Alcoa NSW Safety Training Success | Confined Space & Height Safety Case Study

Background

Alcoa Rolled Aluminium, located in Yennora, NSW, employs over 160 staff members. The plant primarily focuses on the casing and rolling of aluminium products, with many areas involving significant safety risks such as working at heights and within confined spaces. In late 2009, Fire and Safety Australia (FSA) was approached by Alcoa to conduct a comprehensive review of their safety training and procedures related to confined space and height safety. Over the years, this partnership has grown, ensuring that Alcoa meets stringent safety standards while prioritising the well-being of its workforce.

Key Achievements with Alcoa

Ongoing Partnership: FSA partnered with Alcoa for over three years, delivering tailored Confined Space Entry Training and Height Safety Training at their Sydney site.
Extensive Audits: Completed confined space audits and risk assessments across the Yennora facility. Over 400 confined spaces were reviewed to assess compliance with the AS2865 confined space definition, a crucial Australian standard for ensuring safety in hazardous environments.
Training in Safe Environments: Utilised FSA’s dedicated confined space entry training trailer, ensuring all staff received hands-on training in a controlled and secure environment.

Confined Space & Safety Procedure Overhaul

In early 2010, FSA began a comprehensive review of Alcoa’s existing confined space procedures. This included:

Needs Analysis: Conducting a thorough needs analysis to determine gaps in training and safety procedures. This analysis enabled the creation of a customised training plan tailored to Alcoa’s specific requirements.
Training Roll-Out: Developed and implemented a new confined space entry training programme, covering over 125 personnel across the Alcoa NSW site. This training focused on understanding and mitigating the unique risks associated with Alcoa’s operations, such as the dangers related to working with molten aluminium.
PPE Training: Given the hazardous nature of the site, specific training on Personal Protective Equipment (PPE) was conducted. This included selecting the right PPE for confined spaces, especially when working around molten materials, ensuring staff safety in extreme environments.

Continued Excellence: Refresher Courses

From 2012 to 2013, FSA provided refresher courses for Alcoa’s staff, ensuring that safety standards were consistently upheld. These refresher courses were crucial for:

Reinforcing critical safety knowledge for existing staff.
Integrating any updates in safety standards and procedures.
Ensuring compliance with the latest industry best practices.

Customised Training Solutions for Alcoa NSW

One of the strengths of FSA’s approach is our ability to customise training to fit the specific needs of our clients. For Alcoa, we focused on:

Addressing the unique hazards associated with aluminium manufacturing.
Emphasising risk assessment techniques, hazard identification, and emergency response protocols.
Providing practical, hands-on training using our confined space entry trailer and other specialised equipment to simulate real-life scenarios safely.

The Impact

The tailored training and thorough audits conducted by FSA have had a significant impact on Alcoa’s safety culture:

Enhanced Safety Compliance: Alcoa’s training now fully aligns with AS2865 standards, ensuring compliance with Australian safety regulations.
Improved Safety Procedures: Staff members are better equipped to handle emergencies in confined spaces and working at heights, leading to a safer working environment.
Increased Confidence: Alcoa’s workforce has developed greater confidence in managing complex safety situations, reducing the risk of incidents and fostering a proactive safety culture.

Relevant Training Courses for Your Organisation

If your business faces similar challenges, Fire and Safety Australia offers a range of training solutions to improve safety and compliance. Explore our training options:

Confined Space Entry Training – Designed to meet AS2865 standards, providing comprehensive education on safely entering, working, and exiting confined spaces. We offer confined space entry training course (2 days), confined space entry course (basic 1 day) and confined space entry refresher training.
Height Safety Training – Specialised courses focusing on the risks of working at heights, covering fall protection, rescue plans, and safe work practices. We offer Height Safety Training Course, Vertical Rescue Training Course, Tower Rescue (Non-Electrical Stream) training, Road Crash Rescue training and many more.

Client Testimonial & Reference

Alcoa has been a valuable partner, and their positive feedback reflects our commitment to safety and excellence. For a verbal reference or more information on how we have supported Alcoa’s safety training initiatives, please contact us.