Geocycle: Introduction to

OH&S 2012

John Jones
© 2008 Holcim/Switzerland
Geocycle India Workshop

• Location: Narogong
• Date: February 9th

© 2008 Holcim/Switzerland,
Holcim OH&S Cardinal Rules

• 1. Do not override or interfere with any safety provision (nor

let override or interfere anybody else, regardless of their seniority
to yourself)
• 2. Personal Protective Equipment (PPE) rules, applicable to
a given task, must be adhered to at all times
• 3. Isolation and Lock Out Procedures must always be
followed
• 4. No person may work if under the influence of alcohol or
drugs
• 5. All injuries & incidents must be reported

© 2008 Holcim/Switzerland,
Geocycle Introduction to OH&S

• OH&S related actions are being implemented at all steps of

Geocycle business processes
• Know your processes, identify all possible risks at all steps of the
customer service chain
• Risk registers for all possible risks (safety, health, environmental,
quality, legal and business) are being generated
• Be aware of all local legal requirements
• A Holcim AFR OH&S Directive has been approved by ExCo and has
been released
• Corporate requirements in Holcim: AFR Policy, AFR OH&S
directives, OH&S Handbook, AFR H&S Manual, AFR QA-QC Manual
• At all times our approach is: Hazard Identification, Risk Assessment
and Control

© 2008 Holcim/Switzerland,
Geocycle/ Holcim Risk Assessment Template

© 2008 Holcim/Switzerland,
Assessment of a Geocycle OH&S Risk

• Identify a hazard or incident scenario (including: loading, transport,

unloading, sampling, analysis, storage, pre-processing, co-
processing, quality impacts)
• Identify existing risk controls
• Identify the consequences and likelihood for a given scenario (this
may be done by assuming the existing controls (residual risk) to be
in place, or by calculating the risk in the absence of controls)
• Assign Likelihood and Consequence rankings from the tables
• Combine them in the matrix to give a measure of risk
• Implementing the appropriate actions based upon the risk ranking

© 2008 Holcim/Switzerland,
 Geocycle OH&S Risk Rankings

Consequence
RANKING DESCRIPTION OF CLASSIFICATION
1 Illness, injury requiring first-aid or no treatment
2 Medical (doctor) treatment
3 Single serious (hospitalization) injury
4 Single death or major permanent disablement
5 Multiple deaths

Consequence can be rated from a ranking of 1 (considered minor)

to 5 (catastrophic), see corporate procedure

7 © 2008 Holcim/Switzerland, John Jones

Geocycle OH&S Risk Rankings

Likelihood
RANKING DESCRIPTION OF CLASSIFICATION
A Expected many times per year
B Expected about once per year
C Expected between once every year and once every 10 years
D Expected between once every 10 years and once every 100 years
(possibly once or twice in the life of a site/plant)
E Expected between once every 100 years and once every 1000 years
(not expected to occur in the life of a site/plant)

Likelihood ranks from A (considered certain) to E (improbable) with

a range of values in between as shown below. IMPORTANT:
Typically the likelihood scale is logarithmic with each succeeding
level being a factor of ten times more or less likely than the
adjacent level.

© 2008 Holcim/Switzerland,
 Geocycle OH&S Risk Rankings
Risks are ranked from low (possibly acceptable) to extreme. The risk
ranking is used to provide a prioritization of risks and therefore the
basis for developing risk management plans and allocating valuable
risk management resources
Consequence 1 2 3 4 5
Likelihood
A H H E E E
B M H H E E
C L M H E E
D L L M H E
E L L M H H

• E = Extreme risk - immediate top management action required.

• H = High risk - senior management attention required quickly
• M = Moderate risk - management responsibility must be specified
• L = Low risk - manage by routine procedures; eg. Work Instructions

© 2008 Holcim/Switzerland,
 Geocycle OH&S Pyramid

Legend Health &

Wellness
Issues
Development OR
Implementation
<25% complete
Occupational Management
Development AND Procurement
Rehabilitation of Changes
Implementation
>25% complete

Both >85% = Full Audit and

Safe Working Inspection Design
Implementation System
Procedures & Testing Safety
Improvement

Incident Industrial Employee

Induction Information
Investigation & Hygiene & Communication
& Training & Reporting
Corrective Action Monitoring & Consultation

Roles Hazard
Management
Responsibilities Hazardous Work Identification Planned Legal
Commitment
and Activities and Risk Inspections Obligations
& Planning
Accountabilities Assessment

10 © 2008 Holcim/Switzerland, John Jones

Waste to AFR Process Flow

© 2008 Holcim/Switzerland,
 Geocycle OH&S: Hierarchy of Controls

The hierarchy of controls is as follows:

• Eliminate the hazard
• Substitute with a lesser hazard
• Use Engineering controls to reduce hazard
• Administrative controls such as workplace procedures
• Personal Protective Equipment
• In many cases, it will be necessary to use more than one control
method. Back-up controls (such as personal protective equipment
and administrative controls) should only be used as a support to
other control measures

12 © 2008 Holcim/Switzerland, John Jones

Geocycle Controls

• All daily work practices require a procedure to be developed

• For non-daily tasks, a Job Safety Analysis (JSA) is to be done
• Carefully choose contractors and third party service providers
• Provide training in all aspects of the business

© 2008 Holcim/Switzerland,
Geocycle Standard Operational PPE

© 2008 Holcim/Switzerland,
Chemical Information

• Obtain the chemical name

• Check the safety data sheet
• Gather all available chemical information from the customer
• Complete all chemical and physical analysis
• If in doubt, check with the Geocycle laboratory and/ or the OH&S
department

© 2008 Holcim/Switzerland,
 Geocycle OH&S Audits

• Halcrow has conducted Geocycle ‘fit for purpose’ audits in Thailand,

Indonesia, Vietnam and Sri Lanka
• Some deficiencies have been identified, such as temporary
equipment being used for an unspecified time
and ensuring that there is sufficient CAPEX
• Indonesia participated in Holcim pilot
AFR OH&S audits
• Regional audit team is being developed
• Internal audits and external audits are being
conducted, use action logs to monitor progress
• ACert program is being developed

16 © 2008 Holcim/Switzerland, John Jones

 Geocycle Plant Visits

• Each Geocycle plant visit involves Safety Observation Tours (SOTs)

• Some good observations and some not so good

17 © 2008 Holcim/Switzerland, John Jones

 Geocycle OH&S Training

• Geocycle introduction to OH&S training sessions have been held in

Sri Lanka, in Thailand and in the Philippines
• Waste sampling training sessions have been conducted
• Training in risk assessment and risk management is to be
conducted in India
• Regional health monitoring training was conducted in Indonesia
• ‘Certificate in OH&S’ training has been conducted in Vietnam
• Regional waste management operational training was conducted in
Thailand

18 © 2008 Holcim/Switzerland, John Jones

Trilogy Software

• OH&S recording and reporting tool

• Is being rolled out across the region
• Regional training sessions have been held
• Able to generate reports and collate data for corporate
requirements
• All injuries and incidents must be reported
• Able to attach photos and investigation report
• For Geocycle some of reportable incidents are when a customer has
for example sent in sub-standard pallets or drums

© 2008 Holcim/Switzerland,
 Geocycle AFR OH&S Directives

• Draft document had feedback provided from our region

• The main changes are that the scope of Geocycle responsibility has
specifically been expanded to include transporters and waste
generators
• With particular attention to be paid to Geocycle pre-processing and
co-processing activities (including own collection centers)
• Workshop was held in Thailand in August 2008
• Each country conducted a gap analysis
• Q1 implementation feedback was provided to Albert Tien

20 © 2008 Holcim/Switzerland, John Jones

Regional Support

• Regional core OH&S group has a representative from all countries

and from all business segments
• John Jones is the Geocycle representative
• Geocycle platforms are working on accreditation plans, John Jones
is supporting
• Regional product risk profile procedures and templates are being
developed
• Trilogy OH&S reporting software is being rolled out across the
region
• Regional training programs are in place
• Knowledge transfer within the region

© 2008 Holcim/Switzerland,
From Holcim AFR OH&S Directives

• The equipment and facility design used for waste handling must
comply with the minimum criteria specified in the Holcim Corporate
Engineering Design Specifications for Waste / AFR facilities. Key
criteria include: Ease of maintenance must be incorporated into the
design
• Necessary process information must be available to all operators
and maintenance staff at the time that the facility is first
commissioned
• A maintenance program must be established for all waste handling
facilities, AFR facilities, co-processing facilities and equipment. This
program must demonstrate: compliance with the requirements of
the Holcim Occupational Health and Safety Management system
and Holcim FPEs; and, focus on intersecting / overlapping activities
within the facility

© 2008 Holcim/Switzerland,
Geocycle Maintenance OH&S Approach

• Have a safety data sheet for the waste

• Flush/ clean the equipment as best you can
• Remove the equipment from the process area (if possible)
• Wear the correct PPE
• Apply good industrial hygiene
• Apply good housekeeping standards
• Do a JSEA for each maintenance task that involves a significant risk
• Develop appropriate work instructions for each task with training
• Develop isolation and lockout procedures for each task to ensure
any residual or stored energy is dissipated/ neutralised (eg - a
pump even though electrically isolated may be jammed and under
load so by freeing it you can release any potential energy and
possibly cause a spill/ spray person etc

© 2008 Holcim/Switzerland,
Summary

• Remember the Holcim OH&S Cardinal Rules

• Always apply principles of HIRAC
• If in doubt, stop and check
• If in doubt with regards to a waste stream, check the safety data
sheet
• Every problem is also an opportunity
• Provide training in all aspects of the business
• Report all injuries and incidents, investigate and learn from them
• Every injury, incident and accident is a learning opportunity
• When it comes to OH&S, lead by example

© 2008 Holcim/Switzerland,
 Questions

• ???

25 © 2008 Holcim/Switzerland, John Jones