Following a recent survey conducted by Housebuilder & Developer (which found that 58% of readers cited health and safety as their organisation’s most important concern), Philip Pointon of Saint-Gobain Off-Site Solutions looks at how offsite manufacturing can mitigate onsite risks.

The construction industry has one of the worst records for health and safety – we are all too familiar with the stark statistic that the fatal injury rate is four times higher than the all-industry average.

According to the latest figures on the construction sector from the Health and Safety Executive, there were 39 fatal injuries to workers in 2020/21, a slight increase on the 36 fatalities for 2016/17-2020/21. There were also a hugely significant 61,000 non-fatal injuries, averaged over the three-year period 2018/19-2020/21. 

Falls from height comprise half of all these injuries and, when compared with data from all other industrial sectors, are more than double the rate.

Across the supply chain, it is not uncommon for suppliers to reject bidding opportunities because they deem the project to carry too much risk – while contractors are becoming increasingly selective in their choice of provider, based on their safety track record.

So, it came as no surprise that health and safety is cited as a key concern for housebuilders, but what the survey did highlight was some fresh insights into how respondents are seeking new ways to resolve common issues. 

SAFE DELIVERIES

One such example is in the safe delivery of materials, particularly during unloading to ensure the driver, and nearby workers’ safety. Concerns raised included the method for unloading and the requirement for onsite manual handling, both of which are seen as potential risks.

Fabricating offsite in a quality, process-driven manufacturing environment can help to alleviate many of these concerns. Health and safety issues are significantly reduced by constructing away from the hazards of a building site.

For example, roof truss and floor joist systems can be manufactured and supplied to carefully coordinate with planned delivery sequences to complement the build programme. This can result in fewer deliveries, minimising the requirement for onsite manual handling and unloading. 

As factory manufacturing can be scheduled to start as the site is being prepared, processes can run in parallel, helping to reduce waste and the movement of vehicles. This can also create less disruption to residents or businesses close to the construction site.

WORKING AT HEIGHT

As we have learnt, falls account for 50% of all construction injuries, so reducing the frequency and duration of working at height is accepted as one of the best ways to limit accidents. In addition, the ongoing skills shortage in the industry may compound the problem, where there may be a reliance on temporary labour.

Manufacturing engineered trussed rafters and floor solutions in a controlled environment – and prioritising offsite work – can help significantly reduce the need for working at height. These efficiencies carry through to the construction site – with many component parts pre-installed, so there is no need to work off scaffolding or ladders.

Alongside the clear productivity improvements, the quality-controlled environment relies on a skilled, permanent workforce. Numerous measures will be in place to ensure that the production process is efficient and systematic, most likely including a target of zero lost-time incidents. 

Checking a supplier’s credentials for externally recognised certification, including the ISO45001:2018 Occupational Health & Safety Standard, is a good starting point.

MATERIAL SPECIFICATION

Respondents to the Housebuilder and Developer survey also commented on the importance of the correct material specification, and the requirement to ensure site deliveries meet the latest safety regulations. 25% of respondents agreed that keeping up to date with fire regulations was the most important to their organisation – the second most common requirement below health and safety.

This is another area where using offsite manufacturing techniques can pay dividends. Contractors have the assurance that materials have been stored correctly, processed and then finished to strict quality standards and a defined audit trail. These standards will dictate everything from the material’s regulatory compliance to its sustainable credentials and/or FSC certification to its suitability within the finished building. 

Philip Pointon is quality & risk director at Saint-Gobain Off-Site Solutions