Module 2:

1
Module 2 Safe Operations and Internal Traffic
Control in the Work Space
2
Overview of Module 2

• 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

3
Introduction and Background

• Highway and street construction (HSC) 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)

4
Typical Work Activities Within Work Space
5
Typical work zone activities
6
Facts and Statistics

• Injury and fatality exposures are extremely high
  in highway work zones
• Each year, over 100 HSC workers are killed and
  more than 20,000 are injured
• Half of the HSC 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

7
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.

8
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.

9
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.

10
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

11
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

12
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

13
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

14
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

15
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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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

20
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 coordinators role and authority
• Establish employees roles in implementing the
  ITCP

23
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

24
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 ITCP Diagrams

• Typically include
• Standard symbols for pieces of equipment and
  project personnel on site
• A layout of the work space positioned in the
  overall work zone
• Locations of proximate traffic control devices
  (e.g. drums, cones, etc.)
• Areas around equipment and operations prohibited
  to on-foot workers

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Elements of an ITCP ITCP Diagrams

• Also, diagrams showing
• Locations for staging, storing and servicing
  materials and equipment
• Locations of visitor and worker parking areas
• Dimensions and locations of lateral buffer zones
• Description of internal signage and all internal
  traffic control devices

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30 ft trench Pedestrian free area
Sample Internal Traffic Control Plan for
Trenching Work in a Highway Work Zone
60 ft backfill Vehicle free area
Source Graham - Migletz
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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
• 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

30
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

31
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.
32
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.
33
Limited work space - a challenge for internal
traffic control and operations
34
Employee vehicle parked near equipment, and
blocking the truck route
35
Parking near heavy equipment and crane
36
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

37
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

38
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.
39
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

40
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.)

41
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

42
Collisions within the work zone involving
construction trucks and/or equipment
43
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

44
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

45
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

46
Rigid Barriers
Taper Length
Work Space
A Typical Diagram Showing an Acceleration Lane
47
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
49
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.
50
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.
51
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

52
Safe Procedures for Night Work

• Worker Responsibilities
• Stay alert
• Get plenty of rest. Dont 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

53
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

54
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)

55
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

56
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

57
Additional Safety Considerations

• Hand and power tools shall be used, inspected,
  and maintained in accordance with the
  manufacturers 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

58
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

59
In many cases, workers do not use all required
PPE . In the pictures , the workers are not using
hard hats and high visibility vests.
60
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
• 1926 Subpart P Excavations

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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
• OH Part 680 - Noise 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 )
• Article108 Confined Space Sections (5156
  5159)

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Sample Photographs
66
Picture showing roadway work space in close
proximity to motoring traffic
67
Barrels offset too far onto the lane
68
Worker shifting the offset drums inside.
69
Pedestrian in the work zone? Pedestrian crossing
locations should be provided where necessary.
70
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
71
Improper separation between working equipment and
motoring traffic lane
72
Worker should not be talking on his cell phone
near the roadway
Worker should not be hanging on construction
vehicle. Note the improper clothing.
73
Equipment too close to traffic
74
Worker between excavator, loader and moving
traffic
75
Moving traffic close to loading truck and
excavator
76
Loader with loaded material and moving traffic
together
77
Excavator too close to through lane
78
Questionable physical separation between through
traffic and heavy equipment space for swing
radius of the equipment is a problem
79
Continuous physical separation between through
traffic and equipment should be provided where
necessary
80
Workers working under operating crane vehicle
parked inside work space and workers without
hard hats and safety vests
81
A worker with a jack hammer close to through lane
Chipping hazard to moving traffic
82
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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End of Module 2