Design for Construction Safety (DfCS) 2 to 4 Hour Course WHAT IS DESIGNING FOR CONSTRUCTION SAFETY? The process of addressing construction site safety and health, and planning for future maintenance in the design phase of a project. WHY IS IT NECESSARY? Currently there are no requirements for construction safety in building codes IBC Chapter 33 Safeguards During Construction-Pedestrian Safety OSHA 1926-Engineering Controls 1926.452 1926.502 1926.552 1926.652 1926.703 1926.705 Scaffolds Fall Protection Anchorages Hoists Excavations Shoring Lift Slabs DfCS Process1-It’s a Team Concept • Establish design for safety expectations • Include construction and operation perspective • Identify design for safety process and tools Design Kickoff Design Trade contractor involvement 1 Gambatese Internal Review • QA/QC • Crossdiscipline review External Review • Focused safety review • Owner review Issue for Construction U.S. Construction Accident Statistics1 Nearly 200,000 serious injuries and 1,226 deaths each year 5.5% of workforce but 21.5% of fatalities Construction has one of the highest fatality rates of any industry sector 1 Bureau of Labor Statistics-2006 CONSTRUCTION ACCIDENTS IN U.S.1 1 Photos courtesy of Washington Group International CONSTRUCTION FATALITIES BY OCCUPATION1 1 Total fatalities 1,226 Construction laborers 360 Electricians 117 Carpenters 114 First Line supervisors 113 Roofers 82 Painters and paper hangers 54 Structural steel 36 BLS,2006 MOST FREQUENTLY CITED/HIGHEST PENALTY OSHA VIOLATIONS IN CONSTRUCTION1 Scaffolding 29 CFR 1926.451 Fall Protection 29 CFR 1926.501 Ladders 29 CFR 1926.1053 Excavations 29 CFR 1926.651 Aerial Lifts 29 CFR 1926.453 1Most Frequently Cited Standards 2005 www.osha.gov Considering Safety During Design Offers the Most Payoff1 High Conceptual Design Detailed Engineering Ability to Influence Safety Procurement Construction Start-up Low Project Schedule 1 Szymberski 1987 DESIGN CAN INFLUENCE CONSTRUCTION SAFETY11,2 22% of 226 injuries that occurred from 2000-2002 in Oregon, WA and CA linked to design 42% of 224 fatalities in US between 1990-2003 linked to design In Europe, a 1991 study concluded that 60% of fatal accidents resulted from decisions made before site work began 1 2 Behm, “Linking Construction Fatalities to the Design for Construction Safety Concept”, 2005 European Foundation for the Improvement of Living and Working Conditions 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 39-45 inch guardrail or other fall protection If the design professional specifies a 39-45 inch high parapet wall, fall protection would not be required DfCS Examples: Roofs Skylights Upper story windows and roof parapets COURSE OBJECTIVES To provide design and construction professionals with skills to identify construction safety hazards To provide design and construction professionals with skills to eliminate or reduce the risk of a serious injury in the design phase COURSE OBJECTIVES Safety Engineering-skills to recognize hazards and uncover “hidden” hazards Design features to eliminate or reduce the risk of an injury due to a hazard OSHA resources for DfCS Crash Course in Safety Engineering Safety Engineering is a specialty within the engineering field that deals with the identification and elimination of hazards. Safety Engineering cuts across all engineering disciplines: Civil, Mechanical, Chemical, Electrical, as well as many branches of science. What is a Hazard? A HAZARD is the potential to do harm or damage RISK is a measure of the probability of a hazard-related incident occurring and the severity of harm or damage Recognized Hazards Gravity-Falls from elevation Falling objects Slopes-Upset Rollover Unstable surfaces Water- Drowning Recognized Hazards Walking/working surfacestripping, slipping Mechanical hazardsRotation, reciprocation, shearing, vibration, pinch points, hydraulics, pneumatics, entanglement Recognized Hazards Stored energy- springs, pneumatics hydraulics, capacitors Electrical-electrostatic, current, voltage, sparks, arcs Chemical-corrosive, combustion, toxic Recognized Hazards Biological-allergens, carcinogens Radiant Energy-sound, nuclear, X-rays, light, lasers Recognized Hazards-Sources ANSI Standards ANSI Z49.1 Safety in Welding and Cutting ANSI Z117.1 Safety Requirements for Confined Spaces ANSI D6.1 Manual on Uniform Traffic Control Devices ANSI 10.8 Safety Requirements for Scaffolding ANSI 14.2 Safety Requirements for Portable Ladders Recognized Hazards-Sources ANSI Standards ANSI Z93.1 Fire Hazards in Oxygen Enriched Atmospheres ANSI A14.4 Job Made Wooden Ladders ANSI A10.6-Safety Requirements for Demolition Operations ANSI A1264.1-Safety Requirements for Workplace Floor and Wall Openings, Stairs & Railing Systems Recognized Hazards-Sources ANSI Standards ANSI A10.13 Safety Requirements for Steel erection ANSI A145.1 Recommended Practice for Concrete Formwork ANSI Z244.1 Lockout/Tagout of Energy Sources Recognized Hazards-Sources ASTM Standards ASTM F802 Guide for Selection of Certain Walkway Surfaces When Considering Footwear Traffic ASTM 04.09 Wood Construction ASTM D4532 Respirable Dust in Workplace Atmospheres ASTM STP 1150 Fire Hazard and Fire Risk Assessment Recognized Hazards-Sources ASTM Standards ASTM O 4.07 Building Seals and Sealants Recognized Hazards-Sources NFPA Standards NFPA Volume 13, 53M Fire Hazards in Oxygen Enriched Atmospheres NFPA 654 Prevention of Fire and Dust Explosions in the Chemical, Dye, Pharmaceutical, and Plastics Industries NFPA 241 Safeguarding Construction, Alteration, and Demolition Operations Recognized Hazards-Sources Government Regulations OSHA 1926.550 Cranes and derricks OSHA 1926.251 Rigging Material for Material Handling OSHA 1926.452 Scaffolds OSHA 1926.800 Underground Construction OSHA 1926.52 Occupational Noise Exposure Recognized Hazards-Sources NFPA Standards NFPA 30 Flammable and Combustible Liquids NFPA 325M Fire Hazard Properties of Flammable Liquids, Gases & Volatile Solids Recognized Hazards-Sources Government Regulations OSHA 1918.95 Longshoring Operations in the Vicinity of Repair and Maintenance Work OSHA 1926.1050-1053 Stairways and Ladders OSHA 1926.650 Excavations Federal Motor Carrier Safety Regulations Recognized Hazards-Sources Other Sources National Safety Council MSHA SAE NIOSH US Army Corps of Engineers ACI Recognized Hazards-Examples Fall Hazards 6 Feet or More1 1Photos courtesy of Washington Group International Unprotected edges Recognized Hazards-Examples Confined Space Recognized Hazards-Examples Power Lines 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. Engineer could have specified wells be dug away from power lines and/or better informed the employer of hazard posed by wells’ proximity to powerlines through the plans, specifications, and bid documents. Hidden Hazards-Examples Underground utilities Electrical wire buried in a wall Asbestos Rot/Decay of structural members Gas lines Any hazard uncovered during project execution Hidden Hazards-”What If” Analysis A “What If” analysis is a structured brainstorming methods of uncovering hidden hazards Select the boundaries of the review and assemble an experienced team Gather information-video tapes of operation, design documents, maintenance procedures, etc. Hidden Hazards-”What If” Analysis “What If” Situation Questions Failure to follow procedures Procedures are followed, but are incorrect Equipment failure Utility failure Weather Operator not trained Hidden Hazards-”What If” Analysis Example Highway Construction Project What if workers have to access drains? Are drains a possible confined space? What about the power lines? Will equipment be operating near power lines? What about worker/public injury from traffic accidents? Do trucks have enough turning space? Is there signage/barriers to re-direct pedestrians? Will construction vehicles have enough shoulder space to stop on road What if worker attempts to manually pick up drain covers? Are they lightweight? Do they have handles? Hidden Hazards-Other Methods Fault Tree Analysis Design Check Lists Plan review, if your gut feeling tells you that something is unsafe, it probably is. Read case studies on construction accidents “Fatal Facts” Fatal Facts Fatal Facts Fatal Facts Fatal Facts Fatal Facts Design for Safety (DFS) Identify the hazard(s) Assess the Risk Propose design features to eliminate the risk or reduce it to an acceptable level DFS- Risk Assessment Estimate Injury Severity Severe-Death or serious debilitating long-term injury such as amputation or coma Serious-Permanent or nonreversible injury that severely impact enjoyment of life and may require continued treatment DFS- Risk Assessment Estimate Injury Severity Moderate-Permanent or reversible minor injury that does not significantly impact enjoyment of life, but requires medical treatment. Slight-Reversible injury requiring simple medical treatment with no confinement DFS- Risk Assessment Estimate Probability of Hazardous Event High- Very likely to occur, protective measures are nearly worthless Medium-Occurrence is likely. The frequency of control measures is significant or control measures are inadequate DFS- Risk Assessment Estimate Probability of Hazardous Event Moderate-Occurrence is possible, but not likely Low- Occurrence is so unlikely as to be considered nearly zero. DFS-Risk Assessment Matrix Severity Probability Severe Serious Moderate Slight High High High Medium Low Medium High Moderate Medium Low Low Low Low Medium Low Low Low Negligible Negligible Negligible Other Forms of Hazard Identification/Prevention Matrix1 1Hazard Information Foundation, Inc. Eliminate the Hazard Hazard Natural Structural/ Mechanical Electrical Chemical Radiant Energy Biological Artificial Intelligence Safety Guard the Hazard Hazard Safety Provide a Safety Factor Hazard Safety Provide Redundancy Hazard Safety Provide Reliability DFS-Design Hierarchy First-Design out the hazard Second-Provide safety devices Third-Provide warning devices Fourth- Implement operating procedures and training programs Fifth-Use personal protective equipment END OF CRASH COURSE IN SAFETY ENGINEERING Typical Construction Project Arrangement Project owner separately contracts with a Architect/Engineer and with a general contractor, prime contractor, construction manager, program manager or owner’s agent Above entities may subcontract out some or all of the work to specialty trade contractors Project owners occasionally contract with a design-build firm to perform both design and construction Root Causes for Construction Accidents1 1 Inadequate construction planning Lack of proper training Deficient enforcement of training Unsafe equipment Unsafe methods or sequencing Unsafe site conditions Not using safety equipment that was provided Toole, “Construction Site Safety Roles”, 2002 Potential Areas of Concern in Construction Safety Falls Hazardous materials Fire Protection Electrical Scaffolding Floor and wall openings, stairways, ladders Potential Areas of Concern in Construction Safety Cranes, derricks, hoists Material handling and storage Excavating and trenching Confined Space Work Zone Potential Areas of Concern in Construction Safety Trade specific Steel workers Electrical HVAC Plumbing Excavators Concrete Designing for Construction Safety (DfCS) – What is it? An extension of DfS to cover construction projects Recognizes construction site safety as a design criterion The process of addressing construction site safety and health in the design of a project Designing for Construction Safety Process1 1Gambatese Prelim. Design Review 30% Review Planning Review 60% Review 90% Review Planning Preliminary design/ Schematics Design Construction Operation and Maintenance DfCS Examples: Prefabrication Concrete Wall Panels Concrete Segmented Bridge Steel stairs DfCS Examples: Anchorage Points DfCS Examples: Roofs Skylights Upper story windows and roof parapets DfCS Examples: Steel Design National Institute of Steel Detailing and Steel Erectors Association of America. Detailing Guide for the Enhancement of Erection Safety. Avoid hanging connections; design to bear on columns instead using safety seats Require holes in columns for tie lines 21” and 42” above each floor slab Specify shop welded connections instead of bolts or field welds to avoid dangerous positions during erection Consider approximate dimensions of connection tools to prevent pinches or awkward assemblies DfCS Examples: Residential Fall Protection Other DfCS Design Examples Design underground utilities to be placed using trenchless technology1 Specify primers, sealers and other coatings that do not emit noxious fumes or contain carcinogenic products2 Design cable type lifeline system for storage towers3 1 Weinstein, “Can Design Improve Construction Safety”, 2005 2 Gambatese, “Viability of Designing for Construction Worker Safety”, 2005 3 Behm, “Linking Construction Fatalities to the Design for Construction Safety Concept”, 2005 CASE STUDY #1-CIRCULATOR PUMPS CASE STUDY #1-CIRCULATOR PUMPS Replacing circulator pumps requires a ladder,pumps are located in a tight space. Maintenance worker could fall off ladder, drop pump, or suffer hand injury from hitting adjacent piping CASE STUDY #1-CIRCULATOR PUMPS Design review questionsIs there enough room to replace the pumps? How high off the ground are the pumps? What if a maintenance worker has to shut off a valve an emergency? CASE STUDY #1-CIRCULATOR PUMPS Identify Hazard- Fall and mechanical CASE STUDY #1-CIRCULATOR PUMPS Assess Riskseverity- slight (knuckles) to serious (head injury) probability-medium (likely) risk- low to medium Additional consideration- solution is simple and inexpensive CASE STUDY #1-CIRCULATOR PUMPS Severity Probability Severe Serious Moderate Slight High High High Medium Low Medium High Moderate Medium Low Low Low Low Medium Low Low Low Negligible Negligible Negligible CASE STUDY #1-CIRCULATOR PUMPS DfCS solution: design pumps close to ground level so that a ladder is not required, provide adequate space around pumps, provide a metal identification tag for each valve and provide a permanent identification board in the mechanical room that identifies each valve and it’s purpose. CASE STUDY #1-CIRCULATOR PUMPS CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) HVAC System installed in the attic of a commercial office building No floor or platform/walkways were designed or installed HVAC technicians had to walk on joists/trusses CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) Design review questions What will workers stand on when installing HVAC system? Will regular maintenance be required? What will the maintenance workers stand on? What are the pertinent OSHA regulations? CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) Design review questions What will workers stand on when installing HVAC system? Will regular maintenance be required? What will the maintenance workers stand on? What are the pertinent OSHA regulations? CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) Identify hazard FALL CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) Assess Riskseverity- serious (knee) to severe (death) probability-medium (likely) risk- medium to high CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) Severity Probability Severe Serious Moderate Slight High High High Medium Low Medium High Moderate Medium Low Low Low Low Medium Low Low Low Negligible Negligible Negligible CASE STUDY #2INSTALLATION\MAINTENANCE OF HVAC SYSTEM (ATTIC) DfCS solution: design permanent platforms and walkways with guardrails CASE STUDY #3-RAW COAL RECLAIM FACILITY1 Plant utility worker was fatally injured while performing clean-up duties at a raw coal reclaim area Victim either fell through a 56” x 80” opening in a platform or entered through a coal feeder opening 1Case study courtesy of Washington Group International CASE STUDY #3-RAW COAL RECLAIM FACILITY Design review questionsWill workers need to have access to conveyors? Are covers and/or guardrails provided for all openings near or over conveyors? Are covers and/or guardrail gates interlocked? CASE STUDY #3-RAW COAL RECLAIM FACILITY CASE STUDY #3-RAW COAL RECLAIM FACILITY Identify hazard Mechanical CASE STUDY #3-RAW COAL RECLAIM FACILITY Assess Riskseverity- severe (death) probability-medium to high risk- high CASE STUDY #3-RAW COAL RECLAIM FACILITY Severity Probability Severe Serious Moderate Slight High High High Medium Low Medium High Moderate Medium Low Low Low Low Medium Low Low Low Negligible Negligible Negligible CASE STUDY #3-RAW COAL RECLAIM FACILITY DfCS solution: design covers and/or guardrails over conveyor belts and opening to conveyor belts. Design interlocks for covers and gates. CASE STUDY #4-BLIND PENETRATION INTO CONCRETE1 A construction worker penetrated an embedded electrical conduit containing an energized 120-volt line while hand drilling into a concrete bean to install pipe hanger inserts. The conduit was 1 inch from the surface. 1 Dept. of Energy Blind Penetration Incidents CASE STUDY #4-BLIND PENETRATION INTO CONCRETE Design review questions How will the worker install the pipe hangers? Are there any electrical lines in the concrete beam? Are there any pipe hangers that will be near an electrical line? CASE STUDY #4-BLIND PENETRATION INTO CONCRETE Assess Riskseverity- severe (death) probability- moderate to medium risk- medium to high CASE STUDY #4-BLIND PENETRATION INTO CONCRETE Severity Probability Severe Serious Moderate Slight High High High Medium Low Medium High Moderate Medium Low Low Low Low Medium Low Low Low Negligible Negligible Negligible CASE STUDY #4-BLIND PENETRATION INTO CONCRETE DfCS Solution: Design embedded electrical lines deeper than the maximum depth of the pipe hanger bolts, clearly mark locations of electrical lines on contract drawings CASE STUDY #5-INCINERATOR CLEANOUT1 An incinerator located adjacent to a main catwalk on 4th floor There was no catwalk from the main catwalk to the incinerator Workers periodically had to go into incinerator to clean Workers used make shift planking to from main catwalk to incinerator 1Note the catwalk from the main catwalk to the incinerator with the yellow guardrails was not in place at the time the worker fell. CASE STUDY #5-INCINERATOR CLEANOUT CASE STUDY #5-INCINERATOR CLEANOUT CASE STUDY #5-INCINERATOR CLEANOUT Design review questions.. Will regular maintenance be required? How will the workers gain access to the incinerator What are the pertinent OSHA regulations? CASE STUDY #5-INCINERATOR CLEANOUT Identify hazard FALL CASE STUDY #5-INCINERATOR CLEANOUT Assess Riskseverity- severe (death) probability-medium (likely) to high (very likely) risk- high CASE STUDY #-INCINERATOR CLEANOUT Severity Probability Severe Serious Moderate Slight High High High Medium Low Medium High Moderate Medium Low Low Low Low Medium Low Low Low Negligible Negligible Negligible CASE STUDY #5-INCINERATOR CLEANOUT DfCS solution: design catwalk with guardrail and toeboards from main catwalk to incinerator. IDEAS FOR DESIGNERS www.safetyindesign.org Case Studies Trimming tops of Concrete Piles Modular Construction and Installation of Services Temporary Support Steelwork for High Level Work Platform Atrium Lighting Integrated Service Column / Panel Design Prefabrication of Steelwork Modular Construction of Stone Panels TRAILER ACCESS PLATFORMS1 1 www.safetyindesign.org CAST-IN SOCKETS FOR RAILINGS1 1 www.safetyindesign.org COLOR CODED BOLT BAGS1 1 www.safetyindesign.org SAFETY BARRIER TO LOAD PALLETS ONTO MEZZANINE1 1 www.safetyindesign.org PREFABRICATION OF STEELWORK1 1 www.safetyindesign.org MAINTENANCE LIFT TO ACCESS ATRIUM LIGHTING1 1 www.safetyindesign.org MODULAR SERVICE RISERS1 1 www.safetyindesign.org GUIDANCE FOR DESIGNERS www.safetyindesign.org Hazardous materials Asbestos Musculo-Skeletal Noise Excavations Erection of Structures Steelwork GUIDANCE FOR DESIGNERS www.safetyindesign.org Refurbishment Temporary work equipment Work at height Roofs Spatial Designs Suspended Access Equipment Blockwork GUIDANCE FOR DESIGNERS www.safetyindesign.org Demolition Manual Handling Lifting-cranes GUIDANCE FOR DESIGNERS T 20.008 Work at Height1 1 Design service runs for so that they can be maintained from floor above Pre-assembly and fitting of trusses Position splices for steel columns so the splices can be done from a finished floor Install stairways early to avoid the need for temporary access Locate service equipment on ground if possible www.safetyindesign.org GUIDANCE FOR DESIGNERS T 20.002 Erecting Steelwork1 1 Check all steel members for erection loads Ensure that all slender members can resist compression imposed by lifting slings Maximize pre-fabrication Ensure the spacing of purlins allows for the largest component to lowered down through www.safetyindesign.org GUIDANCE FOR DESIGNERS T 20.009 Roofs1 Provide anchors points for fall protection Ensure roof structure can handle stacks of materials Position gutters so that cleaning can be done from cherry pickers or from safe access routes Consider parapets 1 www.safetyindesign.org GUIDANCE FOR DESIGNERS H 20.002 NOISE1 1 Cast in crack inducers rather than saw cutting Cast in anchors rather than site drilling Avoid vibro-compaction of ground Keep site grinding, cutting, etc. to a minimum www.safetyindesign.org GUIDANCE FOR DESIGNERS H 20.001Musculo-skeletal1 1 Provide adequate space for lifting machines Design for machine laying of pavers Design brick laying to reduce long duration repetition www.safetyindesign.org GUIDANCE FOR DESIGNERS H 10.001 Hazardous Materials1 1 Cast in chases for services rather than cut to reduce dust Specify water base or solvent free paints Check to see if there any existing contaminants on the site, alert workers www.safetyindesign.org Summary/Closing Introduce the DfCS Process Basic Safety Engineering Design Features Case Studies to Illustrate Process Summary/Closing DESIGNERS CAN HAVE A POSITIVE IMPACT ON REDUCING CONSTRUCTION ACCIDENTS DfCS Tools/Resources Construction Industry Institute database • www.constructioninstitute.org/scriptcontent/more/rr101_11_more.c fm United Kingdom Health & Safety Executive designer guides • www.hse.gov.uk/construction/designers/index.ht m CHAIR • www.workcover.nsw.gov.au/Publications/OHS/Saf etyGuides/chairsafetyindesigntool.htm OSHA Website • www.osha.gov DfCS Tools/Resources Inherently Safer Design Principles for Construction, The Hazard Information Foundation, Inc. besafe@hazardinfo.com www.safetyindesign.org