Health Safety and Wellbeing Lessons Learned

Transforming Tunnel Safety are pleased to provide copies of Lessons Learned circulars below.

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PUTEF Surface Settlement

Pipe Jacking was underway at Putney Embankment Foreshore. The machine head was 12m into the drive and about to pass under the front of a crawler crane located at the surface when the crane operator noticed a level change on the crane readout sensors. The crane operator noticed signs of surface settlement occurring in front of the crane tracks. To reduce the load on the affected track, he immediately slewed the ballast so that it was over the stable side of the crane hardstanding and raised the boom to near vertical. Concurrently the TBM operator had noticed the changing conditions and stopped the TBM. All tunnelling and lifting operations were suspended while BMB senior managers were informed and attended site to support the site team and assist with assessing the situation.

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GREPS Radio Communication Failure in the Shaft

Failure of radio communication during the lowering of a Man Rider cage. During the lowering of a Man Rider cage from the shaft top to the shaft bottom the crane supervisor and crawler crane driver lost contact with the pit bottom slinger. Other members of the lifting team continued to hear the radio communications.

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TBM Head Interventions

A cutter head intervention is required to inspect cutters and the condition of the head, change the cutter tools and make any repairs. Interventions at rings 667, 721 and 727, were attempted at atmospheric pressure when the TBM was within the potentially deoxygenated ground area between R667 and R917. The interventions were aborted due to bad ground within the face. At this point, the team reviewed options to enable a safe cutter head intervention (CHI) and decided to use foam resin (ATEGLOB Polimper) as a method to stabilise the face for a CHI without the use of compressed air. The foam is an extremely fast reacting two-component-injection resin, CFC-free, halogen-free and fire proof. The resin is designed for sealing and consolidation and restricts the movement of any running sands and water.

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CARRR Train derailment

Carnworth Road Main Tunnel - The rear set of wheels on an un-occupied man-rider car came off the track, as it was travelling in-bye when it reached the first Y section on the mobile crossing.

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ALBEF Airline incident

A Lifting Supervisor was struck by the loose end of the airline at the machine end.

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Loosen Anchor Plate

A member of the crew supporting the assembly of th TBM was hit by a loosen anchor plate on the Rijnland Route Project, Leiden, Netherland.

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Chain Clutch Failure

An 8.5 tonne excavator was being lifted into the basement excavation between two props. The excavator had been slung from the 3 no. designated lifting points identified in the lifting plan. During the test lift about 400mm off the ground the shortening clutches on 2 of the 4-leg chains being used sheared and load fell forward uncontrollably.

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Lifting Activity

At Hinkley Point C, the site lifting team were made aware of some damaged lifting accessories namely a concrete blow out skip. The skip had been damaged due to the wrong lifting eyes being used to lift the full weight of the skip.

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Glove entanglement during drilling task causes severe thumb injury

Some short timbers had been fixed to the SCL between the invert and axis, the operative was standing on these timbers during the drilling activity. The operative was holding the control handle with their right hand and had their left hand on the side handle, he was just starting to drill the hole when he slipped backwards. The drill went upwards and whilst still holding the drill with his right hand, he put his left hand up and the drill bit came into contact with his glove and became entangled.

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Fume Management in TBM

Health communication on fume management for TBM from Tideway.

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GREPS - Failed Web Sling

The webbed sling was put directly through the 'pad eye' of the lifting beam without the use of a shackle. The skip was lifted onto the collection vehicle. The vehicle driver was unhappy with the position of the beam and skip so the position of it was moved several times. One the last movement, one of the webbed slings was cut by the sharp edge of the pad eye. The Gecko Skip dropped approximately 2 inches back onto the vehicle with the lifting beam landing diagonally inside the skip.

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HAMPS Allergic Reaction Incident

An operative undertaking waterproofing operation within the Hammersmith Connection Tunnel suffered an allergic reaction to the chemicals being used in the tunnels.

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CHAWF Sheared Lug

One of the lugs of the Gecko skip was found to have sheared off. The lug was used for the attachment of chains for the open-door mechanism on the bottom of the skip.

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Near miss - dropped self-rescuer when descending shaft staircase

A site engineer had collected a self-rescuer from the pit top tally hut and put it over his shoulder. The engineer was descending the shaft staircase when the self-rescuer became detached from the webbing belt and fell approximately 10 meters down the staircase.

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Safety Chains Failure

A safety alert issued by a Highways England supplier regarding the failure of a lifting chain

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Silica Dust Awareness

A presentation highlighting the dangers from silica dust

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Unintentional discharge of Fire Suppression System

During tunnel excavation, a tracked dumper was being loaded and the excavated material came into contact with the fire suppression system tube. The tube is connected to a cylinder containing the extinguishing agent, the tube was damaged allowing the extinguishing agent to be released into the tunnel work space.

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Air Release from a concrete pump

Towards the completion of a concrete pour using a boomed concrete pump into the inlet chamber, some concrete and air was sprayed from the end placing hose of a concrete pump towards a worker

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