4%Foot

5%Arm 5%

Head 11%

Leg 17%

Hand 30%

Eye 27%

Restart Injury Cause

Trap Injury 13%

Slip/Trip/Fall 17%

Airborne Particles 25%

Hot Work 8%

Hand Tools 15%

Hit by Object 8%

Stationery Object 7%

Manual Handling 7%

0

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15

20

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day

Tues

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Wed

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Injuries by day

0

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20

25

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0-12

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0-13

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0:16

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Injuries By Time of Day

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The Risk assessment andsafe method of work to

remove salamander fromFurnace submitted

By DGC

Which was very different from the waythey tried to move one

lump of salamander

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4. Pecker Pulling Front loader via Wire Strop Attached to Tow Bar

2. Salamander Segment Chained Up

3. Front Loader Dragging Segment via Chain

1. Digger Pushing Salamander Segment

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DGC French demolition operative crushed two fingers, losing tip of middle finger while replacing wire strop in position. This operation was outside of the safe working procedure.

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A redundant platform had been placed on the cast house floor awaiting removal to scrap area. This had been laid for several hours, when the IP came and stood close to the platform talking to another operative. The second operative then stood on the platform causing it to move and land on the IP’s foot. The IP was taken to hospital where it was found that 2 metatarsals were broken.

A support under the platform which had been Cut off,was attached to a cleat by a bolt.As weight was applied to theplatform this acted as a pivotand made the structure movelanding on the IP’s foot.

Redundant Platform(wood should have been placed

Under platform to prevent movement)

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Contractor tripped over step at the steelmaking clarifier. Dislocated knee and received damage to ligaments. Hospital treatment and operation on ligaments.

SSI Operative slipped while descending down stairs in the RBF work shop office area, as he slipped he held on to the hand rail resulting in a dislocated shoulder.

Redcar Power Station office worker fell exiting Power & Energy restart project cabin. Fractured ankle in fall.

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Distributed to all project contractors & SSI personnel

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Dropped / Falling Objects Trend

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0 5 10 15 20 25 30 35 40 45 50

VehicleAsbestos

HazardHot workAt Height

ManualScaffold

Hand toolsFalling object

House PTW Issue

LiftingIsolation Hot workAccess

LeakFire

Near Miss Incidents

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Restart Project Summary Safety Report 2

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