Kerblay (UK) Limited || Health and Safety ||

Method Statement and Risk Assessment for Extrusion of Concrete Kerbraces and Finished Kerbing
*Note* – Kerblay (UK) Limited is part of the Adenstar Construction Group and this Method Statement must be read in conjunction with the Adenstar Group Health and Safety Policy.
Brief description of Kerblay (UK) Limited operations – Kerblay provide a service to housing developers, contractors and local authorities to extrude Kerbrace on site. The concept of a Kerbrace, is to lay the kerb foundation as a separate operation to laying precast kerbs, usually many months in advance of the kerbing operation, by doing this the road can be built quickly and services laid. The precast kerbing then becomes part of the finishing's process; therefore kerbs are not damaged during construction and have to be replaced. The Kerblay Kerbrace is mechanically laid and therefore many times faster than using formwork.
Method Statement
Kerblay lay Kerbrace using their Arrow 770 kerbing machines and these are operated by Kerblay operatives who have been trained on the use of the machines. To be able to operate these machines to produce accurate line and level requires highly skilled operatives. All of our operatives have obtained NVQ Levels in Construction. The machines are transported to site on a trailer towed by a four-wheel drive vehicle.
Once on site Kerblay's Foreman will inspect the setting out pins and sub-base preparation and may request remedial works so that the sub-base is within tolerance. Our specialist brackets are fixed to the setting out pins and string line fed through the brackets and tensioned. It is the Contractors responsibility to inform all operatives on site that the string line forms a "trip hazard" and that designated access routes are used at all times and no "short cuts" are taken.
Our machine runs along the string line, the machine sensor takes information off the string line altering the line and level of the finished concrete accordingly.
Once the string line is set up and the sub-base is checked, Kerblay is ready to commence work, our machine commences work on the right hand side of the road, concrete is fed into the machine directly from the ready mixed delivery truck, the machine compacts the concrete against what it has already laid, moving the machine forward at a speed of approximately 2 metres per minute, the ready mixed truck moves at the same speed.
The Kerblay Foreman is at the front of the machine checking line, level and quality. Kerblay has two other operatives in the gang, one works at the rear of the machine, his job is to signal to the concrete truck driver when to move forward and when to discharge concrete (older mixer trucks require to operate the discharge mechanism at the rear of the truck), the third operative is at the outside of the machine (the other side to the mixer truck), his duty is to ensure a steady flow of concrete into the machine, moving concrete discharged by the truck mixer as required.
The Kerblay Foreman is in charge of the extruding operation at all times. At no time must any part of our operative's body be placed in the machine when the machine is working, if there is a problem the machine is switched off and inspected. If a foreign object is placed in the machine, the machine will stall and switch itself off.
The centre of the road to be worked on must be graded off so that the concrete mixer truck is running on a level safe surface (no soft spots). Manholes and gullies must be covered up and protected, usually with steel plates, so that operatives, mixer trucks or the machine cannot fall down the access holes or get stuck. Once extrusion is completed the string lines can be taken down and setting out pins removed.
Kerblay Kerbrace – Risks 1. Erection of string lines – tripping hazard 2. Vehicle movement on site – if possible Kerblay will ensure forward movement of ready mixed truck. If reversing is required a Banksman is provided at all times by Kerblay and lorries are fitted with reversing "bleepers". All Kerblay operatives have and wear PPE, with vehicle movements the wearing of reflective jackets or vests is strongly recommended for all other operatives. 3. Protection of openings or open excavations – the Client/Contractor must ensure that openings in manholes/gullies are properly protected with heavy duty steel plates (not weak ply that a boot could go through). 4. Concrete Burns – the only material that Kerblay uses is concrete. Concrete is a corrosive material and causes burns when in contact with human skin. We attach a Material Assessment sheet on Ready Mixed Concrete, which forms part of this Risk Assessment. 5. The Machine – when running the engine the exhaust becomes very hot and must not be touched. The moving part is a ram that compacts the concrete through the mould, parts of the body must not be placed between the ram and the mould. 6. Lifting – sometimes the machine may require lifting. There are 3 no designated lifting points on our machines. We use 3 legged chains to lift the machine and Kerblay's chains must be used as these are all certified for lifting. It is the Foreman's responsibility to ensure certification is up to date. The weight of the machine is 1 tonne; the excavators used for lifting must be rated for this weight. Our Foreman will supervise all lifting operations. 7. The Finished Kerbrace – because of the speed of our operation there is a tripping hazard as the Kerbrace was not there minutes before!
Adenstar Developments Limited BUILDING & CIVIL ENGINEERING CONTRACTORS HEALTH AND SAFETY DATA SHEET
PRODUCT:	Ready Mixed Concrete is a mixture of aggregate, cement and water. Admixtures may be added to improve the handling characteristics of the properties of the hardened concrete. The resultant mixture is abrasive and alkaline.
MAIN HAZARDS:	Contact with wet cement mixes such as concrete can cause skin disease: Irritant contact dermatitis can be caused by the combination of the wetness, alkalinity and abrasiveness of the mixture. Allergic contact dermatitis occurs where there is an individual sensitivity to chromium compounds which may occur in cement. A form of skin ulceration may result from freshly mixed concrete coming into contact with broken skin.
PRECAUTIONS:	Anyone handling the product should be aware of the above hazards and will significantly reduce the risk by taking the following sensible precautions: Wear effective protective clothing to reduce to a minimum skin contact with the product. Where skin contact occurs, whether directly or through saturated clothing, wash thoroughly without delay with clean water. Where eye contact occurs, wash thoroughly without delay with clean water. In all cases of doubt, or where symptoms persist, medical advice should be obtained.
TRANSPORTATION:	The carriage of Ready Mixed Concrete is not subject to Hazardous Substance Conveyance Regulations and vehicle labelling is not required. In the event of spillage, entry of the material to water courses should be avoided. If you require any further information, please contact your local RMC supplier.

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