Module 2: Safe Operations and Internal Traffic Control in the Work Space

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 (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)

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 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

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

16. 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?

17. 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.

18. 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

19. 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

21. 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

22. 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

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.

25. 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

26. 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

27. 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

28. 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

29. 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

48. 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.