During routine water jetting in the pre-heater tower (PHT), an employee mis-stepped while moving backwards during water jetting, causing his right foot to step into the gap beyond the walkway kickboard. This led him to momentarily lose balance and roll his left ankle. The gap, located between the walkway and the chalk riser duct, measured 18cm and was obviously never large enough for a person to fall through.
The duct’s structural flange acts as a natural handrail, guiding individuals away from the gap when adjacent to it. On typical walkways, protected by a handrail, stepping beyond the kickboard often exposes workers to much larger gaps and fall potential. The kick board met the required height and complied with both British and Cemex Standards.
A precautionary x-ray revealed a small bone fracture in his ankle. His ankle was not placed in a cast, and to facilitate a speedy recovery, he remained on shift with modified duties.
KEY FINDINGS
Safe Systems - The SSOW was up to date and was reviewed in the second half of 2024.
Competency
- The injured person (IP) was fully trained and certified to carry out the task. He was carrying out the task with his colleague.
- The IP received external independent re-training on water jetting during November 2024. He has many years of experience.
- 169 VFLs were conducted in the PHT in 2024, with a significant proportion focusing on water jetting and Cardox activities. The IP was last observed during a VFL in late December 2024.
PPE - All required PPE was worn, in compliance with the Safe System of Work (SSOW).
Standards - In 2024, the PHT underwent multiple independent Health & Safety inspections, as it has at least annually in previous years. These inspections were carried out by the UK H&S team, and in 2024, the Corporate Governance Audit team also conducted an inspection of the PHT. These compliment the frequent inspections by site staff. No issues in this area had been identified.
