CDM 2015 in Action: Delivering a £70m Advanced Recycling Facility Safely and On Schedule

Written By Andrew Souter

Delivering a major industrial construction project on time and without major incident is never straightforward — especially when it involves complex recycling technology, multiple contractors, and high-risk commissioning phases.

Cornerstone Safety Limited, recently completed a 15-month engagement as on-site H&S Manager/Consultant for a £70 million Advanced Recycling Facility (ARC) in Shrewsbury. The results speak for themselves: 1,247 site-specific inductions, 84 companies managed, 2,150 permits issued, and strong overall performance with only one isolated RIDDOR lost-time injury.

Here’s how we put CDM 2015 principles into practice to achieve this outcome.

Understanding the Project Challenges

The project involved construction of a state-of-the-art facility to process post-consumer plastic bottles into high-quality recycled Polyethylene terephthalate (PET). Key complexities included:

  • Installation and commissioning of advanced optical sorting systems

  • Heavy mechanical equipment including; industrial shredders, extensive conveyor networks, flake wash line, and flake sorting systems

  • High-voltage and Low-voltage electrical installation and integration

  • Confined space work, lifting operations, and work at height

  • Simultaneous construction and commissioning activities (SIMOPS)

  • Strict environmental and waste management requirements

These factors demanded a proactive, rather than reactive, approach to health and safety.

Applying CDM 2015 – The Cornerstone Approach

1. Strong Client & Principal Designer Collaboration From the earliest phases we worked closely with the client and design team to ensure health and safety was designed in. This included early risk workshops and input into temporary works and permanent design solutions.

2. Robust RAMS & Permit Systems Implementation of a comprehensive Risk Assessment and Method Statement (RAMS) review process. Every contractor’s method statement was thoroughly reviewed and approved before work began — with 220 RAMS reviewed to date. Our permit-to-work system managed high-risk activities such as electrical isolation, hot works, and lifting operations — issuing 2,150 permits with strong control throughout.

3. Comprehensive Induction & Training Programme We delivered 1,247 site-specific inductions, supplemented by 70 toolbox talks and 342 daily safety points. This ensured every worker understood the site-specific risks and kept engagement high throughout the project.

4. Temporary Works Supervision (TWS) Provided a Temporary Works Supervisor, who supported the Temporary Works Coordinator in the day-to-day oversight of all temporary works throughout the project, ensuring compliance with BS 5975 and project-specific requirements.

5. Safe Commissioning Phase The transition from construction to commissioning is often where incidents occur. We developed detailed isolation and LOTO procedures, SIMOPS risk assessments, and maintained strict permit control during the integration of complex machinery. We also supported the development of a suite of operational Safe Operating Procedures (SOPs) for key plant and equipment, helping ensure a structured and safe handover into the operational phase.

Key Results Achieved

  • One isolated RIDDOR lost-time injury (immediate corrective action taken)

  • 1,247 workforce inductions completed

  • 84 contractors successfully managed under one safety framework

  • 2,150 permits issued and controlled

  • 220 RAMS reviewed

  • 70 toolbox talks delivered

  • Positive feedback from client, principal contractor, and supply chain

  • Smooth progression through construction into commissioning

Lessons Learned & Recommendations

  1. Start safety early — involve the safety team from the design phase.

  2. Treat RAMS as living documents — regular reviews and updates are essential.

  3. Communication is critical during SIMOPS and commissioning.

  4. Metrics matter — track leading indicators (permits, inductions, near-misses) as well as lagging ones.

  5. Culture beats paperwork — visible leadership and workforce engagement make the biggest difference.

Conclusion

This project demonstrates that excellent safety performance and project delivery are not mutually exclusive — they are mutually reinforcing when approached with the right expertise and systems.

At Cornerstone Safety Ltd we specialise in translating CDM 2015 requirements into practical, on-site solutions that protect people and enable successful project outcomes.

Ready to strengthen safety performance on your project?

Whether you’re in the construction, recycling, manufacturing, or industrial sectors, contact us today for a no-obligation discussion about how we can support your team.

Andrew Souter
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