Work Zone Safety in Construction

Protecting workers on road and
highway construction sites
Presented by:
The Windsor Consulting Group, Inc.
Road Construction Work
Zone Safety
WCG
Copyright © 2014 The Windsor Consulting Group, Inc.

Safety in Road Construction Work Zones

What this presentation covers
 Road construction hazards
 Roadway worker fatalities
 Traffic control measures
 Construction vehicle blind spots
 How to protect roadway workers
 Resources

Introduction
Workers in construction, utilities, or public works jobs on
both highways or city streets are at risk of fatal or serious
debilitating injuries.
The work is in congested areas
with exposure to high traffic
volumes and speeds, as well as
under conditions of low lighting,
low visibility, and inclement
weather.
The work is routinely near both
moving construction vehicles and
passing motor vehicle traffic.

Are roadway workers exposed or at risk?
Workers in temporary traffic control work zones are
exposed to risk of injury from construction vehicles and
motorized equipment:
 Operating in andOperating in and
around the activearound the active
work zone(s)work zone(s)
 Operating in trafficOperating in traffic
control or secondarycontrol or secondary
areas that supportareas that support
the work zonethe work zone
(temporary batch(temporary batch
plants)plants)

 Entering and leavingEntering and leaving
the work zonethe work zone

This attenuator truck was rear ended at
63 mph by an inattentive driver, despite
workers’ attempts to get the driver’s
attention.
Two workers were hurt and the driver
received minor injuries.
The driver pled guilty to reckless
endangerment of a road-way worker. 0
How are roadway workers at risk?
Workers in the roadway are at risk of injury from a variety of
general traffic vehicles entering the work zone:
• Drunk drivers
• Sleepy or impaired drivers
• Impatient, reckless drivers
• Drivers using cell phones;
other inattentive drivers
• Law enforcement and
emergency vehicles
• Disabled vehicles pulling in
and parking
• Lost drivers looking for
directions
Courtesy of Washington State Dept. of Transportation

How are workers on foot at risk?
Flaggers and other workers on foot are exposed to
the risk of being struck if they are not visible to
motorists or equipment operators.
Workers on foot refers to any pedestrian
worker on the ground in the work zone
Driver’s view
passing by a
work zone under
overcast/rainy
conditions...
Do you see the
flagger?

Source: NIOSH/CDC. “Deaths Caused by Vehicles and Heavy Equipment on Construction Sites”,
Other trades
33%
Truck drivers
9%
Construction
laborers
42%
Operating
engineers
9%
Supervisors
7%
Distribution of Work Zone
Fatalities by Occupation

Collision between
Vehicles
10%
Noncollision
Highway Incidents
9%
Nonhighway
Transportation
Incident
8%
Highway
Transportation
Incident
23%
Caught in
Equipment or
Object
5%
Struck by Object
7%
Struck by Falling
Object
4%
Contact with
Objects and
Equipment
14%
Fall to Lower
Level
3%Harmful
Substances or
Environment
5%
Contact with
Current
(Electrocution)
4%
All Others
8%
(Source: Bureau of Labor Statistics)
Events Leading to Worker Fatalities

Picture showing roadway work spacePicture showing roadway work space
in close proximity to motoring trafficin close proximity to motoring traffic

Barrels offset too far onto the lane

Worker shifting the offset drums insideWorker shifting the offset drums inside.

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

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

Improper separation between workingImproper separation between working
equipment and motoring traffic laneequipment and motoring traffic lane

Worker should not beWorker should not be
hanging on constructionhanging on construction
vehicle. Note thevehicle. Note the
improper clothing.improper clothing.
Worker should not beWorker should not be
talking on his cell phonetalking on his cell phone
near the roadwaynear the roadway

Worker between excavator, loader, andWorker between excavator, loader, and
moving trafficmoving traffic

Excavator too close to through laneExcavator too close to through lane

Workers working under operating crane; vehicleWorkers working under operating crane; vehicle
parked inside work space; and workers withoutparked inside work space; and workers without
hard hats and safety vestshard hats and safety vests

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

How are equipment operators at risk?
Workers who operate construction vehicles or
motorized equipment risk injury due to rollovers,
collisions, being caught between or struck by
operating equipment.
Overturned compactor on loose soil

Turning radius for trucks should be designedTurning radius for trucks should be designed
properlyproperly
How are equipment operators at risk?

 Abilities
– Communicate
– Move and maneuver
– Control signaling
devices
– Understand Temporary
Traffic Control practices
– Recognize dangerous
situations, warn workers,
drivers and pedestrians
– Personal protective
equipment
Flagger Qualifications

Flagger Personal Protective Equipment

Using cell
phone in
middle of
the lane
(distraction)
Improper Personal Protective Equipment
No shirts (and
other PPE)
No steel toed
shoes

Flagger Hand Signals
 Stop/Slow Paddle
– Stop command
– Proceed command
– Alert/Slow command

Flagger is not using hard hat
Improper Flagging Techniques
Flagger is sitting while working
Flagger is not
flagging, is not
using hard hat
and is facing
back to traffic

Automated Flagger Assistance Devices

One Lane – Two Way Traffic Control
Flaggers

Traffic Control Component Distance
• Buffer Space
• Tapers
• Advance Warning

Traffic Control Component Distance

Traffic Control Component Devices
• Proper response
time
• Design
• Placement,
Operation
• Maintenance

10 WORKER DEATHS occurred
in New Jersey and 16
WORKER DEATHS occurred in
New York roadway work
zones in 2012
A total of 609 WORKER
DEATHS occurred across
the country
91% of these were related
to motor vehicle traffic,
construction equipment, or
both
Source: Fatality Analysis Reporting System (FARS) 2012 ARF, NHTSA
How bad is the problem of road
construction workers fatalities in the
United States?

 From 2003 to 2010, 962
workers were killed at
road construction sites
 Nearly half of these
deaths resulted from a
vehicle or mobile
equipment striking the
worker
 Analysis shows workers
died when they were
working at or passing
through the road
construction site
Worker Fatalities in Roadway Work Zones
Emergency vehicles at accident scene

• Dump trucks were
responsible for 41%
of the “worker on
foot” related deaths
• 52% of these involved
dump trucks backing
up!
Worker Fatalities in Roadway Work Zones
Victim (under sheet) who was
backed over by the Dump Truck

No rigid barriers to
separate workers
from passing traffic
Hazard to On-Foot Worker: Type of
Barrier

Truck may be
traveling at a
high speed
Worker is in traffic lane
Worker Hazard: Too Close to Traffic Lane

Workers in close proximity to equipment
Worker Hazard: Too Close to Equipment

Working too close to equipment against a rigid barrier
(possible pinch point)
Hazards to On-Foot Workers

NJ and NY Roadway Worker Fatalities
17 workers were killed in
traffic control work zones
between 2012 and 2013
• 10 deaths involved
construction equipment
• 15 were workers on foot
- 8 killed by dump trucks
(6 were backed over)
- 7 deaths resulted from
motorist traffic entering
the work zone
- 2 were ejected from
equipment and crushed
(not wearing seat belts)

Traffic Control Around the Work Zone
Flaggers and other workers
assigned traffic control
responsibilities work very
close to motor vehicles and
are at risk of getting struck or
run over by them.
Flaggers:
Trained in traffic control
techniques
Valid Traffic Control Flagger
card (or card from a state
with reciprocal flagger
training)

A Traffic Control Plan helps move
motorist traffic safely through or
around roadway work zones to
protect the public and workers.
•Use of traffic control devices,
standard signage, and buffer and
transition zones.
•When flaggers will be used on a
job lasting more than one day,
there must be a current site-
specific traffic control plan that is
kept on site.
Traffic Control Around the Work Zone
Example template from the Manual
on Uniform Traffic Control Devices
Site-specific Temporary
Traffic Control Plans

• Temporary Traffic Control zone,
construction vehicles and equipment
moving inside create a risk to
workers on foot requiring additional
protection planning and policies to
minimize backing-up maneuvers in
the “activity area”
• Temporary Traffic Control “Activity
Area” is section of highway where the
work activity takes place. It is made
of work, traffic, and buffer spaces.
• “Work space” is that portion of road
closed and set aside for equipment,
workers, and material.
• Work spaces are usually delineated
from the traffic space, to exclude
vehicles and pedestrians, by
channelizing devices or temporary
barriers and signs.
Temporary Traffic Control Plan
Temporary Traffic Control Plans
Paving Model Plan – Traffic Adjacent
Example:

Temporary Traffic Control Plan
•Restrict personnel access points into
work areas and designate “no
backing zones” and “pedestrian-free
zones”
•Design flow paths for equipment
and vehicle traffic to minimize
backing maneuvers and buffer
spaces to protect pedestrian workers
from traffic vehicles and/or work
zone equipment
•Establish procedures for entering
and exiting work zone
•Train all employees on the plan and
its precautionary measures

Hazardous Work Environment
(Poor Visibility)
Hard to see a
worker in the
shadow of a truck
Lack of high
visibility
apparel/vest

Working at Night
• Visibility is greatly reduced at night.
• Your risk of getting injured or killed increases in the dark.
• Drivers may be more tired, sleepy, and less attentive.
Hazards and Risks:
• Poor visibility
• Glare off lights
• Adverse weather
conditions
• Tired drivers
• Inattentive workers

Working at Night
• Being aware of your surroundings at
ALL TIMES
• Wearing High Visibility Apparel
• Arranging good work area lighting
• Setting up proper traffic controls
• Knowing the traffic flow plan/pattern
Protect yourself when you must work at night by:

Working Around Vehicles/Heavy Equipment
A blind spot (or blind area) is the area around a vehicle
or piece of construction equipment that is not visible to
the operator, either by direct line-of-sight or indirectly
by use of internal and external mirrors.
This compact wheeled loader, with its bucket raised,
is approaching the work site and no one is watching.

Blind Spots or Areas
Example: this mapping
diagram shows the blind
areas around a Ford F-800
dump truck.
8 ft in front and 16 ft in
rear are the most
hazardous areas.
The driver side door area
is the only zone within 8
feet of the dump truck
that is safely visible.

Blind Areas: Struck-By or Run Over
DRIVER’S and OPERATORS
What happens when you can’t see around you?
HAZARDS:
● Running over or
striking pedestrians
● Smashing site
materials and tools
● Striking other
equipment or vehicles
● Rollover on steep
slopes
● Contact with utilities Figure in white shows where the worker
was standing when he was run over.
The driver did not see the victim.
“Roadway Construction Worker Dies
From Crushing Injuries When Backed
Over by a Dump Truck”

Broken windows
Hazards of Heavy Equipment: Impaired Vision

Vehicle Blind Spots
Construction equipment is
typically large and has an
enclosed cab, which can
make the blind areas
around this equipment very
large and hard to see.
The bigger the equipment
the larger the blind spots
or hazardous areas for
pedestrians and ground
workers.
The problem is that pedestrian or ground workers
Often need to be near moving equipment and vehicles
to perform their work.
Operator’s view from inside a motor
grader cab

Vehicle Blind Spots
Driver's field of view inside of a tanker
truck. Can you see the workers in front of
and directly to the right of bug shield?
(circle)
Truck drivers and equipment operators sit high above
the ground and cannot see pedestrian workers
crossing close to front of them.
Obstructions in a driver’s
LINE of SIGHT might be:
• Cab arrangements
• Mirrors
• Door and window post
• Stacks and air cleaners
• Bug shield or other
ornamentations
•Box, tank, and other
equipment
configurations

Vehicle Blind Spots
Tools/Attachments on vehicles can create greater
blind spots, reduce visibility, or swings that increases
the risk to workers being struck or pinned.
Watch out for heavy
equipment moving with
raised buckets
Be ready for possible sudden
movements of booms or
changes in direction of
equipment operationKnow equipment swing radius
(how far can it reach, move or rotate)

 Don’t cross directly in front of
or immediately behind large
heavy equipment or trucks
where the operator sits higher
in the vehicle.
 Communicate with an operator
(verbally and/or by eye
contact) before entering any
area near heavy equipment or
large trucks.
 Stand near parked equipment
or trucks, in front or operator
side so if equipment comes into
use, the operator can see you
and you can see them.
How can you protect yourself
when working near heavy equipment?
Vehicle Blind Spots
Courtesy of Construction Safety
Association of Ontario

Operating Dump Trucks in Reverse
Before backing a dump truck the
driver must determine that no one is
currently in the backing zone and it
is reasonable to expect that no
employee will enter the backing
zone while operating the dump truck
in reverse.
If employees are in the backing
zone or it is reasonable to expect
that an employee will enter the
backing zone, you must make sure
the truck is backed up only when:
- An observer signals that it is safe to
back; or
- An operable mechanical device that
provides the driver a full view behind
the dump truck is used, such as a
video camera.
Backing Zone
(Distances in feet)
The backing zone is defined by the shaded
area. The driver cannot see anything in the
blind spot, either directly or by using mirrors.
Because of the significant number
of deaths caused by backing
dump trucks, Washington
adopted this rule directed at their
operation.

If employees are in the backing zone or it is reasonable to expect that
employees will enter the backing zone behind a dump truck, then ensure that:
AND
An observer who signals when it is
SAFE to back up or stop
OR
the vehicle has an operable device
installed which provides the
driver a FULL VIEW of the area
behind the dump truck
The vehicle has an operable automatic reverse signal
alarm which is audible above surrounding noise level;
and is audible at least 15 feet from rear of the vehicle
Courtesy of Construction Safety
Association of Ontario

Exemption to Rule
Workers are considered protected when they are on the opposite
side of a fixed barrier such as a jersey barrier or a six-inch concrete
curb or heavy equipment like a paving machine.
The left photo show a
camera mounted on
the rear of the
vehicle - the monitor
is mounted in the cab
of the truck.
An “operable mechanical device” provides the driver
with a full view behind the dump truck can be a video
camera.

How Do You Protect Workers in
Roadway Work Zones?
 A comprehensive Site-specific
Safety Program (APP)
 A Temporary Traffic Control
Plan in place for the project site
 Conducted crew meetings and
trained all workers on work
zone safety; discussing
potential hazards, equipment
blind spots, movement
precautions in the activity area
Employers must have...

Roadway Work Zones?
Workers must:
(1) Wear high-visibility safety
apparel (vest & head gear)
(2) Be alert for construction
vehicles, equipment and general
traffic
(3) Check surroundings for hazard
(4) Know plan for traffic flow
(5) Keep a safe distance from
traffic
(6) Communicate with other
workers, especially when there
are changes in procedures,
locations, or traffic flow pattern

Pedestrians and Workers
 Keep in eye contact with
operators when working
near moving equipment
 Remember equipment blind
spots and limited visual
areas
Equipment/Vehicle Operators
 Keep windows and mirrors
clean
 Watch for workers on foot;
know where they are
 Remember equipment blind
spots and limited visual
areas
Can you see the parked vehicles
through this window?
Roadway Work Zones?

 Stay behind protective
barriers where possible
 Do not linger or cross into
areas around moving
equipment if you have no
reason to be there
 Use extra precautions and
additional safety apparel
at night and during poor
weather conditions
Roadway Work Zones?

Rolled over equipment
Equipment Rollovers

Equipment Rollovers

Truck/equipment in potential contact with overhead
power lines, which may result in electrocution
Overhead Power Lines

Parked car too close to heavy
equipment in operation
Incident involving parked car
and loader
Parking Hazards

More Information and Resources
 DOSH – Noise in Road Construction:
http://www.lni.wa.gov/Safety/TrainTools/Online/Cours
 Federal Highway Administration – work zone
mobility & safety program: FHWA Work Zone
 OSHA – Compactor Rollover Hazard -
Compactor Rollover Hazard
 NIOSH – Highway Work Zone Safety:
NIOSH Topic: Highway Work Zone Safety | CDC/NIOSH

Work Zone Safety in Construction

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