NSLS-II ESH Program Status Review

1. ESH Program Status Steve Hoey NSLS-II ESH Manager Conventional Facilities Advisory Committee Review November 9-10, 2009

2. Agenda • Best in Class Goal • 9/30/09 Construction Accident • ESH Program Elements • Construction Risks & Controls • IAO Assessment

3. Project ESH Vision – “Best in Class” • A strong ESH program is essential to the safety of the workers and the successful completion of the project • We believe all accidents and injuries are preventable and we strive to establish an injury free work environment • ESH is being fully integrated into the project and managed as tightly as quality, cost, and schedule • We are committed to a strong Integrated Safety Management System for the project • Safe working conditions and practices are an absolute requirement for all staff and contractors

4. Plan to Achieve “Vision” • Build on successful ISM/EMS/OHSAS programs and make use of lessons learned from recent BNL & DOE construction activities (SNS, CFN, RSB) • Clearly establish and articulate expectations via the Project Construction ESH Plan, ESH Management Plan, Request for Proposal & daily interface with contractor • Select contractors who have demonstrated excellent safety performance and are committed to continuous improvement • Flow down expectations to sub-contractors • Partner with the contractor and subs to assure success • Hold contractor accountable for performance • Adequately staff construction safety oversight

5. Description of Accident On Wednesday, September 30, 2009, at approximately 8:45 AM, a contractor laborer working at the NSLS-II construction site was struck by a load of rebar steel resulting in a compound fracture of the lower right leg below the knee. The contractor was transported to a local area hospital for treatment. The treatment of the injured party has gone well and a full recovery is anticipated. He was released from the hospital on Oct 6.

6. Immediate Actions on Day of Accident • Stand-down of construction site to inform staff of the event • Suspension of all rebar mechanical material handling activities involving a Lull • Management walk down of site • A post-incident fact-finding meeting was conducted • Charge written and membership identified for an independent construction safety investigation team to perform a thorough investigation, determine causal factors, identify corrective actions, and make recommendations

7. Immediate Corrective Actions • Conducted on-site (retraining session for mechanical material handling and instituted specific PHA’s for rebar material handling • Torcon required concrete subcontractor (Macedos) to bring a full-time field safety superintendent • BNL senior management met with Torcon senior management on Oct 6 to discuss expectations for safety and further corrective actions • Torcon Corporate Safety Manager is on-site full-time to support development of Torcon corrective action plan & supplement on-site ESH Mgr until such a time that second full time field safety inspector can be identified • Instituted daily meetings between Torcon field and safety staff and NSLS-II safety and construction management staff • NSLS-II is accelerating the hiring an additional full-time construction safety engineer to supplement the two currently on site • Torcon meeting with union Business Managers to convey ESH expectations and training/qualification requirements

8. Ring Building Construction ESH Program • Pro-active ESH program elements for this project • 851 compliant Occupational Med Program (credited with saving one life thus far) • On-site medical professional >50 workers (EMT) • The EMT was the first responder to incident and provided immediate care • Detailed worker ESH orientation (Bi-lingual) • Worker Safety Committee – represents each sub, meets weekly • Routine tool box safety meetings • Routine third party insurance evaluations (Liberty Mutual & Zurich) • Internal & External Audit/Assessment program • Routine ESH Meeting including contractor, BHSO, Lab CSE, and SME’s • Contractor Controlled Insurance Program (CCIP)

9. Site Work Controls • All work performed in accordance with BNL’s SBMS: • Under an approved Permit or the GC Safety Health and Environment program • Site access permits for general access • Rad work permit for soil monitoring • Specific SOP, e.g, equipment inspection, safety inspections • Torcon Project ESH Site Specific Program • Meets BNL’s “model” program • Defines elements such as inspections, tool box mtgs, industrial hygiene monitoring, Occ Med program etc • Phase Hazard Analysis developed to identify and control hazards

10. Construction ESH Plan • The GC was required to submit a written ESH Plan for review and approval before work began. Plan consistent with the requirements established in the NSLS-II Construction Project ESH Plan (model plan) • Plan ensures that; • Personnel possess the necessary experience, skills and training • Resources are effectively allocated to address ESH considerations • Hazards are evaluated prior to work • Engineering or administrative controls are in place • Line management responsibilities are clear • Clear and unambiguous lines of authority and responsibility for assuring ESH compliance • Plan was reviewed and approved by Project, Lab and BHSO Site HASP template upgraded to mimic NSLS-II model

11. ESH Management Plan for Construction • “ESH Management Plan for Construction” has been developed to; • Define specific roles, responsibilities and reporting mechanisms of project, contractor, DOE and Lab oversight staff. • Establishes “call down” procedure for emergencies • Establishes reporting criteria • Identifies key procedures for construction site (i.e., daily construction inspection, stop work etc)

12. Site Access, Security & Orientation • Contractor access is via main gate, down Princeton Ave directly to site. (peak population 300-350) • Analysis done in conjunction with Security to evaluate traffic flow and contingencies • Concluded main gate could handle flow and peaks • Early arrival and departure of contractors • Site is fully fenced, access is via South end of site (some utility work beyond fence) • CVO & Badging moved to construction site trailer eliminates 3 stops. • Restrictive policy for authorized access • These controls have been working well

13. On-Site Safety Coverage • Continuous coverage by NSLS-II Construction Safety Engineers and Torcon Safety Manager • Daily visits by NSLS-II ES&H Manager (increased since accident) • Weekly visits by Lab Construction Safety Engineer (increased since accident) • Periodic visits by NSLS-II Project Director, Assistant Project Director and other NSLS-II & lab management • Weekly visits by BHSO CSE (Increased since accident) • Periodic visits by Liberty Mutual and Zurich Insurance • 2 time/week concrete sub Risk Manager site visits • Changes due to accident include; • full time concrete sub field safety inspection and Torcon addition of full time field safety inspector • Project is in the process of adding a third CSE

14. Emergency Response • Covered by Torcon Safety Health and Environment Program • BNL developed Local Emergency Plan required by SBMS • Torcon and BNL LEP are coordinated • Assignment of Local Emergency Coordinators (BNL) • Construction site muster points • Shelter in place (Building 735) • Project specific call down process to notify management and DOE • Pre- Emergency Planning was a significant positive factor in the accident

15. Environmental Controls Enhanced environmental controls, all equipment parked on hard surface or tarped. Perimeter silt fencing

16. NSLS-II Specific ES&H Procedures • Adopted from existing Plant Engineering Program: • Heavy Equipment Inspection • Rigging Inspection • Safety Inspections • Site Access for Visitors and Guests • Stop Work and Work Interruptions • Permits • Heat Stress • Reporting of Events • Construction Safety Audits (new since accident) • Controlled documents

17. ESH Risk Analysis & Management

18. Site Prep – Legacy Issues • Remnants of a known 1978-81 geothermal/solar experiment unearthed during excavation on 5/6. • Glycol pumped out and cleared by NYDEC • Undocumented (pre-BNL) tank discovered on 5/19. • 20-25 gallons pumped out (kerosene and water) • Contaminated soil remediated approximately 20-25 yards • NYDEC approved remediation and cleared site Historical Artifacts discovered and preserved

19. Site Prep - Migratory Birds Killdeer & Canadian Geese have begun nesting on site NYS Fish and Wildlife are called in to remove Killdeer nests BNL Licensed to remove Geese nests Eggs

20. Project Safety Record Injury Data

21. Accidents – April 2009 DART Case & Occurrence NSLS-II Project April 16, 2009 Contractor Injury DART Injury NSLS-II Project April 16, 2009 Location: NSLS-II Project Site Injury : Fractured Right Heel Description: Sub-Contractor employee to ModSpace (Sub to Torcon the NSLS-II Ring Building Contractor) was descending from a eight foot step ladder after taking measurements to install an outside seal between two trailer sections. The worker missed the fourth step of the ladder and fell to the ground landing upright on his right foot. The worker was descending facing the ladder and not carrying any equipment, the ladder was on stable ground. He sustained a fractured right heel as a result of this fall. The contractor had recently gone through Contractor Vendor Orientation and the Torcon site specific training which both address ladder safety. • Cause: • The worker missed the fourth step on the ladder as he was descending facing the ladder • Corrective Actions: • The General Contractor conducted a tool box safety talk on this incident • CVO training and the Torcon site indoctrination will discuss this incident • Increased surveillance by Torcon of all site activities • Incident will negatively impact Torcon’s safety incentive for period one (3/09-3/10)

22. Contractor Injury

23. Construction Hazard Controls Material handling approved lifting fixtures & tag lines Site 6’ Fall Projection Rule

24. Construction Hazard Controls Mandatory PPE, Hard Hat, Safety Glasses, Safety Shoes & high visibility shirts/vests Rebar caps or rails used on all potential impalement hazards and horizontal protrusions

25. Construction Hazard Controls Ramps and defined access into formed areas

26. Construction Hazard Controls Defined Walkways provide safe access & egress from work areas

27. Construction Hazard Controls Dedicated Laborer’s for improved housekeeping

28. Independent Audit & Oversight • Laboratory Director has commissioned BNL Independent Audit and Oversight to conduct a “Construction Safety Program Review” for NSLS-II • SME’s from IA&O, ESH Directorate, Liberty Mutual • Three Phases • Phase One – Review of documentation and requirements - Complete • Phase Two – Field Observations of training, tool box mtgs, qualifications etc. - Complete • Phase Three – Field Observations of work in progress and compliance to plans and management observations - Ongoing • Phase one began 6/2009 – Phase three complete 11/09 • Will continue periodic site visits by Liberty Mutual