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Design for Safety (DfS)

Design for Safety (DfS) . Driving Out Project Costs Frank Wampol CHST Corporate Safety Director, B.L.Harbert International John J. Placey CSP SVP Risk Control Willis of Alabama Inc . “Last picture I ever took…”. J. DfCS Practices Around the Globe.

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Design for Safety (DfS)

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  1. Design for Safety (DfS) Driving Out Project Costs Frank Wampol CHST Corporate Safety Director, B.L.Harbert International John J. Placey CSP SVP Risk Control Willis of Alabama Inc

  2. “Last picture I ever took…” J

  3. DfCS Practices Around the Globe • Designers first required to design for construction safety in the United Kingdom in 1995 • Other European nations have similar requirements • In Europe, a 1991 study concluded that 60% of fatal accidents resulted from decisions made before site work began • Australia also leading in DfCS http://www.ascc.gov.au/ascc/HealthSafety/SafeDesign/Understanding F

  4. Here at home • Industry studies show 30% of work related injuries are design or lack of design related • 6000 people on average die of work-related injuries or illnesses • 250,000 illnesses, 4 million injured • $130 billion in costs • Currently there are no requirements for construction safety in building codes F

  5. DfCS = Design for Construction Safety (constructability) • An extension of DfS to coverconstruction projects • Recognizes construction site safety as a design criterion • The process of addressing construction site safety and health in the design of a project • Excerpts from UK law… • Designers shall “ensure that any design…includes among the design considerations adequate regard to the need (i) to avoid foreseeable risks to the healthy and safety of any person at work carrying out construction work….” and • “The design shall include “adequate information about any aspect of the project or structure or materials … which might affect the health and safety of any person at work carrying out construction work….” F

  6. Our project ABC / AIA / ASSE Whitepaper • Genesis in Associated Builders and Contractor’s Alabama Chapter Safety Committee • A multi disciplined group was tasked with a best practices whitepaper development to be shared with national entities and throughout our industry J

  7. DfS task group members • Owner – Southern Company Generation • Bob Fitzgerald Manager of Construction Safety and Health for Engineering and Construction Services, Bob Powers, Alan Speegle, Thomas Ricketts • Contractor – B.L.Harbert International • Frank Wampol corporate safety director • Architect – Aycock Architecture Studio • Jamie Aycock • Legal – Huie, Fernambucq & Stewart law firm • Joe Duncan attorney • Insurance / Risk Management • John Placey SVP Willis, Mike Fredebeil SVP National Director Construction Safety Willis • Academia – University of Alabama • Dr. Robert G. Batson Professor Construction Engineering Program • Associated Builders and Contractors • Jay Reed Alabama Chapter President J

  8. Influencing Safety, Cost, and Constructability High Conceptual Design Detailed Engineering Ability to Influence Procurement Construction Start-up Low Start date End date Project Schedule (Source: Szymberski, R., “Construction Project Safety Planning.” TAPPI Journal, Vol. 80, No. 11, pp. 69-74.) J

  9. Common non-mandated “best practices” • Drug testing • RTW • Stretch and Flex - STI prevention • Comprehensive safety manuals • Benchmarking – safety ROI • Contractor prequalification • Project and activity pre-planning F

  10. “War stories” …. Alabama Power Georgia Power Mississippi Power Gulf Power Southern Nuclear Fortune's 'Most Admired' Fortune magazine's 2011 list of the "World's Most Admired Companies" has Southern Company at the top in the electric and gas utility sector. J

  11. Modular Ductwork Field Assembly 4 truck modules insulated and assembled into lift pieces! … Exactly as planned several years prior! J

  12. DfS examples “Real-world” a picture is worth 1,000 words! • Southern Company flue gas duct work • 3D imaging • Analyzing component parts • Pre fab • Truck to site • Assembly at ground level • Protected work platforms (PM) • Reduced hazard • $3 Million savings J

  13. “Southern Company representatives from Design and Construction Services improved the design of the flue gas duct work to eliminate most field welds and moved some of the large steel duct assembly to the fabricator’s shop… …This redesign reduced cost, improved quality, shorted the construction field schedule, and made a safer construction job site” Southern Company DfS report J

  14. Example: Squirter Washers J

  15. Auburn University Basketball Arenalong span truss installation (DfCS = $500,000 savings) F

  16. Multi-crane critical lift and fall hazards avoided Computer modeling design and installation of long span trusses to accommodate single crane pic and control worker hazards “stub columns” to facilitate steel erection Elevated work platforms for connectors Engineered horizontal lifeline pre-fab onto each truss prior to erection for fall protection and end user One crane mobilization for pre-cast and steel erection Savings - $500,000 F

  17. Falls – construction’s #1 killer • What impact could DfCS have on this statistic? • Anchorages • For personal fall arrest / swing stage scaffolding • Steel pre-punched • Parapet wall height • Window height • Rooftop equipment installed at safe distances F

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  19. Multiple anchorages for end user and construction Engineered anchorages… but – what if the parapet were just a little taller? F J

  20. What Types of Design Decisions? • IBC paragraph 704.11.1 requires that a parapet wall be at least 30 inches high • OSHA 1926 Subpart M requires a guardrail at 42 inches (+/- 3”) or other fall protection • If the design professional specifies a 39 - 45 inch high parapet wall, additional fall protection would not be required F

  21. A 1996 paper by Professor John Smallwood showed that 50% of general contractors interviewed identified poor design features as affecting safety. F

  22. Pre-punched steel for perimeter protection US Army Maneuver Center HQ Expansion, Ft Benning Ga F

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  24. Warrior in Transition Barracks… Ft Bragg NC and Ft Benning Ga True design build project with full time design manger PE employed by contractor Incorporated directly by input from builder… Worker access / egress Construction live load staging on elevated levels Material staging and crane pads Hoist beams in elevator shafts Roof anchorages F

  25. DfCS Example: Residential Roofs J

  26. DfCS Examples: Prefabrication Concrete Wall Panels Concrete Segmented Bridge Steel stairs J

  27. DfCS Examples: Roofs Upper story windows and roof parapets Skylights J

  28. End user • Based on occupancy • Patient handling systems • Non-skid floor surfaces • Sprinkler systems • Diking for hazardous materials • Avoid costly retrofit J

  29. DfS…. Or retrofit? J

  30. Whitepaper… some highlights • Owner • Decreased costs • Short term • Long term • General Contractor • Improved worker and workplace safety • Enhanced productivity • Architect • Anchorage points • Dialog with Contractors • Legal • Statue of repose • Limiting liability • Insurance / Risk Management • Fall from elevation controls • Amortization • Control of overall cost of risk • Academia • Teach it! J

  31. Get started basic checklist… • Use preplanning • low-hanging fruit • Feedback from builders and end users • Hazard identification (assembly at ground level) • PM (location of items at roof level) • Anchorage points • Punched steel • Live loads? • Building (construction materials) and ground condition (crane pad) • Parapet • Design underground utilities to be placed using trenchless technology1 • End user 1 Weinstein, “Can Design Improve Construction Safety”, 2005 F

  32. DfCS checklist continued… • Specify primers, sealers and other coatings that do not emit noxious fumes or contain carcinogenic products2 • Design cable type lifeline system for storage towers3 • Provide at least two means of egress on large maintenance platforms or walkways. • Worker access / egress to upper levels during construction • Use red dye concrete to encase underground utility or electrical duct runs. 2Gambatese, “Viability of Designing for Construction Worker Safety”, 2005 3Behm, “Linking Construction Fatalities to the Design for Construction Safety Concept”, 2005 F

  33. More considerations… • Laydown – material staging areas • Construction loads verses end user live loads • Design the slope, width, height, turning radius, and surface treatment of traffic surfaces with consideration of the anticipated size, weight, and maneuverability of the construction equipment. • Emergency vehicles should have access to all parts of the plant and construction site. Provide, if possible, two controlled intersections at access points to the site. • Group roof openings together to create one larger opening rather than many smaller openings. F

  34. Worker electrocuted when his drill rig got too close to overhead power lines. Design engineer specified groundwater monitoring wells were to be dug directly under power lines. Design engineer could have specified wells be dug away from power lines and/or better informed the employer of hazard posed by wells’ proximity to power lines through the plans, specifications, and bid documents. Example of the Need for DfCS F

  35. DfCS Resources Design for Construction Safety - Look for 2 to 4 hour course for Design Professionals. www.designforconstructionsafety.org Construction Industry Institute database www.construction-institute.org/scriptcontent/more/rr101_11_more.cfm United Kingdom Health & Safety Executive designer guides www.hse.gov.uk/construction/designers/index.htm www.workcover.nsw.gov.au/Publications/OHS/SafetyGuides/chairsafetyindesigntool.htm ABET. 2011. Criteria for Accrediting Engineering Programs, 2010-11 Review Cycle. www.abet.org/forms.shtml Behm, M. 2008. Rapporteur’s Report: Construction Sector. Journal of Safety Research, 39, 127-130. Brauer, R. L. 2006. Safety and Health for Engineers, 2nd Edition. Hoboken, NJ: John Wiley & Sons. US Department of Labor- OSHA- Alliance Program Construction Roundtable http://www.osha.gov/dcsp/alliances/roundtables/roundtables_construction.html NIOSH Prevention through Design http://www.cdc.gov/niosh/topics/PTD/ The Construction (Design and Management Regulations 2007 http://www.legislation.gov.uk/uksi/2007/320/contents/made J

  36. Continued… American Society of Safety Engineer https://www.asse.org/cartpage.php?link=standards Chair New South Wales Government (Australia) www.workcover.nsw.gov.au/Publications/OHS/SafetyGuides/chairsafetyindesigntool.htm Christiansen, W. C. and Manuele, F. A. (Eds.). 1999. Safety through Design. Itasca, IL: NCS Press. Christiansen, W. C. 2003. Safety through Design: Helping Design Engineers answer 10 Key Questions. Professional Safety, 48(3), 32-39. Christiansen, W. C. 2010. Safe Designs: A Challenge to SH&E Professionals. Professional Safety, 55(4), 29-34. Manuele, F. A. 2008. Prevention through Design (PtD): History and Future. Journal of Safety Research, 39, 127-130. NIOSH. 2007. NIOSH Safety and Health Topic: Prevention through Design. Washington, DC: U.S. Department of Health and Human Services, CDC. http://www.cdc.gov/niosh/topic/ptd J

  37. Questions? J

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