Ibstock Concrete is to invest across its extensive UK manufacturing facilities to improve the safety and efficiency of its operations by undertaking innovative upgrades to its engineering practices.

Following extensive employee feedback, Ibstock Concrete has made significant upgrades to the manufacturing processes at its Bedford and Northwich sites, which manufacture a comprehensive portfolio of landscaping, flooring, building, rail and infrastructure products for its industry leading Supreme Concrete and Anderton Concrete brands.

At its Northwich facility, Ibstock Concrete has achieved a unique and industry leading approach to the casting process, which consistently reduces the trigger time for vibration to below the HSE’s Control for Vibration at Work Regulations 2005 Daily Exposure Limit Value.

Following an in depth review of the existing casting process, which involved filling moulds with concrete and applying vibration at 55Hz to remove any air voids, a three stage visual indicator and three level vibration system has been installed.

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This process is not only a new concept for Ibstock Concrete, but is a revolutionary approach for the entire industry, as it effectively reduces the associated risks of high levels of potential exposure to vibration, by providing individuals with real time information on the level of vibration the manufacturing equipment is currently operating at.

Even on the highest setting, a vibration survey has evidenced the potential exposure limit as low as 2.7 m/s2 A(8), whilst on the lowest setting, the potential exposure is as low as low as 0.5m/s2 A(8), both of which are below the HSE's Daily Action Limits.

Following the success of this new process and its reflection of best practice, a plan is in place to phase in the technology across all Supreme Concrete and Anderton Concrete manufacturing sites where vibrating tables operate.

As part of this dedicated programme of investment, Ibstock Concrete has also reviewed its slotted post casting process at its Bedford facility. Following extensive employee consultation, reducing the frequency of manual handling required was identified as a key priority, to ensure the consistent safety of all operatives, without affecting the overall manufacturing process.

As a result, a central element of the production process has been automated through the installation of a dedicated rebate lifter, which mechanically lift the rebate from the cast product.

This eliminates the operator having to physically lift the rebates from the mould, substantially reducing the level of manual handling required by the operator.

The automation of this process is a completely new approach, again not only for Ibstock Concrete, but for the entire industry, as it modernises a traditional and established stage of the casting phase.

This technology is now being implemented across all relevant Ibstock Concrete manufacturing sites throughout the UK, providing an even safer working environment for employees by considerably reducing manual handling with the aid of mechanical means and in accordance with the HSE’s Manual Handling Operations Regulations.