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Presenters:Jennifer Beaupre
Mat Hause and Bob Hammer
Preventing Workers from Being Struck by Roadway Construction Equipment
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NIOSH PublicationBuilding Safer Highway Work Zones: Measures to Prevent
Worker Injuries from Vehicles and Equipment
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OutlineBackgroundFatality InvestigationsBlind Area MeasurementsPrevention Measures
Administrative ControlsEngineering Controls
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910 worker deaths in work zones from 1992-2000 826 (91%) were vehicle or equipment-related (traffic vehicle, construction vehicle, or both)
Background
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Worker Fatalities in Roadway Construction
0
20
40
60
80
100
120
140
1992 1993 1994 1995 1996 1997 1998 1999 2000
Year
Dea
ths
Trend from 1992-2000 (n=910)
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Worker Fatalities in Roadway Construction
Construction vehicles account for as many “worker on foot” deaths as traffic vehiclesConstruction vehicle deaths are responsible for the recent increase in worker deaths
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Worker Fatalities in Roadway Construction
01020304050607080
1992 1993 1994 1995 1996 1997 1998 1999 2000
Year
Dea
ths Construction vehicle
Traffic vehicle
Both
Deaths by Vehicle Type and Year, 1992-2000 (n=797)
Source: Census of Fatal Occupational Injuries, special research file (excludes NYC)
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Worker Fatalities in Roadway Construction
0 100 200 300 400 500 600 700 800
All other
Services
Public administration
Other construction
Bridge construction
Special trades contractors
Highway and street construction
Indu
stry
Deaths
Source: Census of Fatal Occupational Injuries, special research file (excludes NYC)
Deaths by Industry, 1992-2000 (n=910)
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Workers on Foot – Construction Vehicle Only
0 20 40 60 80 100 120
Other vehicle/other source
Other machine
Other/unspec truck
Excavating machine
Grading/surfacing machine
Semi-truck
Dump truck
Veh
icle
Deaths
Source: Census of Fatal Occupational Injuries, special research file (excludes NYC)
Deaths by Construction Vehicle Type, 1992-2000 (n=258)
41%
14.3%
14%
7.7%
10.4%
6.5%
6%
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Backing Fatalities in Roadway Construction
0 10 20 30 40 50 60 70
Other machine or vehicle
Other/unspec truck
Pickup truck
Semi-truck
Grader or scraper
Dump truck
Veh
icle
Deaths
Source: Census of Fatal Occupational Injuries, special research file (excludes NYC)
Deaths by Construction Vehicle Type, 1992-2000 (n=130)
52%
9%
7%
5%
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Fatality Investigations
http://www.cdc.gov/niosh/face/faceweb.html
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Participating FACE States
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Example Fatality Cases Case 1: 45-year-old boom truck driver run over
by dump truck that was backing during a repositioning maneuver.
Case 2: 31-year-old worker run over by front-end loader at the site of a crushing machine.
Case 3: 35-year-old laborer run over by dump truck at roadway resurfacing operation.
Case 4: 54-year-old laborer run over by motor grader at housing development roadway under construction.
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Case 1
Minnesota Face Program (MN9207)
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Turn-around
Pave
r
Truck Line
Concrete Paving Operation Layout
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XX
Truck Line
Turn-around
New Truck
Last Truck
Truck Queue Repositioning
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Case 2
Minnesota FACE Program (98MN030)
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Original Site Layout
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Redesigned Site Layout
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Two-lane County Road -- Four-lane State Highway
Case 3
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Two-lane County Road
Paving Machine
RollerTruck
Victim’s Work Area
Victim
Flagger
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View from the Street
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View from Inside the Cab
Bug Shield
Stickers
Fan
Air Cleaner and Door Post
Mirror
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Case 4
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View from Grader
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Ensure that trucks are equipped with audible back-up alarm and look into installing rear sensing unitsInstall strobe lights on all company-owned work trucksMaintain equipmentHeavy equipment should be driven in the forward direction as much as possible
Summary of Safety Hazards Identified in FACE
Investigations
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Summary of Safety Hazards Identified in FACE
InvestigationsHave a comprehensive safety planConduct a pre-work safety meeting to discuss potential hazardsPedestrians should wear high visibility clothing and head gear
http://www.cdc.gov/niosh/face/faceweb.html
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Prevention MeasuresInclude:
Identifying Blind AreasAdministrative Controls
Backing Safety ProgramInternal Traffic Control Plans
Engineering ControlsProximity Warning Systems
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Blind Areas
LCDR Mat HauseSafety Engineer
NIOSHMorgantown, WV
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Definition of Blind Area
A blind area is the area around a vehicle or piece of construction equipment that is not visible to the operators, either by direct line-of-sight or indirectly by use of internal and external mirrors.
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ProblemWorkers must be near moving equipmentBlind areas around equipment extensive
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Vehicle Blind Spots
Running over people
Running over materials
Striking other equipment
and vehicles
Rollovers
Contact with utilities
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Working in Work Zones
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Non-Construction Vehicle Blind Spot Measurements
What About Construction Equipment?
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Operator sight distancesfrom eye level to ground
Vehicle: L-132 5 ton Dump Truck
Area of fullyobstructed view
The No-Zone
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Methods
Manual methods
Computer method
International Organization for Standardization (ISO) 5006
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Manual Light Bar Method
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Target Stand
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Blind Area Diagrams - Ford 880
Ground Construction Barrel Worker ~3ft partially bent over
~5ft
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Marking Blind Areas Within a Polar Grid
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Blind Area Determination
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Blind Area
Not Visible to Operator
Visible in mirrors only
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Comparison of Manual Methods
Field Crew Light Bar
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Hazard Area Analysis
Vehicle operating speedsVehicle direction of movementWorker reaction time
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Hazard Area Around Ford 800 Dump Truck
Greatest Risk
No Risk
Dump Truck
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Hazard Area Around Ford 800 Dump Truck
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Future WorkComplete blind area diagrams for 14-16 more pieces of construction equipment.
Package and distribute comprehensive blind area diagram document.
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Conclusions
With these techniques, worker exposure assessments across the different types & makes of construction equipment are possible.
Understanding where current visibility limitations are around heavy equipment, and what levels of risk exist, will aid in the development of new protective technologies, worker training, and safer operational procedures.
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Contract Deliverable
Center for Disease Control and Prevention
Contract 200-2002-00563
“Construction Vehicle and Equipment Blind Area Diagrams”
Final Report
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Questions?Questions?Questions?
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Prevention Measures (con’t)Administrative Controls
Backing Safety ProgramInternal Traffic Control Plans
Engineering ControlsProximity Warning Systems
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Administrative Controls
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Key Elements of a Vehicle Backing Safety ProgramEquipment designed to minimize blind areas
Equipment inspections/preventative maintenance
Layout work areas to avoid backing
Use of spotters
Training for operators and workers on foot
Use of high visibility vests
Use of other backing safety devices (engineering controls)
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Backing Safety Program Prevention Measures
Equipment designed to minimize blind areas
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Backing Safety Program Prevention Measures
Operator Training:Avoid having to backup
Do walk around
Be aware of blind areas
Use a spotter
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Backing Safety Program Prevention Measures
Worker Training:Be aware of equipment blind areas
Stay out of all blind areas and swing radius
Make positive eye contact with operators
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Operator Human FactorsExpectancyPerception timeReaction timeAbility
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Worker Visibility:Require workers to wear high-visibility clothing.
Apparel that covers moving parts of the body is best.
Consider apparel with different designs front and back.
Backing Safety Program Prevention Measures
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Internal Traffic Control Plans
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Why Develop an Internal Traffic Control Plan?
Coordinate vehicle/equipment movement inside the work zoneLimit exposure of workers on foot to construction trafficReduce hazards for equipment operators
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Traffic Control Plans
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Proposed Definition of Internal Traffic Control Plans (ITCP)
“STRATEGIES TO CONTROL THE FLOW OF CONSTRUCTION WORKERS, VEHICLES AND EQUIPMENT INSIDE THE WORKZONE”
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ITCP Principles of Safe Construction Traffic ControlReducing the need to back up equipment
Limiting access points to work zones
Establishing pedestrian-free areas where possible
Establishing work zone layouts commensurate with type of equipment
Providing signs within the work zone to give guidance to pedestrians, equipment and trucks
Designing buffer spaces to protect pedestrians from errant vehicles or work zone equipment
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Notes PageSafety PointsPersonnelEquipment
Legend• Method Specific
Work Area Diagrams• Dimensions• Movement Flow• Workzone Limits• Signage
ITCP Components
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Safety Points:No workers in traffic zoneSpotter uses hands free radio to talk to trucksNo workers on foot between a backing truck and the paverNo rollers within 50 feet of the back of the paverInspectors remain away from paving train and notify spotter before obtaining samples
Internal Traffic Control Plan
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PEDESTRIAN-FREE ZONE
TRUCK MOVEMENT
DIRECTION OF TRAFFIC
DIRECTION OF TEMPORARY TRAFFIC OR DETOUR
CHANNELING DEVICE(S)
SIGN (SHOWN FACING RIGHT)
- On foot personnel classes -
OTHER CLASS
SURVEYORINSPECTOR
FLAGGERSPOTTER
FOREMANPEDESTRIAN WORKERP
D
I S
F
A
LIGHT(S)
BARRIER
PORTABLE LAVATORY
Internal Traffic Control PlansSymbols’ Legend
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WATER TRUCKOIL TRUCK
DUMP TRUCK (FULL)
DUMP TRUCK (EMPTY)
DOZER
BACKHOE
FRONT LOADERGRADER
PAVING MACHINEROLLER
OIL WATER
CRANE FORKLIFT
SWEEPER
- Vehicle Types -
BOTTOM DUMP
PICKUP TRUCK MILLING MACHINE
Internal Traffic Control PlansSymbols’ Legend
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Internal Traffic Control PlansPaving Model Plan – Traffic Adjacent
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Review TCP (for Work Zones) and Other
Contract Documents
Determine Site Specific ITCP Needs
Draw Work Space
Add Pedestrian and Equipment Paths
Locate Staging Areas
Prepare Notes and Plan
Steps in Preparation of ITCPs
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Internal Traffic Control PlanHow-To Guide
Internal Traffic Control PlanInternal Traffic Control PlanDraft Development GuideDraft Development Guide
Internal Traffic Control Plans for Internal Traffic Control Plans for Asphalt Paving Operations Asphalt Paving Operations
On Freeway SegmentsOn Freeway SegmentsTask 8.1Task 8.1
Contract No. 200Contract No. 200--20022002--0059600596
Submitted to theSubmitted to the
CENTERS FOR DISEASE CONTROLCENTERS FOR DISEASE CONTROLand PREVENTIONand PREVENTION
CONTRACTS MANAGEMENT BRANCHCONTRACTS MANAGEMENT BRANCHSubmitted bySubmitted by
C.L. Williams Consulting, Inc.C.L. Williams Consulting, Inc.4720 W. Maverick Lane, Suite #1034720 W. Maverick Lane, Suite #103Lakeside, Arizona 85929Lakeside, Arizona 85929
June 19, 2003June 19, 2003
Revised Internal Traffic Control PlanRevised Internal Traffic Control PlanSite 2Site 2
Internal Traffic Control Plans forInternal Traffic Control Plans forAsphalt Paving Operations Asphalt Paving Operations
On Freeway SegmentsOn Freeway SegmentsTask 7.1Task 7.1
Contract No. 200Contract No. 200--20022002--0059600596
Submitted to theSubmitted to the
CENTERS FOR DISEASE CONTROLCENTERS FOR DISEASE CONTROLand PREVENTIONand PREVENTION
CONTRACTS MANAGEMENT BRANCHCONTRACTS MANAGEMENT BRANCHSubmitted bySubmitted by
C.L. Williams Consulting, Inc.C.L. Williams Consulting, Inc.4720 W. Maverick Lane, Suite #1034720 W. Maverick Lane, Suite #103Lakeside, Arizona 85929Lakeside, Arizona 85929
May 16, 2003May 16, 2003
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Engineering Controls
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Blind Spot Intervention Types
Backup alarmsSpottersVisual DevicesSensors/Parking AidsOther/Hybrid devices
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Evaluating SystemsPreliminary test in parking lot.• Feasible to mount system
on trucks?• Minimal false alarms?• Reliable detection of a
person?Long term test.• System evaluation forms• Driver interviews• First hand observations
during ride-along• Winter and summer tests
Which work best for construction sites?
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Systems Selected for Long Term Tests with
WSDOT
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Radar SystemsPreview
Preco Electronics Guardian Alert
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Camera Systems
Clarion heated camera Intec camera
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Ultrasonic System
Sensors
Hindsight 20/20
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Camera and Radar Sanding Truck
Two systems selected for winter tests on a sanding truck:
Preco’s Preview radarClarion heated camera with shield
2 month test (Dec. –Jan.) in harsh conditions
Camera
Radar
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Camera and RadarSanding Truck
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Camera and RadarSanding Truck
Results:Camera and radar effective in dry conditionsProblems in snow, rain:
Snow, ice, mud build-up after 5 milesCamera lens shield froze then brokeRadar false alarms from snow and mud on antenna
Improvements needed!
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Camera and RadarDump Truck
Camera and radar worked best when mounted highCould not mount either system on the tailgate or hitch areaDesigned bridge for mounting systems
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Camera and RadarDump Truck
Radar detection of a standing person
Camera field of view
Crouching person not detected here
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Camera and Radar Dump Truck
Results:Ride-along showed very few false alarms from radar, but camera more usefulClearance problem with bridge under asphalt loading bins and wheeled loadersBridge won’t work -camera and radar must be mounted on dump box
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Hindsight SonarDump Truck
Ultrasonic-based system
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Hindsight Sonar Dump Truck
Results:Drivers said system is reliable in most conditions
Concerned about detection range of 8 ft
Some false alarms in heavy dust
Constant false alarms when trailer is being pulled (optional trailer system needed)
Tests continue on smaller vehicles
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Intec Camera SystemDump Truck
Small camera that can mount on side of dump boxSize of 2 inch cube
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Intec Camera SystemDump Truck
Results:Small size allowed for good mounting locationMost drivers found it usefulReliable operation during 5 month testWould have problems in winter
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Guardian Alert Radar SystemDump and Bridge Insp. Trucks
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Guardian Alert Radar SystemDump and Bridge Insp. Trucks
Results:Small and easy to mountDoes not detect people very wellGood detection of other objects
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ConclusionsSensor systems (radar, sonar, infrared):
False alarms are possibleNuisance alarms can be numerous in crowded work areas
Camera systems:Provide view of blind areaDo not alarm so potential collision may go unnoticedMay not work in winter conditionsGood solution for crowded work zones during warmer months
A combination of sensors and a camera may be best solution for warmer months
Alarm prompts driver to check videoVideo allows driver to check source of alarm
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System ImprovementsPrevious test results prompted Preco to modify their radar system:
Smaller packageIgnores some mud/snow on sensor faceTests on 3 dump trucks this spring
Radar antenna
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System ImprovementsIntec developing new cameras for winter-time use:
Small, heated enclosureInnovative methods to keep lens cleanWinter tests to be scheduled
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New IdeasThe TagView System
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www.cdc.gov/niosh
NIOSH PublicationEvaluation of Systems to Monitor Blind Areas Behind Trucks
Used in Road Construction and Maintenance: Phase 1