"There is not another contractor for whom we work with a stronger commitment to safety than Wayne Brothers. You deserve the highest accolades for your efforts and your achievements. Virtually everybody in the industry talkes the talk on safety but very few actually dig in to make it stick. Wayne Brothers has developed a partnering approach that encourages subcontractors, like ourselves, to raise their standard and work out safe procedures in advance of the work; all under a watchful eye. Recent experience with the opposite approach has convinced me how effective your firm, but helpful method is."
Chip Wilt
Southern States Rebar

THIRD QUARTER 2009 SAFETY SPOTLIGHT
Linville Land Harbor Dam - Newland, NC

WBI recently completed work at the Linville Dam project in Newland with Phillips & Jordan. The scope of work consisted of under slab “dental” concrete (to true up the profile of rock), block foundation slabs, and battered walls. Work began in May and the project was completed in November of 2009.
 
Part of the work at Linville Dam was performed close to a near-vertical slope. This required the implementation and use of an engineered excavation plan. Most work at Linville Dam was performed at a height where conventional lanyards were not suitable for use as effective fall protection. Self-retracting lifelines (SRL) and positioning chains were used to protect the WBI workforce from falls to lower levels.
 
Equipment used to construct the dam included: a rough-terrain forklift, lattice boom crawler crane, concrete placing boom, and scissor-lifts. Proper inspection and use of rigging equipment played a significant role in creating a safe work environment.

 Each wall required a three-day wait period before formwork could be stripped, and a seven-day wait period before adjacent wall sections could be placed. WBI used 180 tons of rebar and placed 4,686 cubic yards of concrete to construct the new dam. An average crew size of 15-20 worked over 17,000 total man hours without a single incident or injury on the project. There were no OSHA recordables or lost-time accidents. Congratulations on a job well done.

SECOND QUARTER 2009 SAFETY SPOTLIGHT
Bush Beans – Chestnut Hill, TN 

 WBI recently completed work at the Bush Beans plant in Tennessee with Bush Brothers & Co. which added additional manufacturing capacity at the plant. Our scope of work consisted of concrete demo & replacement, foundation excavations, and piers. Work began in July of 2009.
 
Most of the work at Bush Beans was performed inside the facility. The plant shut down its manufacturing operation during the first week of work as part of their annual maintenance schedule. This presented challenges on the front end of the job including a schedule push.
 
During this shutdown period, WBI needed to complete demo and removal of a section of suspended slab and beam, shoring formwork, reinforcing and installation of steel beams, and concrete replacement.
 WBI worked long hours for seven straight days to complete this part of our scope. The work was completed ahead of schedule.   
 
Work areas needed to be established, barricaded, and maintained separate from ongoing plant operations. Equipment selection for indoor excavations was critical due to limited access and the fact that conventional diesel-powered equipment could not be used indoors.
 
WBI placed over 300 cubic yards of concrete and worked approximately 4,300 man hours without a single incident or injury on the project. There were no OSHA recordables or lost-time accidents.  WBI received a “Letter of Commendation” from the owner for the exceptionally safe and clean work that was performed.  Congratulations on a job well done.   

 FIRST QUARTER 2009 SAFETY SPOTLIGHT
Progress Energy Heavy Haul Road - Roxboro, NC

WBI was awarded a project at the end of October 2008 at Progress Energy in Roxboro, NC. Work began at the site in mid November.

The scope of work for this project consists of relocating about thirty five hundred feet of fence, grading a little more than a mile of road, installing edge forms (which were held in place by sand bags due to the ground being too hard to drive stakes to hold them) and pouring concrete.

WBI has initiated a stretching program at this project in consideration of the manual lifting involved in the scope of work. The stretching program is designed to help eliminate the everyday muscle strains that occur when lifting heavy objects. Tasks requiring manual lifting include moving sixty-foot sections of edge forms and sand bags that are fifty plus pounds. The stretching program starts the day at Progress Energy, before any other activity begins, with the full participation of all WBI employees and supervisors.

WBI has worked 7,134 man-hours with an estimated 2,100 left to complete the project. The group has worked thus far with no OSHA Recordables!  Congratulations on a job well done!  

FOURTH QUARTER 2008 SAFETY SPOTLIGHT
Natural Gas Dike Stabilization – Huntersville, NC

WBI recently completed work on a project for Piedmont Natural Gas in Huntersville, NC. Our primary contract objective was to strip and reform the existing retention dike (or earth slope) from a 1-1/2:1 slope to a 3:1 slope. Work began in early October, 2008, and lasted the entire month. 

Our grading group cleared nearly four acres of land for use as an onsite borrow pit, and 15,000 cubic yards of dirt were excavated and placed to rebuild the slope. WBG worked closely with an environmental testing agency to ensure all material excavated and used to reform the slope was not contaminated previously.

WBI Grading Group was also obligated to place nearly 2000 tons of riprap and ABC stone on one face of the slope, which introduced dangerous fall hazards to the work area. A site-specific fall protection plan was developed and implemented for the project.

Liquefied natural gas (LNG) is odorless, which makes it difficult to identify. High concentrations of LNG will displace oxygen from the atmosphere, particularly in a confined space. Continuous air monitoring was performed to ensure that manpower and equipment resources were not exposed to potential hazards associated with liquefied natural gas.

WBI Grading Group worked a total of 1,641 man hours, with an average crew size of seven. There were no reportable injuries, recordable injuries, or lost-time accidents. The project was completed ahead of schedule and under budget. Congratulations on a job well done.

THIRD QUARTER 2008 SAFETY SPOTLIGHT
NGK Ceramics - Mooresville, NC

WBI was recently awarded a project at the NGK Ceramics Plant with CH & Sons Construction. In order to add an additional kiln line and expand manufacturing capacity at the plant, the project scope consisted of two large concrete pits, heavy mat foundations, rail foundations, and slab on grade (SOG). Work began in mid July 2008.

All work at NGK Ceramics Ph.II was performed inside the existing plant. Multiple excavations were required at depths of 13ft, and an engineered excavation plan was used that included soil nailing to shore existing building foundations.

Continuous air monitoring was conducted to ensure potential hazardous atmospheres were identified and controlled effectively. This was a major concern due to limited ventilation inside the plant and the depth of our excavations. Forced ventilation was required during backfill operations.

There was one point of access for all equipment moving in and out of the building. This presented an elevated level of risk for struck-by and/or caught-between hazards. WBI equipment operators, ready-mix trucks, and concrete pumps were able to move in and out of the work area safely while NGK plant crews and equipment worked simultaneously in the area.

WBI placed a total of 650 cubic yards of concrete and worked a total of 6,000 man hours without a single injury on the project. There were no OSHA reportables, OSHA recordables, or lost-time accidents. Congratulations on a job well done.