The Future of Design for
Construction Safety
18th Annual Construction Safety Conference
Rosemont, IL
February 12, 2008
John Gambatese, PhD, PE
Assoc. Prof., Civil & Construction Engineering, Oregon State University
Mike Toole, PhD, PE
Assoc. Prof., Civil & Env. Engineering, Bucknell University
Brad Giles, CSP, PE
Vice President ESH&S, URS Washington Division
Overview

Introduction to DfCS
• Principles and Process
• U.S. and Abroad
• Resources and examples


Lessons from the field
Where DfCS is heading
• 5 “trajectories”

The future of DfCS is you!
What is Designing for Construction
Safety (DfCS)?



The process of addressing
construction site safety and health in
the design of a project
Recognizes construction site safety
as a design criterion and part of
constructability
Also called Prevention through
Design (PtD)
Why Perform DfCS?

It is the right thing to do

It is the smart thing to do
U.S. Construction Accident Statistics1



1
Nearly 200,000 serious injuries and
1,200 deaths each year
7% of workforce but 21% of fatalities
Every statistic had a name…..
Bureau of Labor Statistics-2005
photo credit: New York Times
Accidents Linked to Design1,2

22% of 226 injuries that occurred from
2000-2002 in Oregon, WA and CA

42% of 224 fatalities in US between 19902003

In Europe, a 1991 study concluded that 60%
of fatal accidents resulted in part from
decisions made before site work began
1
Behm, “Linking Construction Fatalities to the Design for Construction Safety Concept”, 2005
2
European Foundation for the Improvement of Living and Working Conditions
Considering Safety During Design
Offers the Most Payoff1
High
Conceptual Design
Detailed Engineering
Procurement
Ability to
Influence
Safety
Construction
Start-up
Low
Project Schedule
1
Szymberski 1987
Designing for Safety Pays



Reduced workers compensation
premiums
Increased productivity
Fewer delays due to accidents
• Allows continued focus on quality

Proactive clients
• Starting to demand safer construction
and safer designs
Example of the Need for DfCS

Design spec:
• Dig groundwater monitoring wells at
various locations.
• Wells located directly under
overhead power lines.

Accident:
• Worker electrocuted when his drill
rig got too close to overhead power
lines.

Engineer could have:
• specified wells be dug away from
power lines; and/or
• better informed the contractor of
hazard posed by wells’ proximity to
powerlines through the plans,
specifications, and bid documents.
Example: Parapet Walls
IBC paragraph 704.11.1 requires that a
parapet wall be at least 30 inches high
 OSHA 1926 Subpart M requires a
36-42 inch guardrail or other fall protection
 If the design professional specifies a
36-42 inch high parapet wall, fall protection
would not be required

Example: Anchorage Points
Examples: Prefabrication
Concrete
Wall Panels
Concrete Segmented Bridge
Steel stairs
DfCS Examples: Roofs
Skylights
Upper story windows
and roof parapets

The Erector
Friendly Column
• Include holes in
columns at 21”
and 42” for
guardrail cables
and at higher
locations for fall
protection tie-offs
• Locate column
splices and
connections at
reasonable
heights above
floor
• Provide seats for
beam connections

Avoid hanging
connections
• Design
connections to
bear on
columns

Avoid
awkward and
dangerous
connection
locations

Avoid
tripping
hazards

Eliminate
sharp
corners

Provide
enough
space for
making
connections

Know
approximate
dimensions of
necessary
tools to make
connections
Other DfCS Design Examples



Design underground utilities to be placed
using trenchless technologies1
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 et al., “Can Design Improve Construction Safety” (2005)
2 Gambatese et al., “Viability of Designing for Construction Worker Safety”
(2005)
3 Behm, “Linking Construction Fatalities to the Design for Construction Safety
Concept” (2005)
DfCS Resources



www.designforconstructionsafety.org
OSHA workgroup 2-4 hour powerpoint
Construction Industry Institute database
• www.constructioninstitute.org/scriptcontent/more/rr101_11_mo
re.cfm

CHAIR
• www.workcover.nsw.gov.au/Publications/OHS/
SafetyGuides/chairsafetyindesigntool.htm

United Kingdom Health & Safety Executive
designer guides
• www.hse.gov.uk/construction/designers/index.
htm
Example
from:
www.hse.go
v.uk/constru
ction/design
ers
Barriers to DfCS


Like many good ideas, DfCS faces
barriers:
• Contract terms
• Added costs
• Designers’ fear of liability
• Designers’ lack of knowledge
Potential solutions to these barriers
involve long-term education and
institutional changes.
Example Construction
Site Accident #1
Fall from Elevation
Example Construction Site
Accident

Project:
• McNairy Dam Fish Facility

Project Description:
• Construction of a laboratory visitor
center, a large fish collection facility,
and power line from the dam to the
visitor’s center.

Location:
• Columbia River, Oregon
Example Construction Site
Accident

Owner/Engineer:
• U.S. Army Corps of Engineers (COE)


General Contractor: Heart Construction
Electrical Subcontractor: J&J Electric
• Scope of work: Install electrical lines and
controls throughout the project.
• Company owners (brothers):


Frank Jones (on-site project superintendent)
Jerry Jones (office manager, some work on-site)
Example Construction Site
Accident

Project background:
• Fish containment area consists of an
upper working level and a lower fish
collection level.
• Upper level constructed of steel framing
supporting galvanized metal removable
grating. (3 feet wide x 4 feet long
sections)
• Mechanical and electrical equipment is
located on the upper level.
Example Construction Site
Accident

Project background:
• Elevation of lower level is 30 feet below
the upper level, except for a concrete
ledge along one wall which is 3 feet
below the upper level.
• No permanent access (stairway, ladder,
etc.) is available between the upper and
lower levels.
• Lower level is under water during
normal operation.
Example Construction Site
Accident

April 23:
• Fish containment area construction
complete.
• Electrical system testing under way.
• Frank, Jerry, and several Heart
employees enter the upper level of the
fish containment area to prepare a test
of the equipment controls before
opening the facility.
Example Construction Site
Accident

April 23:
• Frank and Jerry work on the first control
panel.
• After the first control panel is
completed, Jerry proceeds south to the
second control panel and begins to
work.
• Frank remains at the first control panel
talking to the Heart employees.
Example Construction Site
Accident

April 23:
• Heart employee, George, sees an
obstruction on the ledge 3 feet below.
• George walks over next to Jerry and
removes a section of metal grating to go
down to the lower level. The section of
grating was not secured with fasteners.
• George jumps down to the ledge (3 feet
below) and replaces the grating above
him, but does not correctly place the
grating over the bolts.
Example Construction Site
Accident

April 23:
• While sliding the grating back into place,
George says to Jerry that he didn’t want
anyone to step in the opening.
• Jerry hears George say something, but
does not understand because of the
high noise level.
• After a few minutes of working on the
second control panel, Jerry calls to
Frank to bring him a wrench.
Example Construction Site
Accident

April 23:
• Frank walks over to hand Jerry the wrench.
• Frank steps on the grating that George
replaced and falls through to the lower level
30 feet below.
• Frank sustains head, back, and neck
injuries.
• Frank now performs only minor office work,
rather than on-site work.
• J&J profits are less since the accident.
Example Construction Site
Accident

Additional information:
• The grating fastener system was not part
of the original design. The fastener system
was proposed by Heart Construction as a
change, and accepted by the Engineer.
• Special wrenches are required to install
and remove the grating fasteners. Two
wrenches, owned by Heart, were available
on the jobsite. The wrenches were
sometimes lost or misplaced and not
available.
Example Construction Site
Accident

Additional information:
• Heart Construction held weekly project
safety meetings. Jerry attended only one
meeting.
• During previous safety meetings, concerns
were brought up about lack of support for
the grating sections at locations where
portions of the sections were modified.
Occasionally wood was placed across the
grating to provide additional support.
Example Construction Site
Accident

Additional information:
• A temporary ladder between the upper
and lower levels which was located
several yards from the accident site was
removed before the accident.
Example Construction Site
Accident

Questions…
• How could the accident have been
prevented?
• What could have been done in the
design and/or the design phase to
prevent the accident?
Example Construction
Site Accident #2
Exposure to Hazardous
Chemicals
Example Construction Site
Accident
Fan #2
Roof
Offices
2nd
Floor
Fan #1
1st
Floor
Testing Lab
Example Construction Site
Accident


Scheduled completion date: July 15
July 15: Conduct punchlist inspection
•



Punchlist includes window cleaning, replace
cracked cover plates, touch-up paint, door
alignment, replace scratched millwork, correct
noise from Fan #2, etc.
July 15: Project is defined as substantially
complete.
July 16: Owner occupies a portion of the
facility.
July 17: Testing lab begins to function.
Example Construction Site
Accident

July 19:
• Electrician’s employee shuts off power
to Fan #2 to trouble shoot the problem.
• Lab technician conducts chemical
analysis at the same time.
• Electrician’s employee determines belt
alignment is the problem. It is
corrected.
• Power is restored; employee forgets to
replace fan belt guard.
• Lab technician complains of headache.
What happens when fan #2 is
turned off?
Fan is turned off
Fan #2
Roof
Offices
2nd
Floor
Duct line has
positive
pressure
Fan #1
1st
Floor
Testing Lab
Example Construction Site
Accident

July 20:
• Contractor is informed by owner of lab
technician’s headache and its cause.
• Contractor instructs all sub’s to turn in
their building keys.
• Sub’s are instructed to gain access only
by owner or contractor personnel.
• Contractor does not explain the reason
for the new policy.
Example Construction Site
Accident

July 28:
• Electrician’s employee shuts off power to
Fan #2 to replace the fan belt guard.
• Lab technician conducts chemical
analysis as the guard is replaced.
• Guard is replaced in 10 minutes.
• Power to Fan #2 is restored.
• Lab technician dies at the work station
from exposure to deadly chemicals.
Example Construction Site
Accident

Questions…
• How could the accident have been
prevented?
• What could have been done in the
design and/or the design phase to
prevent the accident?
“Safety Considerations
in Design”
Implementing DfCS in
Practice
How it Started
Content started in
“Constructability” reviews by
Project Management Teams
working with engineering.
Educational Limitations
Limited amount of safety training
required in engineering
educational activities.
Presented to:





Engineers
Designers
Estimators
Contract Administrators
Procurement Professionals
Over 2,000 Over the Last Year
Awareness
Involvement in Design Build
Activities with our own employees
increased the awareness.
Safety Qualified Supervisor
Two Day Training
 10-Hour OSHA Construction Safety
 Economics of Safety
 Supervisor Responsibilities and
Accountability
 Work Planning/Job Hazard Analysis
 Control of Energy
 “Safety Consideration in Design”
STS Safety Trained Supervisor
Certification
Reference Materials



Construction Safety Management
and Engineering – ASSE
Construction Safety Engineering
Principles – David MacCollum
Safety and Health Engineering –
Roger Brauer
Relevant Data
Utilization of Company specific
examples and applications.
Client/Regulator Interest





OSHA
NIOSH
Corps of Engineers
Navy
Defense Nuclear Facility Safety
Board
Example in Case Study – OSHA
Website
“Washington Group International
Designs and Builds a Waste Treatment
Facility.”
http://www.osha.gov/dcsp/success_stories/alliances/washington
/washington_group_case_study.html#Sidebar3
Advanced Mixed Waste
Treatment Facility (AMWTF)
http://www.osha.gov/dcsp/success_stories/alliances/washington/washington_
group_case_study.htm#3Sidebar3
Objectives
Prevent injuries and accidents:
 Develop and/or expand engineering
principles of Inherently Safer Design
for Construction.
 Implement/educate engineering and
design staff in hazard identification
and legal responsibilities.
 Implement specific aims and goals
for Inherently Safer Design Principles
for Construction.
Training Discusses



Why designers should care about
designing for construction worker
safety.
Opportunities for designing for
construction worker safety.
Barrier for designing for construction
worker safety.
Five Principles of Inherently Safer
Design Principles for Construction





Definition of a Hazard
Establish a Standard of Safe Design
Categorize the Hazard
Establish Safe Design Hierarchy
Control the Hazard with Appropriate
Design
Order of Precedence for
Addressing Safety Hazards
1. Design to eliminate or avoid the
hazard
2. Design to reduce the hazard
3. Incorporate safety devices after the
fact
4. Provide warning devices
5. Institute training and operating
procedures
Hazard Identification Matrix
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
Safety in Design for Material Handling
and Storage Facilities




Number One Concern is the
Machinery, Material and Human
Interface.
Categorize the Hazards Using the Seven Hazard
Sources for Material Handling and Storage
Facilities.
Use the Safe Design Hierarchy to Physically
eliminate the hazards identified for Material
Handling and Storage facilities.
Develop a Hazard Identification Matrix to
document your findings and design the hazards
from the Material Handling and Storage Facilities.
List all the hazards involved with
material handling and storage facilities.

Natural
Hazards:
A.Gravity
1.Falls same level
1.Fall from elevation
1.Falling objects
1.Impact
1.Acceleration
B. Slopes
1. Upset
1.Rollover
1.Sliding
4.Unstable surfaces
A.Limitations on Human
Performance

Natural Hazards:
• Slip, trips
• Improperly
secured materials
on trucks,
structures, cranes
and on the ground.
• Traffic and
personnel
• Drainage ditches
• Weather roadway
and walkway
maintenance
• Potential for
unstable surfaces
Designing for Safety Pays




Reduced workers compensation
premiums
Increased productivity
Fewer delays due to accidents during
construction allow continued focus on
quality
Proactive clients are starting to
demand safer construction and
safety designs.
Case Study #1
Circulator Pumps
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 in an emergency?
Case Study #1 - Circulator Pumps
Identify Hazard –
Fall and mechanical
Case Study #1 - Circulator Pumps
Assess Risk –
Severity- 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

DfCS solutions:
• 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 #2
Installation\Maintenance of
HVAC System in Attic
Case Study #2 - Install\Maint. of
HVAC System in 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 #2 - Install\Maint. of
HVAC System in Attic
Case Study #2 - Install\Maint. of
HVAC System in 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 #2 - Install\Maint. of
HVAC System in Attic
Identify hazard –
FALL
Case Study #2 - Install\Maint. of
HVAC System in Attic
Assess Risk –
Severity- serious (knee) to severe
(death)
Probability- medium (likely)
Risk- medium to high
Case Study #2 - Install\Maint. of
HVAC System in Attic

DfCS solution:
• design permanent work platforms and
walkways with guardrails
Case Study #3
Raw Coal Reclaim Facility
Case Study #3 - Raw Coal Reclaim
Facility


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 questions:
Will 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 Risk –
Severity- severe (death)
Probability- medium to high
Risk- high
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
Concrete
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
beam 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

DfCS Solutions:
• Design embedded electrical lines deeper
than the maximum depth of the pipe
hanger bolts.
• Clearly mark locations of electrical lines
on contract drawings.
National Initiatives


OSHA Construction Alliance
Roundtable DfCS Workgroup
NIOSH NORA Construction Sector
Council CHPtD Workgroup and
Prevention Through Design National
Workshop (July 2007)
Five DfCS Trajectories
1.
2.
3.
4.
5.
Increased prefabrication
Increased use of less hazardous
materials and systems
Increased application of construction
engineering
Increased spatial investigation and
consideration
Increased collaboration and
integration
Increased Prefabrication

Shift site work to safer work site
environment
• elevation to ground
• underground to grade
• confined space to open space

Shift site work to factory
• Allows use of safer, automated equipment
• Provides safer, engineered environment
Increased Use of Less Hazardous
Materials and Systems

Coatings, sealants, cleaners

Building systems
• Steel, concrete, masonry, wood
Increased Construction Engineering

Examples of construction engineering
• Soil retention systems
• Crane lifts
• Temporary loads
• Temporary structures
• Fall protection anchorage points

Why are designers increasingly involved
• Growth of design-build
• Their understanding of structure and site
Increased Spatial Investigation


Communicating site hazards on
project documents
Working distances for each trade
• Cranes and powerlines
• Excavation dimensions for work within
• Steel connections
• Raceways and plumbing pipes

Ergonomic issues
• Overhead
• Awkward angles
Example DfCS Process
• Establish design for
safety expectations
• Include construction and
operation perspective
• Identify design for safety
process and tools
Design
Kickoff
Design
Trade contractor
involvement
Internal
Review
• QA/QC
• Crossdiscipline
review
External
Review
• Focused safety
review
• Owner review
Issue for
Construction
Facilitating Collaboration



Having designers interact with
constructors
Having specialists interact with
generalist planners
Implications for contracting/delivery
method
Implications for Education of
Design Engineers





Shift in mindset
Holistic view
Exposure to DfCS fundamentals
Training in system-specific DfCS
opportunities
Engineering course-specific DfCS
modules
Implications for Contracting


New contract terms needed
Design-Build and Design+Negotiated
construction better facilitate
collaboration during design*
*This is not meant to endorse one project delivery method over another.
Implications for Use of Information
Technology



IT represents efficient means for
providing designers with information
needed to perform DfCS
Manufacturers must make DfCS
information available
All entities will need IT to facilitate
communication, collaboration,
integration
What do you think?

How can we reduce barriers to DfCS?
• Designers’ fear of liability
• Designers’ lack of knowledge
Where Do You Fit In?




Initiate or expand DfCS in your
company
Share information about your DfCS
program
Provide data to make the business
case for DfCS
Serve as a case study
Summary

Designing for construction safety is:
• the right thing to do, and
• the smart thing to do.



Many countries require or promote
designing for safety
National organizations are working to
create tools, eliminate barriers and
facilitate adoption of this important
process in the United States
Your participation is needed!
Thanks for Participating!




Questions?
Comments?
john.gambatese@oregonstate.edu
mike.toole@bucknell.edu
Brad.giles@wgint.com
The following slides are just in case
someone asks….
Barrier: Contract Terms


Model contracts between owner and
designer and general conditions
between owner and contractor
explicitly reject designer role in
safety
Potential Solution: Revise the model
contracts
Barrier: Increased Designer Costs
Associated with DfCS


While DfCS results in decreased total
project life cycle costs for the owner,
DfCS processes will increase both
direct and overhead costs for
designers.
Potential solution: Educate owners
that they must be willing to pay
slightly higher design fees to save
themselves money in the long run.
Barrier: Designers' Fear of Liability



Barrier: Fear of undeserved liability for
worker safety.
Potential solution: Clearly communicate
the DfCS initiative does NOT suggest
designers should be held responsible for
construction accidents.
Potential solution: Propose legislation is
facilitate designing for construction safety
without inappropriately shifting safety
duties and liability onto designers.
Barrier: Designers' Lack of Safety
Expertise



Barrier: Few design professionals
possess sufficient expertise in
construction safety.
Potential solution: include
construction safety in construction,
engineering and architectural
curricula.
Potential solution: Develop and
promote 10-hour and 30-hour OSHA
courses for design professionals.
The Washington Group’s
Training Initiative

The Washington Group International
provides safe design training to:
• Engineering
• Design
• Procurement
• Contracts
• Estimating
WG’s Safety Qualified Supervisor
Training






2 Day Training
10-Hour OSHA Construction Safety
Economics of Safety
Safety Res. & Accountability
Work Planning & Job Hazard Analysis
Safety Construction & Design
An Ounce of Prevention
is Worth a Pound of Cure

Order of precedence for addressing
safety hazards
1.Design to eliminate or avoid the hazard
2.Design to reduce the hazard
3.Incorporate safety devices after the fact
4.Provide warning devices
5.Institute training and operating procedures
(Source: Manuele, F.A., “On the Practice of Safety.” Wiley and Sons, Inc. New York, NY, 1997.)