Bayhead Road Upgrade - Q&A with Matthew Horwill and Theo Fourie

Working on a major Civils project in the Durban CBD, Stefanutti Stocks Civils KZN recently achieved an Industry Milestone of having accomplished 750 000 man hours without a lost time injury. When asked for comment, Association Health and Safety Manager Neels Nortjie lauded the team involved stating that the risk variables on a Civils project, particularly in a major traffic zone, is extremely high and always challenging, "What they have achieved is highly commendable."  We caught up with Matthew Horwill Contacts Manager and Theo Fourie SHEQ Manager for Stefanutti Stocks Civils KZN and asked the following questions on the Bayhead Road Upgrade Contract:  

Tell us about the scope of the project?

"The contract consists of the construction of fuel and gas pipe protection culverts, a new Road over Rail Bridge and the upgrading of approximately 2km of Bayhead Road from the intersection with Langeberg Road through to Pier 1. In addition, the new road alignment caters for the construction of two truck staging facilities that will hold up to 120 super-link trucks. The revised road alignment and truck staging facility will significantly reduce the congestion currently experienced in Bayhead, Iran and Trinidad Roads respectively. This in turn will help streamline the activities to the Cutler Complex, Pier 1 and the Port and hence positively impact on the local and national economy."

What unique challenges does this project present in terms of Health and Safety?

"One of the biggest challenges was minding the National Key Point fuel and gas pipelines belonging to Natcos and TPL. These pipelines run two meters below the ground and the contract required that we excavate to a depth of 4 meters to construct the multi barrel culverts around these lines. Working in dune sand required significant lateral support and innovative construction techniques. The pipes themselves needed to be supported at 10 meter intervals and excavation machinery could not be used to within 1 metre to them. We had to constantly be on the lookout for damage and leaks to the pipelines and every precaution was taken to prevent them. When working in excavations the health and safety requirements cannot be underestimated".

Was there damage to the line at any point?

"No, not at all."

Other safety challenges?

"Traffic management is also a critical factor as fully loaded super and multi-link trucks have to constantly be accommodated around the site which forms part of one of the highest volume heavy vehicle traffic routes in the world. In addition to the usual safety challenges that come with working at heights, when constructing the Road over Rail Bridge, we had to be particularly vigilant with regard to the overhead power lines which remained live throughout the construction of the bridge as they fed into the Kingsrest Rail Yard."

How many people are working on the site?

"At peak we had around 380, however at present there are about 220."

How much longer will this project continue for before completion?

"There are still roughly another 6 months to go and we are programmed to be complete ahead schedule."

What do you attribute your success too?

"One would have to put it down to a solid team effort. We have strong culture of health and safety in our site organisation combined with the back up support from our office."

Are there consequences for members of staff who do not buy into your safety policy?

"We are very strict on this, if needed, disciplinary action will be taken, we do however have strong buy in from our various teams and haven't had a safety disciplinary action in many years."

Is 1 million hours on the cards?

"It is unlikely as the project is nearing completion, our objective is however to conclude it without injury. That remains the focus."

What Safety advice do you have for other Civils Contractors? 

"Our biggest attribute is buy-in; everybody is properly inducted and informed, our motto is 'Be Your Brother's Keeper'.  When it comes to Health and Safety, attention to detail is always important as well as being proactive - rather than reactive."  

Ernest Roper | Regional Manager Durban