“Highway Construction Work Zones and Traffic Control Hazards” A Training Program developed under a Susan Harwood grant from OSHA Prepared by Wayne State University, Department of Civil and Environmental Engineering Detroit, Michigan This material was produced under grant number 46E3-HT18 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

Highway Construction and Work Zone Safety –Concern to many Construction Workers, Contractors, Highway and Safety Agencies, Regulatory Agencies, Transportation Professionals and Engineers,Trade Associations, etc. Highway construction is one of the most hazardous occupations in the USA –In the highway and street construction Industry Over 20,000 workers are injured each year Over 100 workers are killed each year Introduction

Fatality Statistics by Industry Type Risk of death of Highway and Street Construction workers is 2 to 4 times that of the remainder of the construction industry, and building construction industry. Census of Fatal Occupational Injuries (CFOI), Bureau of Labor Statistics

Highway work spaces are unique –Worker exposure to potential hazards include: Construction-related hazards Vehicle intrusion in the work space Workers directing passing traffic and construction traffic Interaction between workers, machinery, equipment, trucks and vehicles within the work space Restricted work space Night operations –Pressure to complete project early exacerbates the situation

Causes of Highway Worker Fatalities 120 to 130 workers die each year in highway and road construction (H&SC) activities Majority of the fatalities (74%) for H&SC workers are due to: –On-foot workers struck by passing vehicular traffic (23%) –On-foot workers struck by construction vehicles (18%) –Construction vehicle operator and occupant events (e.g., rollovers) (18%) –Highway traffic accidents (15%) * Sources: BLS CFOI data, ; and SIC 1661 Contractor OSHA 200 data as posted on the National Work Zone Safety Information Clearinghouse website at

Causes of Highway Worker Injuries Majority of serious injuries are due to: –Over-exertions (27%) –Falls (23%) –Being struck by other objects (17%) Tools, materials, equipment parts, trees, etc. * Sources: BLS CFOI data, ; and SIC 1661 Contractor OSHA 200 data (data log and summary) as posted on the National Work Zone Safety Information Clearinghouse website at

Highway Safety vs. Construction Safety The number of injuries and fatalities from traffic crashes far outweigh the number of H&SC workers that are injured or killed –Traffic Crash Data In the USA, in 2001: –2.9 million people were injured in traffic crashes –42,116 people were killed in traffic crashes –Highway Worker Accident Data In the USA each year, over 20,000 H&SC workers are seriously injured In 2001, 132 H&SC workers were killed in the USA

Highway Safety vs. Construction Safety (Cont.) For Year 2001 –Highway traffic crashes - motorists 1,586 injuries per 100,000 licensed drivers 22 persons killed per 100,000 licensed drivers –Highway and street construction workers 6,765 injuries per 100,000 workers 44.6 persons killed per 100,000 workers

National Work Zone Traffic Crash Trends Source: Fatal Accident Reporting System

Between 1992 and 1998 –A total of 152 H&SC workers were killed from being struck by a vehicle from passing traffic On average, 25 workers are killed per year from intruding vehicles National Work Zone Traffic Crashes (Cont.)

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

Events Leading to H&SC Worker Fatalities Occupational Fatalities - Average 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)

Examples of Common Hazards in Highway Work Zones

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

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

Hazards to On-Foot Workers: Working Near Equipment Workers in close proximity to equipment

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

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

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

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

Equipment Rollovers Rolled over equipment

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

Hazards of Heavy Equipment: Impaired Vision Broken windows

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

Importance of Training Improve knowledge, skills, ability and attitude in order to perform construction related activities safely and efficiently Increase awareness of job hazards and methods to abate them Improve safety for workers and reduce injuries/fatalities

Overview of Training Modules Module 1. Work Zone Traffic Control Module 2. Safe Operations and Internal Traffic Control in the Work Space Module 3. Heavy Equipment Module 4. Overhead and Underground Power Lines Module 5. Hand and Power Tools

Other Training Materials Available Occupational Safety and Health Administration’s (OSHA) –“10-Hour Training Course on Roadway Construction Industry” – Michigan Road Builders Association (MRBA) –“Heavy/Highway Construction Safety Best Practices” Southern California Contractors Association, Inc. –“Safety Manual for Workers on Roadways Open to Motorists” –

Other Training Materials Available National Institute for Occupational Safety and Health/Center for Disease Control and Prevention (NIOSH/CDC) –“Building Safer Highway Work Zones: Measures to Prevent Worker Injuries from Vehicles and Equipment” – Various Training Videos