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success

Spotting a gap in the market has seen Oxfordshire-based firm Terrafirma Roadways go from strength to strength

Words: Roger Brown Images: Tom Cunningham Accessing the UK’s electricity pylons and

pipelines for construction or maintenance work often means utility company trucks have to cross dificult or dangerous terrain in remote locations, or environmentally sensitive areas such as farmland, wetlands, and marshland, sometimes in ice and snow. Temporary roadway panels are usually needed to provide safe access for vehicles and heavy plant, as well as to protect the land from damage while work is taking place.

Traditionally, these panels were made of aluminium, but since 2001 Oxfordshire-based Terrairma Roadways has specialised in Dura-Base, an advanced type of plastic mat manufactured in the US. Terrairma delivers and recovers Dura-Base temporary road surfaces across the UK for customers such as Balfour Beatty, National Grid, Amec and the Royal Parks.

Strong and durable

Speaking at the irm’s head ofice near Abingdon, MD Hugh Robertson tells CM Terrairma is the sole UK distributor of the product, which is made from highdensity polyethylene (HDPE) plastic and contains a special additive designed to improve strength and durability.

“Dura-Base consistently outperforms all other forms of temporary roadway on the market because it provides safe site access, with minimal disruption and damage to the surroundings and the environment,” he says.

“The mat is a strong, safer, cleaner, user-friendly alternative to traditional aluminium roadway panels and, unlike aluminium, requires no security. We saw a gap in the market for the product and went for it. Since 2001, the business has gone from strength to strength with year-onyear growth,” says Robertson.

In the US, Dura-Base mats are typically handled with forklifts, and used in gas and oil drilling operations. Robertson, who started out in business in 1981 as a general agricultural contractor, was faced with the problem of how to transport the mats around the UK. The irm initially purchased several second-hand ERF ECX brick trucks for the work, and designed its own unique multi-grab to facilitate the eficient and safe lifting and laying of the mats without using dangerous chains, nuts or bolts.

“This year we have undertaken a major truck replacement programme and spent in excess of £900,000 on nine Renault Premium Landers, with Optidriver automated gearbox and twin sleeper cabs.

“They deliver excellent fuel performance and are a signiicant improvement over our previous leet, thereby improving our carbon footprint as well as saving money,” says Robertson.

The Renault trucks run in conjunction with a specially designed trailer from Montracon that has a drawbar option, with additional safety features such as a braced headboard, side stabilisers for eficient, safe laying and retrieval of mats, and built-in load binder system. There is also cab accommodation for crew members, which enables remote site working.

Robertson adds: “The vehicles meet our dual objective of improved health and safety and operational eficiency. It’s important that drivers use a low gear when installing or recovering mats, and they must never reverse if they cannot see the ground crew or banksman in their mirrors.

Safety first

“It may be tempting to drag or slide mats but this should never be done, as it damages the teeth on the grab and can harm the locking pins and mats.” Drivers are issued with personal protective equipment (PPE), which must be it for purpose, and any defective items must be reported. “Drivers are equipped with overalls, hard hats, safety boots, high-vis clothing and gloves at all times when working on site and in Terrairma yards. Safety glasses must also be worn when required by the daily risk assessment,” Robertson says.

The irst job drivers do when they arrive on any site is a daily risk assessment. Nearly all risk assessments that Terrairma carries out are speciic to the individual job and hazards often include trees, slopes, trafic, water and animals. “This assessment must be conveyed to other companies that visit the site such as the National Grid,” says Robertson. “Checking and inspecting equipment and taking action over any faults is an ongoing task and crew members should always keep out of the way of potential danger.”

Daily checks

Terrairma is fastidious about ensuring drivers complete their daily defect report at the start of each day, and that it is signed off. “This should also be updated during the day if necessary and logged with a record of time and driver’s initials,” he says. This year the company has expanded its stock to 10,000 mats, and this is expected to rise to 20,000 in three to four years’ time. Each mat weighs 477kg and the Premiums can carry 22 per load. This increases to 46 when pulling the drag.

As well as site access, Dura-Base is used as temporary car parking. For one successful project last year, before the Christmas period – the prime retail spending peak – Terrairma supplied 531 Dura-Base mats to one of the UK’s leading retail parks to create a temporary car park. This was so successful that the contract has been extended until January 2013.

Robertson says: “Terrairma was asked to get involved when the existing temporary roadway, which had been laid, did not live up to the pressure of trafic that travelled over it. We installed the Dura-Base mats directly over the top to form a solid, continuous and safe platform for vehicles and pedestrians to use. The client was delighted with the result.”

Market timing

According to Robertson, Terrairma entered the marketplace at a great time, as at the turn of the millennium the mobile phone telecoms market was expanding, and utility companies were carrying out a lot of off-road work installing and repairing phone masts. At present, the company is ensuring safe site access for utility companies in remote areas of northern Scotland.

“Dura-Base mats can also loat unaided on water and be used as a loating pontoon. Terrairma was recently asked to supply mats to Hampton Court in London to enable maintenance work to be carried out on the moat,” he explains.

Issues of concern

Managers at the irm organise brainstorming meetings with staff so that any health and safety problems and drivers’ concerns can be quickly identiied and rectiied. “We take health and safety seriously, it’s everyone’s responsibility to ensure we all work safely together. All employees receive induction training and it is the responsibility of each individual to guarantee they employ the methods taught. We accept no compromise in this area.” ■

OPTIMUM PERFORMANCE

Renault Trucks South has organised driver training for Robertson and his transport manager, using the manufacturer’s Infomax management system. Infomax is a productivity aid that collects and analyses data on driving styles.

According to Robertson, the challenge for Terrafirma is to change the mindset of the drivers so they drive more slowly to get to their destinations faster, by keeping off the brakes and using cruise control.

“Infomax downloads allow us to monitor driver performance with the aim of achieving 7.5mpg to 8mpg across the board. We like to incentivise the team to improve their performance.

“The company’s new fleet of trucks uses clean engine technology that incorporates the Optimax computerised fuel monitoring system.” Terrafirma Roadways uses premium brands such as Bridgestone and Michelin because Robertson believes budget tyres are a false economy.

Avoiding risks

Drivers use sand bags under any lip that vehicles are likely to cross and check that there are sand bags on the truck before it leaves the yard.

Mats must be laid in exactly the right way to allow ease of installation. All Terrafirma staff undergo rigorous training in the optimum method of installing and retrieving the mats safely and efficiently.

“The crews must ensure they understand what they are being asked to do, and that they are familiar with the method statement and risk assessment for the job,” Robertson says.

“We say to employees that if they are unsure about any health and safety issue, they should ask for help.”

SAFETY MESSAGE

Terrafirma stresses drivers must never stand under suspended mats or allow mats to be swung overhead. Drivers must not stand or climb onto mats that are loaded, especially when strapping the load down. “It is important that ratchet straps are fitted on the passenger side in case any straps come loose,” says Robertson. The outrigger legs must be out and down for support before the crane is used. “It may sound basic, but drivers should only endeavour to get in and out when the vehicle is stationary and the handbrake is applied.” The company selected the Epsilon 132Z crane for its long duty cycles and robust construction and is pleased with its performance and durability.


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