• The Lighthouse Club’s 3rd International Design for Safety Competition

    17 July 2018

    On 16th January 2018, the Lighthouse Club hosted the very well-attended awards ceremony for the 3rd year of the International Design for Safety Competition at the Hong Kong Club.  The awards have been raising awareness of the role of the designer in safety whilst at the same time highlighting those exemplary designers that have truly taken to heart the need to ensure the health, safety and welfare of all those that are on the receiving end of the designs of assets for construction, operation, maintenance, modification and ultimately removal or demolition.

    This year’s competition was modified to include teams as well as individuals.  The response was magnificent with many more entries that in the previous years with many individuals and teams competing for the top prizes.  The designers covered a wide spectrum of the construction industry including client organisations, consulting engineers, contractors, sub-contractors, product designers and academics. 

    The Lighthouse Club extends a big thank you to all those that entered the competition.  Also, thanks to Arcadis for sponsoring the gold prize and to Sambo E&C for sponsoring the silver prize.

    The high quality and number of entries this year made it especially difficult for the judges to determine those that stood above the others and there were some healthy discussions amongst the judging panel as well as a more sophisticated marking scheme!  It was very close between the team that won the gold and silver awards.  The Lighthouse Club extends its thanks to the judges that volunteered their valuable time to shortlist and interview the winning entries.  These are:

    • Robert Gordon, Arcadis & Deputy Chairman of the Lighthouse Club HK
    • Iain Mowatt, Temporary Works Forum & Lambeth Associates
    • Mark Divers, VSL-Intrafor
    • Prasad Ekanayake , The Hong Kong Jockey Club

    There was again a common theme in the winning entries – collaboration. Collaboration within and between design teams, construction teams, clients and key stakeholders.  This was the key to eliminating and mitigating the health and safety risks.  After the awards and in the true spirit of fellowship in the Lighthouse Club the winners stayed on the mingle with the guests and share insights into their entries for the benefit of our construction industry.

    One of the outcomes of the Safety Workshop at the Lighthouse Club’s Construction Conference ‘Reducing Risk in the Construction Industry’ on 15th March 2018 was to publish good examples of design for safety.  Therefore, the entrants to the design for safety competition will be contacted and, subject to permissions, these will be published on the Lighthouse Club HK website as a free resource for all in the industry.

    The awards were presented by our distinguished guest, Ada Chung, President of the Lighthouse Club HK.  The full listing of the awards are as below along with the key citations from the judges.

    Gold Award (HK$30,000) – Dragages – Bouygues Joint Venture for the “The Peanut Shaft & TBM Launching Structure” also add photo of team collecting prize

    Project: MTR Shatin to Central Link Contract 1128 – South Ventilation Building to Admiralty Tunnels

    Team: Michael Cheung – Dragages-Bouyges Joint Venture with Irene Liu – MTRCL, Clayton Chan – AECOM, CK Lee – Arup, Gordon Lee – Intrafor and Andy Kwok – VSL

    Judges comments: “A great example of design for safety with great collaboration and coordination amongst the many parties to the project.  The team adopted a peanut shell shape for the shaft construction, which dramatically reduced the internal temporary works, reducing collision risks for raising and lowering plant and materials and reducing settlement risks for nearby structures.  Other great ideas to remove safety risks included the incorporation of the cut and cover tunnel section into the permanent works, replacement of the steel bell with concrete in the permanent works and reconfiguration of the shaft staircase so it could be used in the construction stage and left in place for the permanent works.  All these modifications came early in the programme demonstrating great planning in the design for safety process”.

    Silver Award (HK$20,000) – Leighton-Chun Wo Joint Venture, Robert Bird Group & VSL Intrafor for the “Erection methodology at the Passenger Clearance Building” also add photo of team collecting prize

    Project: Hong Kong – Zhuhai – Macao Bridge, Hong Kong Boundary Crossing Facilities, Passenger Clearance Building

    Team: William Hopkin, Leighton-Chun Wo Joint Venture with Dustin Lam – Robert Bird Group and Christian Venetz – VSL Intrafor Hong Kong

    Judges comments: “This was a great submission with an innovative use of horizontal launching for the roof trusses.  The roof cladding is modular, in cassettes and slotted on.  All cladding, features and services were installed off-site and 85% of the work was off site in controlled factory conditions.  Demolition can be undertaken by reversing the construction sequence. BIM was used for checking interfaces.  The design and advance planning was exemplary with almost no changes on site.  There was good collaboration with the permanent works designer to incorporate features needed for construction into the permanent works design (e.g. corbels in the roof).  Consideration was also given to all-weather events and temporary storage on site.  All this resulted in elimination and mitigation of significant health and safety risks, especially working at height”.

    Bronze Award (HK$10,000) – Leighton-Gammon Joint Venture & Meinhardt for the “Alternative design for the plenum” also add photo of team collecting prize

    Project: West Kowloon Terminus Station North Contract 810A

    Team: John Adams – Gammon with Alex Yui – Gammon, Rachel Joshua – Gammon and John Man – Meinhardt

    Judges comments: “This alternative plenum design (with only 800mm working height above the ceiling) eliminates the risks associated with a traditional suspended slab design, adopting lightweight panels suspended from the roof slab in a lightweight frame.  There was also off-site prefabrication.  Finger injuries from manual handling were mitigated.  There was a 98% reduction in scaffolding requirements resulting in a safer site with minimal waste.  Construction was completed with no reportable accidents and the workers were happy with the alternative design.  The maintenance team were involved at the design stage for O&M and guidance was provided on how to cut out and replace panels.  We are told that this alternative is so good that MTRCL is now adopting this as a standard design approach.  There were programme and safety benefits and therefore reduced exposure time for workers”.

    The following entries were cited as “Highly commended” by the judges.  These were:

    • Vinci Construction Grands Projets led by Gilles Cahia with Emmanuel Clech, Billy Lo, Keith Lee and Clement Cacarie for their ‘Adaption of horse shoe section for variable width formwork optimisation’ on the ‘MTR Shatin to Central Link Contract 1122 Admiralty South Overrun Tunnel’ project. The judges were impressed with their elimination of work at height risks, checks for finger traps and provision of safe working areas.  The rationalization of the tunnel design’s varying dimensions enabled a safe solution for the roof section formwork.

    • Lambeth Associates led by Ted Lawton – Lambeth with Michael Chak – Lambeth, Mark Robinson – Dorman Long Technology, Antony Lam – Jhong Ji, Billy Wong – BIM and Arthur Wei – Tony Gee for their ‘New machine for the safe erection of precast bridge segments: The Stroller” on the ‘Tuen Mun – Chek Lap Kok Link Viaducts’ project. The judges were impressed again with Ted Lawton’s entry (the only person to have entered all three years of this competition and a former 1st prize winner in its inaugural year).  This time he and his team has addressed the transportation issue of precast deck segments on the deck of a marine bridge under construction with a challenging geometry.  Of particular note, the design includes a remote control that ‘removes man from machine’, use of legs not wheels to eliminate the risk of the machine ‘running away’, high maneuverability to deal with minor adjustments and tolerances, use of BIM to check the design before manufacture and elimination of risk associated with rail-based transporter units where safety issues arise if ‘pins’ are not put replaced. There was also good collaboration between the parties to the project.

    • Lambeth Associates & Mott MacDonald Hong Kong Limited led by David Mepham – Mott MacDonald with Henry Yip – Mott MacDonald, Richard Ellis – Gammon, Frankie Ho – Gammon and Colin Batchelor, Airport Authority Hong Kong for their ‘mechanised construction and associated works’ on the ‘HKA Contract P533 Midfield Concourse Works’ project. also add photo of team collecting prize. The judges noted the client-agreed contractual arrangement that permitted the designer to provide separate teams to work for both the client and contractor to help ensure that elements of design for safety remained in place for construction.  There was off site modular construction for the fixed link bridges with some services built-in.  Mechanised forms removed the need for in-situ formwork and most of the associated traditional falsework resulting in a tidier and safer site. Craneage movements were reduced with larger lifts. The reduced construction time also reduced the overall safety risks to the site workers.

     

    • Sambo E&C led by Patrick Tong – Sambo with Eric Tong – Sambo for their ‘retractable handrail around the deep cement mixing rig’ on the ‘Hong Kong International Airport Three Runway System Project Contract 3203 – Deep Cement Mixing Works (Package 3)’ project. also add photo of team collecting prize – and see if Patrick can provide a drawing or image of the handrail design. The judges noted the design was a result of feedback from site workers to address a maintenance and cleaning issue and also had client support from the Airport Authority Hong Kong.  The retractable handrail was designed to be easily operated with one hand.  It is a simple practical solution with potential applications to other aspects of the construction industry.

    • Black & Veatch Hong Kong Limited & Drainage Services Department, HKSAR Government led by Glenn Chan – Black & Veatch with Andy Kwok – Black & Veatch, Raymond KF Seit – DSD, Dr. Oliver WK Au-Yeung, DSD for their ‘multi-pump sewerage system and dry weather flow interceptors’ on the ‘Lei Yue Mum Village Sewerage’ project. also add photo of team collecting prize. The judges noted that, by design, the project team had eliminated the need for branch sewers by using shallower pipes (depths reduced from 10m to 2-3m below ground) with the use of pumps.  This mitigated the risks associated with deep excavations.  A further highlight was that due to the difficulty of access for construction vehicles, lightweight HDPE pipes were used. Also noted that a H&S plan was included in the contract.

     

    • Aurecon Hong Kong Limited led by Gavin Lau – Aurecon with Percy Chan – Aurecon for their approach to design and construction sequencing on the ‘Site formation and infrastructure works for the development of Anderson Road quarry site’ project. also add photo of team collecting prize. The judges commented that the team’s approach using lattice girders to support the excavation, steel formwork, multi-phase excavation and innovative use of GFRP in place of steel bars had significantly eliminated reduced safety risks.

     

    • Leighton Joint Venture with an entry led by Andy Lau – Leighton with other Leighton team members Ken Fan, Eric Wong and Max Chan for their re-design of the cabling truck on the ‘H2613 – Central- Wan Chai Bypass (CWB)– Tunnel Buildings, Systems and Fittings, and Works Associated with Tunnel Commissioning’ project. The judges commented that this has the makings of a good system that could have far-reaching possibilities.  The modularisation on the truck and removal of a mobile elevated working platform from the process are very worthwhile improvements.

    The following entries were cited as “Commended” by the judges.  These were:

    • Atal Degremont – China Harbour Joint Venture led by Kenneth Lau with Albert Yau for their temporary excavation and lateral support system for the treatment plant on the ‘Contract DC/2013/10 DBO San Wai STW – Phase 1’ project.  The judges noted that safety was improved by design with the aid of a risk register, off-site factory fabrication, making use of the permanent works for construction and good collaboration amongst the construction and design team. 

    • Drainage Services Department & Tsun Yip Waterworks Construction Co. Ltd led by Michael Leung – DSD, with Ken Wong – Tsun Yip Waterworks Construction for their ‘temporary excavation and lateral support design for the treatment plant’ on the ‘DC/2013/09 – Advanced Works for Shek Wu Hui Sewage Treatment Works’ project.  The judges were impressed by the use of BIM to visualize the temporary works for the site workers and to use this as a tool to eliminate and mitigate safety risks. 

    • West Kowloon Cultural District Authority led by Jeremy Stowe, WKCDA with his WKCDA colleagues Max Lee, Andrew Simpson, SM Lin, Ray Lee and Steve Tsang for their ‘approach to design for safety’ for the ‘Xiqu Centre’ project. The judges were most impressed that, as a client organisation, WKCDA has specified in their contracts the use of the Development Bureau’s guidance document on CDM.  Other design for safety features included the implementation of DfMA principles, roof truss assembly at ground level and built-in maintenance and cleaning access routes.


    • Aurecon Hong Kong Limited with an entry from Thomas Wang for his work on the temporary slope as part of the ‘Advance slope works for the ‘In-situ provision of Sha Tin Water Treatment Works (South Works)’ project. The judges noted that the design was developed to minimize temporary works and ensure durability for the duration that the temporary slope would be in place.


    • Samsung – Hsin Chong Joint Venture led by Andy Raine – SSHCJV with Patrick Cheng – MTR, Dennis Leong – MTR, York Chan – MTR, Barry Leung – SSHCJV and Patrick Cheung – SSHCJV for their ‘Holistic design for safety solution for the EEP shaft at To Kwa Wan’ on the ‘SCL 1109 – Sung Wong Toi and To Kwa Wan Stations and Tunnels’ project. The judges cited this submission for its good practice in eliminating formwork in an adit and good client collaboration.


    • Chun Wo Construction & Engineering Co., Ltd.  led by Daniel Ho with Lau Kam Wah, Wu Chun Wang, Tang Hin Shing and Sit Hin Shing all of Chun Wo for their development work on the ‘exo-skeletong’ as trialled on the ‘Liantang/Heung Yuen Wai Site Formation and Infrastructure Works – Contract 3’ project. The judges noted that this was a product under development and testing, which is a wearable aid to help prevent construction worker muscular injuries by providing restoring moments with the potential to reduce up to 71% of muscle usage, easing standard operations and helping to prevent fatigue issues associated with repetitive tasks.


     

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