SSI have cast the first slab.....congratulations to everybody involved!

2. Comprehensive Overhaul Covering 4 areas
Involving 1,230 Contractors at Peak
Over 1 ½ million man hours
Blast Furnace
Sinter Plant
Steelmaking Power & Energy

3. Heavy Vehicles Contractor / commissioning
interface
Asbestos
Joint removal
Confined Space Multi Level
Working
Manual Handling
Work Heavy Lifting
At Height Activities
Traffic / Pedestrian Segregation
Scaffolding

4. The blast furnace is the 2nd largest in Europe and has a 14 metre hearth. It is capable of producing in
excess of 10,000 tonnes a day of iron. The blast furnace has 36 tuyeres which allows air to be blown into
the furnace, and 4 tap holes for removing the iron out of the furnace.
Works included but not limited to;
-Partial carbon hearth replacement -Copper stave replacement
-Cast iron stave replacement -Stove burners & refractory's repair
-Replacement top hoppers & valve chest -Clean slag pits & repair
-Replacement gas cleaning plant cones -Upgrade of PLCs / automation
Outrigger crane repairs & recommissioning -Various casthouse works
Preparation of plant for future coal injection
Mechanical, hydraulic, electrical & instrumentation re-commissioning
1,000,000 Man Hours
850 Men at Peak
Lost time Frequency Rate – 0.4
All Injury Frequency Rate – 5.4
121 Near Miss / hazard observations
Over 1,400 Audits
541 Signed Toolbox Talk sheets returned

5. ! "
The steelmaking facility is made up of the Basic Oxygen Steelmaking plant (BOS) where the steel is made
by three basic oxygen convertors, and the Continuous Casting plant (Concast) where the liquid steel
takes shape and is made into slabs.
Works included but not limited to;
-Vessel relines - LMF Cooling tower remedial works
-Vessel distortion works -Vessel bearing replacement
-Slag splashing reinstatement -Refurbishment of moveable assets
-Strand guide segment refurbishment -Straightener segment refurbishment
-Exhaust fan ducting
-All cranes to be recertified and made available
-Mechanical, hydraulic, electrical & instrumentation re-commissioning
280,000 Man Hours
300 men at Peak
Lost time Frequency Rate – 0.35
All Injury Frequency Rate – 4.6
44 Near Miss / hazard observations
Over 1,500 Audits
254 Signed Toolbox Talk sheets returned

6. # $ "
The Power Station has three package boilers and two turbine blowers that provides the wind to the
furnace.
Works included but not limited to;
- RPS Blower Overhaul
- Heavy Fuel Oil Supply routes (Pipelines & Tanks)
- Turbine Alternator 3 Overhaul
- Estuary Cooling Water works
- Oxygen Storage System requires inspection and verification
- Nitrogen Storage System requires inspection and verification
- HV Electrical supplies require fault calculation analysis and reinstatement
130,000 Man Hours
180 men at Peak
Lost time Frequency Rate – 0.76
All Injury Frequency Rate – 4.6
25 Near Miss / hazard observations
Over 400 Audits
220 Signed Toolbox Talk sheets returned

7. The Sinter plant has a 4 million tonne output and converts a mixture of iron ore fines, fluxes, waste
materials and fine coke into an agglomerate, which makes up the majority of the blast furnace burden.
Works included but not limited to;
-Crane re-commissioning
-New R6 pan conveyor
-De-dust system overhaul
-Sinter Plant process fans
-Replacement of ROSOV valve PST14
-Serck Visco cooling tower replacement
-Sinter machine lowering wheel replacement
-Mechanical, hydraulic, electrical & instrumentation recommissioning
110,000 Man Hours
135 men at Peak
Lost time Frequency Rate – 0
All Injury Frequency Rate – 4.5
27 Near Miss / hazard observations
Over 185 Audits

8. %
Site Induction CDM Project
Steel House Plant induction
Auditing Schedule Toolbox talks
Minimum 1 per week
SSI UK Senior
Management Monthly
audits Take Two
Risk assessment
Daily before each task
SSI UK Mgrs/Eng/super
Weekly Advansa audits
Near Miss Incident
/ Investigation Reports
SSI UK Mgrs/Eng/super
Weekly Hazard
specific audits / BOPs Safety concerns sheets
For workforce
Contractor
Mgrs/Eng/super
Weekly audits
Accident
Investigation Reports

9. 0
1
2
3
4
5
6
7
W/E
06/08
W/E -0n S
ite 38
13/08
-On S 0
W/E ite 44
20/08
-On S 0
W/E ite 52
27/08
-On S 8
W/E ite 60
03/09
-On S 1
W/E ite 69
10/09
-On S 6
W/E ite 78
17/09
-On S 9
W/E ite 83
24/09
-On S 8
W/E ite 86
01/10
-On S 7
W/E ite 97
3
All Injuries
08/10
W/E -On S
ite 94
15/10
-On S 2
W/E ite 98
22/10
-On S 9
W/E ite 10
29/10
-On S 76
W/E ite 11
05/11
-On S 60
W/E ite 12
12/11
-On S 23
W/E ite 11
19/11
-On S 43
W/E ite 11
26/11
-On S 34
W/E ite 12
03/12
-On S 01
W/E ite 12
10/12
-On S 14
W/E ite 11
17/12
-On S 15
W/E ite 12
24/12
-On S 29
W/E ite 11
31/12
-On S 34
Lost Time Injuries
W/E ite 17
07/01
-On S 5
W/E ite 10
14/01
-On S 32
W/E ite 10
21/01
-On S 96
&
W/E ite 11
28/01
-On S 67
W/E ite 12
04/02
-On S 11
W/E ite 12
11/02
-On S 02
W/E ite 10
18/02 31
W/E -On S
ite 85
25/02
-On S 4
W/E ite 85
03/03
-On S 4
W/E ite 86
10/03
-On S 7
W/E ite 66
17/03
-On S 8
W/E ite 53
24/03
-On S 3
W/E ite 44
31/03
-On S 3
Medical Treatments
ite 36
0
Project Lost time Frequency Rate – 0.38 All Injury Frequency Rate – 5.6

10. '
Restart Injury Cause Injuries by day
Stationery Object Hot Work
7% 8% Airborne Particles 20
25%
15
Manual Handling 10
7%
5
0
Hit by Object
sd ay
da y
y
d ay
ay
rd ay
ay
F rid a
8%
Slip/Trip/Fall
S und
n e sd
Hand Tools Trap Injury
T u es
M on
17%
Thur
S a tu
15% 13%
We d
Restart Injuries Injuries By Time of Day
Back Body
Arm Foot 4% Eye 25
1%
5% 5% 27% 20
Head 15
11% 10
5
0
:0 0
:0 0
:0 0
:0 0
:0 0
:0 0
:0 0
:0 0
:0 0
:3 0
0- 10
0- 12
0- 13
0: 16
0- 18
0- 20
0- 22
0- 24
0- 02
0- 07
Leg
Hand
17%
07 :3
10 :0
12 :0
13 :0
16 :0
18 :0
20 :0
20 :0
24 :0
02 :0
30%

11. %& ( ) * ++*,-*+,..
The Risk assessment and
safe method of work to
remove salamander from
Furnace submitted
By DGC
Which was very
different from the way
they tried to move one
lump of salamander

12. %& ( ) * ++*,-*+,..
DGC French demolition operative crushed two fingers, losing tip of middle finger while
replacing wire strop in position. This operation was outside of the safe working procedure.
2. Salamander Segment 3. Front Loader Dragging
Chained Up Segment via Chain
1. Digger Pushing
Salamander
Segment
4. Pecker Pulling Front
loader via Wire Strop
Attached to Tow Bar

13. %& ( +/*.,*+,..
A redundant platform had been placed on the cast house floor awaiting removal to scrap area. This had
been laid for several hours, when the IP came and stood close to the platform talking to another
operative. The second operative then stood on the platform causing it to move and land on the IP’s
foot. The IP was taken to hospital where it was found that 2 metatarsals were broken.
A support under the platform
which had been Cut off,
was attached to a cleat by Redundant Platform
(wood should have been placed
a bolt.
Under platform to prevent movement)
As weight was applied to the
platform this acted as a pivot
and made the structure move
landing on the IP’s foot.

14. & " %& 0
Contractor tripped over step at the SSI Operative slipped while descending down stairs
steelmaking clarifier. Dislocated knee and in the RBF work shop office area, as he slipped he
received damage to ligaments. Hospital held on to the hand rail resulting in a dislocated
treatment and operation on ligaments. shoulder.
Redcar Power Station office worker fell
exiting Power & Energy restart project
cabin. Fractured ankle in fall.

15. 1 ) # % 23 !
2& 4 5& ! 6 7 6 "
Distributed to all project
contractors & SSI personnel

16. "

17. ' 84 "

18. 0
1
2
3
4
5
6
W/ E
20
W/ E /0 8
27
W/ E /0 8
03
W/ E /0 9
10
W/ E /0 9
17
W/ E /0 9
24
W/ E /0 9
01
W/ E /1 0
08
9
W/ E /1 0
15
W/ E /1 0
22
W/ E /1 0
29
&
W/ E /1 0
05
W/ E /1 1
12
W/ E /1 1
19
W/ E /1 1
26
W/ E /1 1
03
"
W/ E /1 2
10
W/ E /1 2
Trend
17
W/ E /1 2
24
W/ E /1 2
31
W/ E /1 2
07
W/ E /0 1
14
"84
W/ E /0 1
21
6
W/ E /0 1
Dropped / Falling Objects
28
W/ E /0 1
04
W/ E /0 2
'
11
W/ E /0 2
18
W/ E /0 2
25
W/ E /0 2
03
W/ E /0 3
10
W/ E /0 3
17
W/ E /0 3
24
W/ E /0 3
31 /0 3

19. ) 6
Near Miss Incidents
Fire
Leak
Access
Hot work
Isolation
Lifting
PTW Issue
House
Falling object
Hand tools
Scaffold
Manual
At Height
Hot work
Hazard
Asbestos
Vehicle
0 5 10 15 20 25 30 35 40 45 50

20. 9