Forterra engineer develops innovative safety device
The stressing procedure is essential to ensure the correct pre-stress strength is applied to the 5ml intense wires used to fortify flooring, including ground floor T-beams and Hollowcore products. However, the process can be dangerous with the potential risk of wires snapping, resulting in flying debris.
Forterra has been praised in the past by the Mineral Products Association (MPA) for its high safety standards surrounding the process. The previous protocols included sounding an alarm before the process starts to evacuate workers off site and secure the area, then the two remaining operators utilise a protective bunker to put the holding pins into place to stabilise the production beds.
Now the process is even safer using the automated device designed by Hoveringham based maintenance engineer, Ed Berridge. His focus and passion for the health and safety of his workplace inspired Ed to find a way to completely remove the need for human involvement in the stressing process. While on a development BTEC course, he designed a simple device made from two gas struts that are fitted to the stressing beds. The devices are then pre-primed, so that when the stress head has completed its process, the two steel pins that secure and stabilise the stressing bed will be pushed into place.
With the instalment of HD CCTV cameras, the operator can see more clearly from a control room than they would have done from the bunkers, and when the stressing process is complete insert the holding pins remotely without any risk to themselves.
The device is currently being kitted out in one of the stressing areas with plans to have it installed across the Hoveringham site by the end of 2023, setting a new safety standard requirement for stressing.
Ed Berridge said, “The Auto-Stressing Pin tool is the last piece in the jigsaw for safety around stressing wires, now all team members are able to stay out of the danger area during the process.
“I am thankful and grateful for all the support I received from my line manager Ady Anstee and the management structure in facilitating the delivery of this successful project. Safety will always be paramount on this site and projects like mine demonstrate how ideas can help to keep my fellow colleagues safe whilst at work.”
Chris Hancock, Forterra Plant Manager at Hoveringham said, “It’s a fantastic achievement that members of our Hoveringham team have been able to focus on Forterra’s core values in Safety First, Driving Improvement and People Matter by implementing the Auto-Stressing Pin.
“Engaging with our workforce and harnessing their ideas by giving them the support, infrastructure, and time to design, trial and implement ideas really does demonstrate what we can do as a team.
“We all have a part to play in our own and others safety; if we can continue to harness the passion to drive improvement, then collectively we will keep pushing towards our ambition to achieve zero harm.”
For more information on Forterra visit: https://www.forterra.co.uk/