Raymond Blanco

FSE / DOLE OSH Practitioner

CONSTRUCTION MACHINERIES
HSE International Consultancy
HEALTH SAFETY & ENVIRONMENT
 Overview
• Introduction and Background
– Facts and statistics
– Case studies
• Hazards in Work Space
• Preventative Measures
– Development of Internal Traffic Control Plans (ITCPs)
– Safe operation and maintenance of heavy equipment and
motor vehicles
– Night work
– Additional safety considerations
– Applicable Standards
• Summary
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 Introduction and Background
• Highway and street construction (H&SC) workers are
exposed to injury and fatality risk
• The work is in proximity to construction equipment,
as well as passing traffic
• The module covers,
– Hazards in the work space
– Injury prevention with an emphasis on Internal Traffic
Control Plans (ITCP)

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 Typical Work Activities Within
Work Space

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 Typical work zone activities

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 Facts and Statistics
• Injury and fatality exposures are extremely high in highway
work zones
• Each year, over 100 H&SC workers are killed and more than
20,000 are injured
• Half of the H&SC workers are killed by construction trucks
and equipment
• On-foot workers represent approximately 57% of the worker
fatalities in work zones
• More than 30% of fatalities involve equipment operators

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 Case Study #1
• A 39-year-old construction laborer was killed after falling
down from moving front-end loader
• Victim was working with the loader operator laying asphalt
around manhole covers.
• Victim was riding on the front-end loader battery box. He
grabbed the forward/reverse control lever. Operator told
victim to stop; he went ahead and pulled it anyway.
• The machine immediately stopped and reversed direction As
a result, he fell from the loader 3 feet, and was run over by
it.

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 Case Study #2
• A 55-year-old highway department supervisor died
after being struck by a backing dump truck at a
multi-lane highway work zone.
• The crew was filling potholes and laying down
asphalt over the repair.
• The supervisor crossed into the lane of the
oncoming truck; the driver did not see him and
backed over him.
• Victim was pronounced dead at the scene.
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 Hazards in the Work Space
• Worker being struck by or caught in/between
equipment
• Electrocution due to contact with overhead and
underground power lines
• Falls on the same level or down to lower levels
• Health exposures (noise, silica, lead)
• Environmental exposures (heat, cold, humidity, etc.)
• Poor visibility exacerbates these hazards
• Untrained workers are particularly vulnerable.

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 Struck by and Caught
in/between Hazards
• On-foot workers close to construction vehicles and
equipment in tight areas
• Operators being caught in running equipment when
collision or overturning occurs
• Flaggers being struck by or caught in between
vehicles and construction equipment

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Health and Environmental Hazards
• Affect workers who may or may not be involved in
the activity creating the hazard
• Substances like silica dust and lead can create
adverse health effects
• Construction and traffic noise can cause hearing loss
• Extreme cold can cause frostbite or hypothermia,
and hot weather can cause heat stress

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 Hazards due to Poor Visibility and
Inadequate Lighting
• Night work and inclement weather produce
poor visibility
• Night work presents problems
– Reduced visibility
– Driver impairment or inattention
– Fatigue and sleepiness
• Lack of adequate lighting magnifies the
problem
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 Untrained Workers
• Untrained workers are more vulnerable
to injuries
– Not using Personal Protective Equipment
(PPE)
– Improper use of PPE
– Unsafe work practices
– Macho behavior, horseplay
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 Other Site Hazards
• Electrocution due to contact with overhead and
underground power lines (Refer to Module No. 4)
• Highway construction materials like asphalt and
concrete pose physical hazards to workers, such as
burns, splashing wet material in the eye, etc.
• Strains and sprains due to overexertion and poor body
positions
• Slips, trips, and falls due to poor housekeeping
• Fall from elevation and falling objects

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 Preventive Measures
• Operating and maintaining heavy equipment and
trucks using safe procedures (Refer to Module No. 3)
• Implementing safe procedures for night work, and low
visibility
• Safety protocols for preventing occupational health
and environmental hazards
• Fall protection and prevention
• Developing a dynamic Internal Traffic Control Plan
(ITCP) to prevent worker – equipment - traffic conflicts
during construction
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 Safe Operations and Traffic
Control in Construction Sites

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 Development of Internal Traffic
Control Plans
• What is an ITCP?
• Why develop ITCPs?
• How to develop an ITCP?
• What are the elements of an ITCP?

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 What is an INTERNAL Traffic
Control Plan (ITCP)?
• Plan for coordinating the flow of construction
vehicles, equipment, and workers operating within
the work space
– For improved safety within the work zone
• A typical ITCP addresses
– Parking issues within the work space
– Safe entry and exit of heavy equipment and trucks to and
from the work space
– Interactions of heavy equipment, trucks, and on-foot
workers.

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 Why Develop ITCPs?
• Provide an organized plan to coordinate
movements in the work area
• Minimize dangerous operations
– Backing and operating near soft shoulders
– Unguarded holes and slopes
• Prevent injuries and fatalities, while
providing efficient operations

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 Developing an ITCP
• Development and implementation of an ITCP should
be required for all major jobs
• Must accommodate changing requirements in
various stages of construction
• Should incorporate all relevant input/feedback from
employees
• Must be developed in coordination with the overall
traffic control plan

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 Developing an ITCP
• Basic principles of ITCP for conflicting
movements
– Separation by space
– Separation by time
– Controls
• Schematic diagrams needed for movement
of construction workers, vehicles and
equipment in the work space

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 Elements of an ITCP
• Typically, an ITCP should cover
– Roles and responsibilities of parties
– Site specific information
– Communication plan
– Schematic diagrams
– Hazard assessments
– Training of site personnel on ITCP
– Effectiveness evaluation

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 Elements of an ITCP –
Roles and Responsibilities
• Chain of command
• An ITCP coordinator assigned to the project
• Establish coordinator’s role and authority
• Establish employees’ roles in implementing the
ITCP

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Elements of an ITCP – Project Specific
Information
• Contact information (company personnel,
emergency services, etc.)
• Location, time table, and scope of project
• On-site equipment and personnel
• Interface between internal and external
traffic control plans

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 Elements of an ITCP – Hazard
Assessment and Control
• Checklist of site specific hazards and mitigation
methods
• Reporting system for incidents (and close calls)
• Safe procedures for traffic control in work space
• Anticipated traffic volumes, speeds, and speed limits
• Specifications for lighting
• Safe speed limits, clearances from high voltage power
lines, blind corners , warnings of drop-off hazards, etc.
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Elements of an ITCP – Communication
Plan
• Designated channels of communication for any
changes in plan
• Means of communications between on-foot
workers, equipment operators, truck drivers,
and other personnel
• Designation of personnel to monitor
communications between vehicle and
equipment operators
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 Elements of an ITCP - Training
• Training is essential for all personnel
• Orientation of truck drivers to work space
activities and ITCP
• To Banksman or flagmans, pedestrians and others
• Training delivered through
– Tool box safety meetings
– Distribution of site-specific safety materials (e.g. a copy
of ITCP, safety guidelines)
– Self-paced e-training
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Elements of an ITCP – Effectiveness
Evaluation
• Comprehensive approach
– Review of ITCP during normal work zone
inspections
– Review and analyze incidents, close calls, and
potential hazards
– Retain schematic drawings and other documents
for future use

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 A pick up truck parked behind the dump truck. Lack of proper planning for parking
causes workers to park in improper and unsafe locations inside work space.

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 An existing lane closed to traffic is utilized as an acceleration lane for trucks, but canalization is done
improperly. No designated exit point for trucks.

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 Limited work space - a challenge for internal traffic control and operations

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 Employee vehicle parked near equipment, and blocking the truck route

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 Parking near heavy equipment and crane
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 Safe Operation & Maintenance of
Heavy Equipment and Trucks in Work
Space
• Safe Equipment Operation around On-foot Workers
• Conflicting Movements of Trucks, Equipment and Workers
• Turning Radius and Geometry
• Safe Operation and Maintenance of Equipment

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 Safe Equipment Operation Around
On-foot Workers
• Separate on-foot workers from equipment as much
as possible
• Design the work space and operations to
eliminate/minimize backing and blind spots
• Train workers and equipment operators on
communication methods
• When necessary, use a spotter so the vehicles do
not run over workers or back into other vehicles

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 “pinch point”

Workers working too close to

working equipment against a
barrier

Shows an extremely hazardous condition where an on-foot worker is working very close to operating
equipment, and is in a tight space between the equipment and the barrier.
Never work so close to operating equipment, especially when there is a “pinch point”.

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 Conflicting Movements of Trucks,
Equipment and Workers
• Conflicts create potential for accidents
• Conflicts between
– Trucks and trucks
– Trucks and equipment
– Trucks and on-foot workers
– Equipment and on-foot workers
– Equipment and equipment
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 Conflicting Movements of Trucks,
Equipment and Workers
• Minimize conflicting interactions as much as possible
– Separation by space
– Separation by time
• Determine the locations of and design various internal
movements
– Entry and exit locations for trucks and equipment
– Truck and equipment routes within work space
– Other activity locations and pedestrian paths (e.g., rest room
locations, site office, etc.)
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Conflicting Movements of Trucks,
Equipment and Workers
• Separation by space
– Use channelizing devices, such as barriers
– Separate activities (e.g., excavating, grading,
staging, etc.)
• Separation by time
– Schedule work with safety in mind
• Arrival and departure of trucks
• Loading and unloading
• Combination of both approaches
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 Collisions within the work zone involving construction trucks and/or
equipment

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Conflicting Movements of Trucks,
Equipment and Workers
• Properly design the elements of internal traffic
control that cause conflicts
– Safe entry and exit points
– Speed change lanes
• Deceleration lane
• Acceleration lane
– Turning radius and geometry
– Traffic control devices
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Conflicting Movements of Trucks,
Equipment and Workers
• Design of entry and exit points
– Consideration of roadway geometry
– Locations of existing driveways
– Access design and management

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Conflicting Movements of Trucks,
Equipment and Workers
• Design of deceleration and acceleration lanes
– Length of speed change lanes
– Speed of trucks
• Terminal speed at entry/exit point
• Cruise/operating speed (speed of roadway traffic)
• Separate entry and exit points to reduce conflicts

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Rigid Barriers
Taper Length

Work Space

A Typical Diagram Showing an Acceleration Lane

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 Turning Radius and Geometry
• Turning radius and geometry at entry and exit points
– Varies with the type of vehicles
– Off tracking
• Larger vehicles - larger off tracking
• Off tracking can cause injuries/fatalities
• Turning radii must be designed by a qualified person
– Geometric design specialist

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 Turning radius for trucks should be designed properly

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 This figure shows the turning characteristics of a typical tractor/semi-trailer combination truck.

Refer to “A Policy on Geometric Design of Highways and Streets, 2001” for details.

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 This figure shows the minimum turning path for Intermediate Semitrailer (WB-12 [WB-40]) Design Vehicle.

Refer to “A Policy on Geometric Design of Highways and Streets, 2001” for details.

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 Safe Operation and Maintenance of
Equipment
• Only authorized personnel must operate or repair equipment
– Must be trained in safety
• Perform daily inspections and make the necessary repairs
– Keep operator manuals in the equipment cab and provide ready
access
• Equipment with poorly functioning safety devices (e.g. backing
signals, head and tail lights, etc.) are unsafe to operate
• Comply with OSHA Standard: 1926 Subpart O - Motor Vehicles,
Mechanized Equipment, and Marine Operations

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 Safe Procedures for Night Work

Worker Responsibilities:
– Stay alert
– Get plenty of rest. Don’t carry on daytime
activities and then work a night shift
– Be aware of surroundings, and the operations
around your work area
– Wear high visibility apparel

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 Safe Procedures for Night Work
Operations
Management Responsibilities
– Improve worker and equipment visibility
• Enforce use of hard hats with retroreflective material
and retroreflective clothing
• Encourage using flashing and warning lights on
vehicles and equipment (without distracting
motorists)
– Plan (through ITCP) to minimize on-foot workers
coming close to heavy equipment
– Ensure temporary lighting for workers does not
distract motorists
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 Additional Safety Considerations
• Avoid overhead power lines by maintaining the minimum
clearance (10 feet or more)
• Before excavation, call appropriate agency to locate
underground cables
• Use control measures to minimize silica exposure (e.g.
wet cutting/drilling, exhaust ventilation)
• Implement a Lead Exposure Control Plan outlining
– Engineering methods (ventilation, isolation)
– Administrative methods (personal hygiene practices)
– PPE (respirators, protective clothing)
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 Additional Safety Considerations
• Heavy equipment, power tools and external traffic creates
high sound levels during operations. Reduce exposure to
noise by:
– Sequencing work to keep workers distant from loud
equipment
– Using spoil piles, parked machinery, etc. as a sound barrier
– Prescribing ear protection
• Train workers on asphalt and concrete hazards and their
prevention
• Provide training on mitigation of heat and cold related
hazards
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 Additional Safety Considerations
• Follow proper housekeeping practices to reduce
trips and slips
• Train workers on safe lifting procedures to prevent
back injuries. Material handling equipment (e.g.
hooks, bars, rollers, and jacks) should be used when
it is unsafe to lift manually
• Safe procedures should be followed for cranes and
rigging operations

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 Additional Safety Considerations
• Hand and power tools shall be used, inspected, and
maintained in accordance with the manufacturer’s
instructions, and shall be used only for the designed
purpose
• Workers should be trained on the recognition and
prevention of electrical hazards
• Design of support and shield systems shall be selected
for excavations in accordance with OSHA Standard

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 Additional Safety Considerations
• A project - specific written hazard communication
program should be established. Copies of this program
must be available to all workers
• Appropriate fall protection and prevention procedures
must be in place for work performed at an elevation of 6
feet or higher
• Precautions must also be taken against falling objects
• Appropriate PPE shall be worn at all times as required

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 In many cases, workers do not use all required PPE . In the pictures , the workers are not using hard
hats and high visibility vests.

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 Worker is not wearing his safety vest

Worker is not wearing his steel-toed

boots.
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 No hard hat

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 Applicable Standards
For further information on additional safety considerations, refer to
the following OSHA standards:
• 1926.52 - Occupational noise exposure.
• 1926.59 - Hazard Communication
• 1926.62 - Lead
• 1910.146 - Permit-required confined spaces
• 1926.955 - Overhead lines
• 1926.956 - Underground lines
• 1926.25 - Housekeeping
• 1926 Subpart K Electric - General
• 1926 Subpart E - Personal Protective and Life Saving Equipment
• 1926 Subpart M - Fall Protection
• 1926 Subpart I – Tools – Hand and Power
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• 1926 Subpart P – Excavations
 Applicable Standards
• MIOSHA –Section B Construction
- CS Part 9 - Excavation, trenching, shoring
- CS Part 19 - Tools
- CS Part 45 - Fall Protection
- CS Part 6 - Personal Protective Equipment
- CS Part 16 - Power transmission and distribution
- CS Part 17 - Electrical Installation
- CS Part 42 - Hazard Communication
- GI Part 90 - Confined space entry
- OH Part 603 - Lead exposure
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 Applicable Standards
• CALOSHA –Subchapter 4 Construction Safety Orders (Sections
1500-1938)
– Article 3 – General –Sections(1913-1922)
– Article 6 - Excavations Sections(1539-1547)
– Article 24 –Fall Protection
– Article 28 – Miscellaneous Construction Tools and Equipment Sections
( 1693-1708)
– Article 33- Electrical Requirements for Construction Work
• CALOSHA –Subchapter 7 –General Industry Safety Orders
(Sections 2299-2974)
– Article 105 – Control of Noise Exposure-sections (5095-5100)
– Article 109-Hazardous Substance and Processes (Hazard
Communication –Sections 5194, Lead – Section 5198 )
– HSE
Article108 – Confined Space –Sections (5156 –5159)
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 Sample Photographs

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 Picture showing roadway work space in close proximity to motoring traffic

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 Barrels offset too far onto the lane
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 Worker shifting the offset drums inside.

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 Pedestrian in the work zone? Pedestrian crossing locations should be provided where
necessary.

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Equipment operator parked the equipment in central left turn lane, went to adjacent work space and now has come
back to move it.
This is not an expected situation by drivers in the work zone

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 Improper separation between working equipment and motoring traffic lane

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 Worker should not be talking on his cell phone
near the roadway

Worker should not be hanging on construction

vehicle. Note the improper clothing.

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 Equipment too close
to traffic

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 Worker between excavator, loader and moving traffic

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 Moving traffic close to loading truck and excavator

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 Loader with loaded material and moving traffic together
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 Excavator too close to through lane
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 Questionable physical separation between through traffic and heavy equipment – space for
swing radius of the equipment is a problem

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 Continuous physical separation between through traffic and equipment should be provided
where necessary
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 Workers working under operating crane; vehicle parked inside work space; and workers without
hard hats and safety vests

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 A worker with a jack hammer close to through lane – Chipping hazard to moving
traffic

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 Summary
• Injury potential is extremely high in highway and street
construction work zones
• Half of highway and street construction workers are killed by
construction trucks and equipment
• Development of Internal Traffic Control Plans is essential for
safe operations inside the work space
• It is imperative to eliminate conflicting movements of trucks,
equipment and workers
• Most of the construction site hazards also exist inside the
work space

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