The Future of Design for Construction Safety 18 th Annual Construction Safety Conference Rosemont, IL February 12, 2008 John Gambatese, PhD, PE Chair,

The Future of Design for The Future of Design for Construction SafetyConstruction Safety

1818thth Annual Construction Safety Conference Annual Construction Safety ConferenceRosemont, ILRosemont, IL

February 12, 2008February 12, 2008

John Gambatese, John Gambatese, PhD, PEPhD, PEChair, ASCE-Construction Institute Prevention Through Design Committee Chair, ASCE-Construction Institute Prevention Through Design Committee

Assoc. Prof., Civil & Construction Engineering, Oregon State UniversityAssoc. Prof., Civil & Construction Engineering, Oregon State University

Mike Toole, Mike Toole, PhD, PEPhD, PEVice Chair, ASCE-Construction Institute Prevention Through Design Committee Vice Chair, ASCE-Construction Institute Prevention Through Design Committee

Assoc. Prof., Civil & Env. Engineering, Bucknell UniversityAssoc. Prof., Civil & Env. Engineering, Bucknell University

Brad Giles, Brad Giles, CSP, PECSP, PEVice President ESH&S, URS Washington DivisionVice President ESH&S, URS Washington Division

OverviewOverview Introduction to DfCSIntroduction to DfCS

• Principles and ProcessPrinciples and Process• U.S. and AbroadU.S. and Abroad• Resources and examplesResources and examples

Lessons from the fieldLessons from the field Where DfCS is headingWhere DfCS is heading

• 5 “trajectories”5 “trajectories” The future of DfCS is you!The future of DfCS is you!

What is Designing for Construction What is Designing for Construction Safety (DfCS)?Safety (DfCS)?

The process of addressing The process of addressing construction site safety and health in construction site safety and health in the design of a projectthe design of a project

Recognizes construction site safety Recognizes construction site safety as a design criterion and part of as a design criterion and part of constructabilityconstructability

Also called Prevention through Also called Prevention through Design (PtD)Design (PtD)

Why Perform DfCS?Why Perform DfCS?

It is the right thing to doIt is the right thing to do

It is the smart thing to doIt is the smart thing to do

U.S. Construction Accident StatisticsU.S. Construction Accident Statistics11

Nearly 200,000 serious injuries and Nearly 200,000 serious injuries and 1,200 deaths each year1,200 deaths each year

7% of workforce but 21% of fatalities7% of workforce but 21% of fatalities Every statistic had a name…..Every statistic had a name…..

11 Bureau of Labor Statistics-2005Bureau of Labor Statistics-2005 photo credit: New York Timesphoto credit: New York Times

Accidents Linked to DesignAccidents Linked to Design1,21,2

22%22% of 226 injuries that occurred from 2000- of 226 injuries that occurred from 2000-2002 in Oregon, WA and CA2002 in Oregon, WA and CA

42%42% of 224 fatalities in US between 1990- of 224 fatalities in US between 1990-20032003

In Europe, a 1991 study concluded that In Europe, a 1991 study concluded that 60%60% of fatal accidents resulted in part from of fatal accidents resulted in part from decisions made before site work begandecisions made before site work began

11 Behm, “Linking Construction Fatalities to the Design for Construction Safety Concept”, 2005 Behm, “Linking Construction Fatalities to the Design for Construction Safety Concept”, 2005

2 2 European Foundation for the Improvement of Living and Working ConditionsEuropean Foundation for the Improvement of Living and Working Conditions

Considering Safety During Design Considering Safety During Design Offers the Most PayoffOffers the Most Payoff11

Conceptual Design

Detailed Engineering

Procurement

Construction

Start-up

High

Low

Ability to Influence

Safety

Project Schedule

1 Szymberski 1987

Designing for Safety PaysDesigning for Safety Pays

Reduced workers compensation Reduced workers compensation premiumspremiums

Increased productivityIncreased productivity Fewer delays due to accidentsFewer delays due to accidents

• Allows continued focus on qualityAllows continued focus on quality Proactive clientsProactive clients

• Starting to demand safer construction Starting to demand safer construction and safer designsand safer designs

Example of the Need for DfCSExample 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: Example: Parapet WallsParapet Walls IBC paragraph 704.11.1 requires that a IBC paragraph 704.11.1 requires that a

parapet wall be at least 30 inches highparapet wall be at least 30 inches high OSHA 1926 Subpart M requires aOSHA 1926 Subpart M requires a 36-42 inch guardrail or other fall protection36-42 inch guardrail or other fall protection If the design professional specifies a If the design professional specifies a 36-42 inch high parapet wall, fall protection 36-42 inch high parapet wall, fall protection

would not be required would not be required

Example: Example: Anchorage PointsAnchorage Points

Examples: Examples: PrefabricationPrefabrication

Steel stairs

Concrete Wall Panels

Concrete Segmented Bridge

DfCS Examples: DfCS Examples: RoofsRoofs

Skylights Upper story windows and roof parapets

The Erector The Erector Friendly ColumnFriendly Column• Include holes in Include holes in

columns at 21” columns at 21” and 42” for and 42” for guardrail cables guardrail cables and at higher and at higher locations for fall locations for fall protection tie-offsprotection tie-offs

• Locate column Locate column splices and splices and connections at connections at reasonable reasonable heights above heights above floorfloor

• Provide seats for Provide seats for beam connectionsbeam connections

Avoid hanging Avoid hanging connectionsconnections• Design Design

connections to connections to bear on bear on columnscolumns

Avoid Avoid awkward and awkward and dangerous dangerous connection connection locationslocations

Avoid Avoid tripping tripping hazardshazards

Eliminate Eliminate sharp sharp cornerscorners

Provide Provide enough enough space for space for making making connectionsconnections

Know Know approximate approximate dimensions of dimensions of necessary necessary tools to make tools to make connectionsconnections

Other DfCS Design ExamplesOther DfCS Design Examples

Design underground utilities to be placed Design underground utilities to be placed using trenchless technologiesusing trenchless technologies11

Specify primers, sealers and other Specify primers, sealers and other coatings that do not emit noxious fumes or coatings that do not emit noxious fumes or contain carcinogenic productscontain carcinogenic products22

Design cable type lifeline system for Design cable type lifeline system for storage towersstorage towers33

11 Weinstein et al., “Can Design Improve Construction Safety” (2005)Weinstein et al., “Can Design Improve Construction Safety” (2005)22 Gambatese et al., “Viability of Designing for Construction Worker Safety” Gambatese et al., “Viability of Designing for Construction Worker Safety”

(2005)(2005)33 Behm, “Linking Construction Fatalities to the Design for Construction Safety Behm, “Linking Construction Fatalities to the Design for Construction Safety

Concept” (2005)Concept” (2005)

DfCS ResourcesDfCS Resources www.designforconstructionsafety.orgwww.designforconstructionsafety.org OSHA workgroup 2-4 hour powerpointOSHA workgroup 2-4 hour powerpoint Construction Industry Institute databaseConstruction Industry Institute database

• www.construction-institute.org/scriptcontent/mwww.construction-institute.org/scriptcontent/more/rr101_11_more.cfmore/rr101_11_more.cfm

CHAIRCHAIR• www.workcover.nsw.gov.au/Publications/OHS/www.workcover.nsw.gov.au/Publications/OHS/

SafetyGuides/chairsafetyindesigntool.htmSafetyGuides/chairsafetyindesigntool.htm United Kingdom Health & Safety Executive United Kingdom Health & Safety Executive

designer guidesdesigner guides• www.hse.gov.uk/construction/designers/www.hse.gov.uk/construction/designers/

index.htmindex.htm

ExampleExample from: from: www.hse.gov.uk/construction/designers

Barriers to DfCS Barriers to DfCS Like many good ideas, DfCS faces barriers:Like many good ideas, DfCS faces barriers:

• Contract termsContract terms• Added costsAdded costs• Designers’ fear of liabilityDesigners’ fear of liability• Designers’ lack of knowledgeDesigners’ lack of knowledge

Potential solutions to these barriers Potential solutions to these barriers involve long-term education and involve long-term education and institutional changes.institutional changes.

Example Construction Example Construction Site Accident #1Site Accident #1

Fall from ElevationFall from Elevation

Project:Project:• McNairy Dam Fish FacilityMcNairy Dam Fish Facility

Project Description:Project Description:• Construction of a laboratory visitor Construction of a laboratory visitor

center, a large fish collection facility, center, a large fish collection facility, and power line from the dam to the and power line from the dam to the visitor’s center.visitor’s center.

Location:Location:• Columbia River, OregonColumbia River, Oregon

Example Construction Site Example Construction Site AccidentAccident

Owner/Engineer:Owner/Engineer:• U.S. Army Corps of Engineers (COE)U.S. Army Corps of Engineers (COE)

General Contractor: Heart ConstructionGeneral Contractor: Heart Construction Electrical Subcontractor: J&J ElectricElectrical Subcontractor: J&J Electric

• Scope of work: Install electrical lines and Scope of work: Install electrical lines and controls throughout the project.controls throughout the project.

• Company owners (brothers):Company owners (brothers): Frank Jones (on-site project superintendent)Frank Jones (on-site project superintendent) Jerry Jones (office manager, some work on-site)Jerry Jones (office manager, some work on-site)


Project background:Project background:• Fish containment area consists of an Fish containment area consists of an

upper working level and a lower fish upper working level and a lower fish collection level.collection level.

• Upper level constructed of steel framing Upper level constructed of steel framing supporting galvanized metal removable supporting galvanized metal removable grating. (3 feet wide x 4 feet long grating. (3 feet wide x 4 feet long sections)sections)

• Mechanical and electrical equipment is Mechanical and electrical equipment is located on the upper level.located on the upper level.


Project background:Project background:• Elevation of lower level is 30 feet below Elevation of lower level is 30 feet below

the upper level, except for a concrete the upper level, except for a concrete ledge along one wall which is 3 feet ledge along one wall which is 3 feet below the upper level.below the upper level.

• No permanent access (stairway, ladder, No permanent access (stairway, ladder, etc.) is available between the upper and etc.) is available between the upper and lower levels.lower levels.

• Lower level is under water during Lower level is under water during normal operation.normal operation.


April 23:April 23:• Fish containment area construction Fish containment area construction

complete.complete.• Electrical system testing under way.Electrical system testing under way.• Frank, Jerry, and several Heart Frank, Jerry, and several Heart

employees enter the upper level of the employees enter the upper level of the fish containment area to prepare a test fish containment area to prepare a test of the equipment controls before of the equipment controls before opening the facility.opening the facility.


April 23:April 23:• Frank and Jerry work on the first control Frank and Jerry work on the first control

panel.panel.• After the first control panel is After the first control panel is

completed, Jerry proceeds south to the completed, Jerry proceeds south to the second control panel and begins to second control panel and begins to work.work.

• Frank remains at the first control panel Frank remains at the first control panel talking to the Heart employees.talking to the Heart employees.


April 23:April 23:• Heart employee, George, sees an Heart employee, George, sees an

obstruction on the ledge 3 feet below.obstruction on the ledge 3 feet below.• George walks over next to Jerry and George walks over next to Jerry and

removes a section of metal grating to go removes a section of metal grating to go down to the lower level. The section of down to the lower level. The section of grating was not secured with fasteners.grating was not secured with fasteners.

• George jumps down to the ledge (3 feet George jumps down to the ledge (3 feet below) and replaces the grating above below) and replaces the grating above him, but does not correctly place the him, but does not correctly place the grating over the bolts.grating over the bolts.


April 23:April 23:• While sliding the grating back into place, While sliding the grating back into place,

George says to Jerry that he didn’t want George says to Jerry that he didn’t want anyone to step in the opening.anyone to step in the opening.

• Jerry hears George say something, but Jerry hears George say something, but does not understand because of the does not understand because of the high noise level.high noise level.

• After a few minutes of working on the After a few minutes of working on the second control panel, Jerry calls to Frank second control panel, Jerry calls to Frank to bring him a wrench.to bring him a wrench.


April 23:April 23:• Frank walks over to hand Jerry the wrench.Frank walks over to hand Jerry the wrench.• Frank steps on the grating that George Frank steps on the grating that George

replaced and falls through to the lower level replaced and falls through to the lower level 30 feet below.30 feet below.

• Frank sustains head, back, and neck injuries.Frank sustains head, back, and neck injuries.• Frank now performs only minor office work, Frank now performs only minor office work,

rather than on-site work.rather than on-site work.• J&J profits are less since the accident.J&J profits are less since the accident.


Additional information:Additional information:• The grating fastener system was not part of The grating fastener system was not part of

the original design. The fastener system the original design. The fastener system was proposed by Heart Construction as a was proposed by Heart Construction as a change, and accepted by the Engineer.change, and accepted by the Engineer.

• Special wrenches are required to install and Special wrenches are required to install and remove the grating fasteners. Two remove the grating fasteners. Two wrenches, owned by Heart, were available wrenches, owned by Heart, were available on the jobsite. The wrenches were on the jobsite. The wrenches were sometimes lost or misplaced and not sometimes lost or misplaced and not available. available.


Additional information:Additional information:• Heart Construction held weekly project Heart Construction held weekly project

safety meetings. Jerry attended only one safety meetings. Jerry attended only one meeting.meeting.

• During previous safety meetings, concerns During previous safety meetings, concerns were brought up about lack of support for were brought up about lack of support for the grating sections at locations where the grating sections at locations where portions of the sections were modified. portions of the sections were modified. Occasionally wood was placed across the Occasionally wood was placed across the grating to provide additional support.grating to provide additional support.


Additional information:Additional information:• A temporary ladder between the upper A temporary ladder between the upper

and lower levels which was located and lower levels which was located several yards from the accident site was several yards from the accident site was removed before the accident.removed before the accident.



Questions…Questions…• How could the accident have been How could the accident have been

prevented?prevented?• What could have been done in the What could have been done in the

design and/or the design phase to design and/or the design phase to prevent the accident?prevent the accident?

Example Construction Example Construction Site Accident #2Site Accident #2

Exposure to Hazardous Exposure to Hazardous ChemicalsChemicals

Fan #2

Fan #1

Roof

2ndFloor

1stFloor

Testing Lab

Offices


Scheduled completion date: July 15Scheduled completion date: July 15 July 15: Conduct punchlist inspectionJuly 15: Conduct punchlist inspection

• Punchlist includes window cleaning, replace cracked Punchlist includes window cleaning, replace cracked cover plates, touch-up paint, door alignment, cover plates, touch-up paint, door alignment, replace scratched millwork, correct noise from Fan replace scratched millwork, correct noise from Fan #2, etc.#2, etc.

July 15: Project is defined as substantially July 15: Project is defined as substantially complete.complete.

July 16: Owner occupies a portion of the July 16: Owner occupies a portion of the facility.facility.

July 17: Testing lab begins to function.July 17: Testing lab begins to function.


July 19:July 19:• Electrician’s employee shuts off power Electrician’s employee shuts off power

to Fan #2 to trouble shoot the problem.to Fan #2 to trouble shoot the problem.• Lab technician conducts chemical Lab technician conducts chemical

analysis at the same time.analysis at the same time.• Electrician’s employee determines belt Electrician’s employee determines belt

alignment is the problem. It is alignment is the problem. It is corrected.corrected.

• Power is restored; employee forgets to Power is restored; employee forgets to replace fan belt guard.replace fan belt guard.

• Lab technician complains of headache.Lab technician complains of headache.


Fan #2

Fan #1

Roof

2ndFloor

1stFloor

Testing Lab

Offices

Fan is turned off

Duct line has positive pressure

What happens when fan #2 is What happens when fan #2 is turned off?turned off?

July 20:July 20:• Contractor is informed by owner of lab Contractor is informed by owner of lab

technician’s headache and its cause.technician’s headache and its cause.• Contractor instructs all sub’s to turn in Contractor instructs all sub’s to turn in

their building keys.their building keys.• Sub’s are instructed to gain access only Sub’s are instructed to gain access only

by owner or contractor personnel.by owner or contractor personnel.• Contractor does not explain the reason Contractor does not explain the reason

for the new policy.for the new policy.


July 28:July 28:• Electrician’s employee shuts off power to Electrician’s employee shuts off power to

Fan #2 to replace the fan belt guard.Fan #2 to replace the fan belt guard.• Lab technician conducts chemical Lab technician conducts chemical

analysis as the guard is replaced.analysis as the guard is replaced.• Guard is replaced in 10 minutes.Guard is replaced in 10 minutes.• Power to Fan #2 is restored.Power to Fan #2 is restored.• Lab technician dies at the work station Lab technician dies at the work station

from exposure to deadly chemicals.from exposure to deadly chemicals.



Questions…Questions…• How could the accident have been How could the accident have been

prevented?prevented?• What could have been done in the What could have been done in the

design and/or the design phase to design and/or the design phase to prevent the accident?prevent the accident?

““Safety Considerations Safety Considerations in Design”in Design”

Implementing DfCS in PracticeImplementing DfCS in Practice

How it StartedHow it Started

Content started in Content started in “Constructability” reviews by “Constructability” reviews by Project Management Teams Project Management Teams working with engineering.working with engineering.

Educational LimitationsEducational Limitations

Limited amount of safety training Limited amount of safety training required in engineering required in engineering educational activities.educational activities.

Presented to:Presented to:

EngineersEngineers DesignersDesigners EstimatorsEstimators Contract AdministratorsContract Administrators Procurement ProfessionalsProcurement Professionals

Over 2,000 Over the Last YearOver 2,000 Over the Last Year

AwarenessAwareness

Involvement in Design Build Involvement in Design Build Activities with our own employees Activities with our own employees increased the awareness.increased the awareness.

Safety Qualified SupervisorSafety Qualified Supervisor

Two Day TrainingTwo Day Training 10-Hour OSHA Construction Safety10-Hour OSHA Construction Safety Economics of SafetyEconomics of Safety Supervisor Responsibilities and AccountabilitySupervisor Responsibilities and Accountability Work Planning/Job Hazard AnalysisWork Planning/Job Hazard Analysis Control of EnergyControl of Energy ““Safety Consideration in Design”Safety Consideration in Design”

STS Safety Trained Supervisor CertificationSTS Safety Trained Supervisor Certification

Reference MaterialsReference Materials

Construction Safety Management Construction Safety Management and Engineering – ASSEand Engineering – ASSE

Construction Safety Engineering Construction Safety Engineering Principles – David MacCollumPrinciples – David MacCollum

Safety and Health Engineering – Safety and Health Engineering – Roger BrauerRoger Brauer

Relevant DataRelevant Data

Utilization of Company specific Utilization of Company specific examples and applications.examples and applications.

Client/Regulator InterestClient/Regulator Interest

OSHAOSHA NIOSHNIOSH Corps of EngineersCorps of Engineers NavyNavy Defense Nuclear Facility Safety Defense Nuclear Facility Safety

BoardBoard

Example in Case Study – OSHA Example in Case Study – OSHA WebsiteWebsite

““Washington Group International Washington Group International Designs and Builds a Waste Treatment Designs and Builds a Waste Treatment Facility.”Facility.”

http://www.osha.gov/dcsp/success_stories/alliances/washington/washington_group_case_study.html#Sidebar3

Advanced Mixed Waste Advanced Mixed Waste Treatment Facility (AMWTF) Treatment Facility (AMWTF)

http://www.osha.gov/dcsp/success_stories/alliances/washington/http://www.osha.gov/dcsp/success_stories/alliances/washington/

washington_group_case_study.htm#3Sidebar3washington_group_case_study.htm#3Sidebar3

ObjectivesObjectivesPrevent injuries and accidentsPrevent injuries and accidents:: Develop and/or expand engineering principles Develop and/or expand engineering principles

of Inherently Safer Design for Construction.of Inherently Safer Design for Construction. Implement/educate engineering and design Implement/educate engineering and design

staff in hazard identification and legal staff in hazard identification and legal responsibilities.responsibilities.

Implement specific aims and goals for Implement specific aims and goals for Inherently Safer Design Principles for Inherently Safer Design Principles for Construction.Construction.

Training DiscussesTraining Discusses

Why designers should care about Why designers should care about designing for construction worker designing for construction worker safety.safety.

Opportunities for designing for Opportunities for designing for construction worker safety.construction worker safety.

Barrier for designing for construction Barrier for designing for construction worker safety.worker safety.

Five Principles of Inherently Safer Five Principles of Inherently Safer Design Principles for ConstructionDesign Principles for Construction

Definition of a HazardDefinition of a Hazard Establish a Standard of Safe DesignEstablish a Standard of Safe Design Categorize the HazardCategorize the Hazard Establish Safe Design HierarchyEstablish Safe Design Hierarchy Control the Hazard with Appropriate Control the Hazard with Appropriate

DesignDesign

Order of Precedence for Order of Precedence for Addressing Safety HazardsAddressing Safety Hazards

1.1. Design to eliminate or avoid the Design to eliminate or avoid the hazardhazard

2.2. Design to reduce the hazardDesign to reduce the hazard

3.3. Incorporate safety devices after the Incorporate safety devices after the factfact

4.4. Provide warning devicesProvide warning devices

5.5. Institute training and operating Institute training and operating proceduresprocedures

Hazard Identification MatrixHazard Identification MatrixEliminate the Eliminate the

HazardHazardGuard the HazardGuard the Hazard Provide a Provide a

Safety FactorSafety FactorProvide Provide

RedundancyRedundancyProvide Provide

ReliabilityReliability

HazardHazard SafetySafety HazardHazard SafetySafety HazardHazard SafetySafety HazardHazard SafetySafety

NaturalNatural

Structural/Structural/MechanicalMechanical

ElectricalElectrical

ChemicalChemical

Radiant Radiant EnergyEnergy

BiologicalBiological

Artificial Artificial IntelligenceIntelligence

Safety in Design for Material Handling Safety in Design for Material Handling and Storage Facilitiesand Storage Facilities

Number One Concern is the Machinery, Number One Concern is the Machinery, Material and Human Interface.Material and Human Interface.

Categorize the Hazards Using the Seven Hazard Categorize the Hazards Using the Seven Hazard Sources for Material Handling and Storage Facilities.Sources for Material Handling and Storage Facilities.

Use the Safe Design Hierarchy to Physically Use the Safe Design Hierarchy to Physically eliminate the hazards identified for Material eliminate the hazards identified for Material Handling and Storage facilities.Handling and Storage facilities.

Develop a Hazard Identification Matrix to document Develop a Hazard Identification Matrix to document your findings and design the hazards from the your findings and design the hazards from the Material Handling and Storage Facilities.Material Handling and Storage Facilities.

List all the hazards involved with List all the hazards involved with material handling and storage facilities.material handling and storage facilities.

Natural Hazards:Natural Hazards:

A.A.GravityGravity

1.Falls same level1.Falls same level

1.1.Fall from elevationFall from elevation

1.1.Falling objectsFalling objects

1.1.ImpactImpact

1.1.AccelerationAcceleration

BB. Slopes. Slopes

1. Upset1. Upset

1.1.RolloverRollover

1.1.SlidingSliding

4.Unstable surfaces4.Unstable surfaces

A.A.Limitations on Human Limitations on Human PerformancePerformance

Natural Hazards:Natural Hazards:• Slip, tripsSlip, trips• Improperly secured Improperly secured

materials on materials on trucks, structures, trucks, structures, cranes and on the cranes and on the ground.ground.

• Traffic and Traffic and personnelpersonnel

• Drainage ditchesDrainage ditches• Weather roadway Weather roadway

and walkway and walkway maintenancemaintenance

• Potential for Potential for unstable surfaces unstable surfaces

Designing for Safety PaysDesigning for Safety Pays

Reduced workers compensation Reduced workers compensation premiumspremiums

Increased productivityIncreased productivity Fewer delays due to accidents during Fewer delays due to accidents during

construction allow continued focus construction allow continued focus on qualityon quality

Proactive clients are starting to Proactive clients are starting to demand safer construction and demand safer construction and safety designs.safety designs.

Case Study #1Case Study #1

Circulator PumpsCirculator Pumps

Case Study #1 - Circulator PumpsCase Study #1 - Circulator Pumps


Replacing circulator pumps requires Replacing circulator pumps requires a ladder.a ladder.• Pumps are located in a tight space.Pumps are located in a tight space.

Maintenance worker could fall off Maintenance worker could fall off ladder, drop pump, or suffer hand ladder, drop pump, or suffer hand injury from hitting adjacent piping.injury from hitting adjacent piping.


Design review questions-Design review questions-

Is there enough room to replace the Is there enough room to replace the pumps?pumps?

How high off the ground are the pumps?How high off the ground are the pumps?

What if a maintenance worker has to shut What if a maintenance worker has to shut off a valve in an emergency? off a valve in an emergency?


Identify Hazard –Identify Hazard –

Fall and mechanical Fall and mechanical


Assess Risk –Assess Risk – Severity- slight (knuckles) to serious Severity- slight (knuckles) to serious (head injury)(head injury) Probability- medium (likely)Probability- medium (likely) Risk- low to mediumRisk- low to medium

Additional consideration –Additional consideration –Solution is simple and inexpensiveSolution is simple and inexpensive


DfCS solutions:DfCS solutions:• design pumps close to ground level so design pumps close to ground level so

that a ladder is not required;that a ladder is not required;• provide adequate space around pumps;provide adequate space around pumps;• provide a metal identification tag for provide a metal identification tag for

each valve; andeach valve; and• provide a permanent identification provide a permanent identification

board in the mechanical room that board in the mechanical room that identifies each valve and it’s purpose.identifies each valve and it’s purpose.



Installation\Maintenance of Installation\Maintenance of HVAC System in AtticHVAC System in Attic

Case Study #2 - Install\Maint. of Case Study #2 - Install\Maint. of HVAC System in AtticHVAC System in Attic

HVAC System installed in the attic of HVAC System installed in the attic of a commercial office buildinga commercial office building

No floor or platform/walkways were No floor or platform/walkways were designed or installeddesigned or installed

HVAC technicians had to walk on HVAC technicians had to walk on joists/trussesjoists/trusses



Design review questions:Design review questions:

What will workers stand on when installing What will workers stand on when installing HVAC system?HVAC system?

Will regular maintenance be required?Will regular maintenance be required?

What will the maintenance workers stand What will the maintenance workers stand on?on?

What are the pertinent OSHA regulations?What are the pertinent OSHA regulations?


Identify hazard –Identify hazard –

FALLFALL


Assess Risk –Assess Risk –

Severity- serious (knee) to severe Severity- serious (knee) to severe

(death)(death)

Probability- medium (likely)Probability- medium (likely)

Risk- medium to highRisk- medium to high


DfCS solution:DfCS solution:• design permanent work platforms and design permanent work platforms and

walkways with guardrailswalkways with guardrails


Raw Coal Reclaim FacilityRaw Coal Reclaim Facility

Case Study #3 - Raw Coal Reclaim Case Study #3 - Raw Coal Reclaim FacilityFacility

Plant utility worker was fatally Plant utility worker was fatally injured while performing clean-up injured while performing clean-up duties at a raw coal reclaim area.duties at a raw coal reclaim area.

Victim either fell through a 56” x 80” Victim either fell through a 56” x 80” opening in a platform or entered opening in a platform or entered through a coal feeder opening.through a coal feeder opening.

11Case study courtesy of Washington Group InternationalCase study courtesy of Washington Group International



Will workers need to have access to Will workers need to have access to conveyors?conveyors?

Are covers and/or guardrails provided for Are covers and/or guardrails provided for all openings near or over conveyors?all openings near or over conveyors?

Are covers and/or guardrail gates Are covers and/or guardrail gates interlocked?interlocked?



Identify hazard:Identify hazard:

MechanicalMechanical


Assess Risk –Assess Risk –

Severity- severe (death)Severity- severe (death)

Probability- medium to highProbability- medium to high

Risk- highRisk- high


DfCS solution:DfCS solution:• Design covers and/or guardrails over Design covers and/or guardrails over

conveyor belts and opening to conveyor conveyor belts and opening to conveyor belts.belts.

• Design interlocks for covers and gates.Design interlocks for covers and gates.


Blind Penetration into Blind Penetration into ConcreteConcrete

Case Study #4 - Blind Penetration Case Study #4 - Blind Penetration into Concreteinto Concrete11

A construction worker penetrated an A construction worker penetrated an embedded electrical conduit embedded electrical conduit containing an energized 120-volt line containing an energized 120-volt line while hand drilling into a concrete while hand drilling into a concrete beam to install pipe hanger inserts. beam to install pipe hanger inserts. The conduit was 1 inch from the The conduit was 1 inch from the surface.surface.

11 Dept. of Energy Blind Penetration Incidents Dept. of Energy Blind Penetration Incidents

Case Study #4 - Blind Penetration Case Study #4 - Blind Penetration into Concreteinto Concrete


How will the worker install the pipe How will the worker install the pipe hangers?hangers?

Are there any electrical lines in the Are there any electrical lines in the concrete beam?concrete beam?

Are there any pipe hangers that will be Are there any pipe hangers that will be near an electrical line?near an electrical line?


Assess Risk-Assess Risk-

Severity- severe (death)Severity- severe (death)

Probability- moderate to mediumProbability- moderate to medium

Risk- medium to highRisk- medium to high


DfCS Solutions:DfCS Solutions:• Design embedded electrical lines deeper Design embedded electrical lines deeper

than the maximum depth of the pipe than the maximum depth of the pipe hanger bolts.hanger bolts.

• Clearly mark locations of electrical lines Clearly mark locations of electrical lines on contract drawings.on contract drawings.

National InitiativesNational Initiatives

OSHA Construction Alliance OSHA Construction Alliance Roundtable DfCS WorkgroupRoundtable DfCS Workgroup

NIOSH NORA Construction Sector NIOSH NORA Construction Sector Council CHPtD Workgroup and Council CHPtD Workgroup and Prevention Through Design National Prevention Through Design National Workshop (July 2007)Workshop (July 2007)

ASCE-CI PtD CommitteeASCE-CI PtD Committee

OSHA Construction Alliance DfCS OSHA Construction Alliance DfCS Workgroup MembersWorkgroup Members

Amer. Society of Civil Engineers-Construction InstituteAmer. Society of Civil Engineers-Construction Institute American Society of Safety EngineersAmerican Society of Safety Engineers Independent Electrical Contractors Independent Electrical Contractors ADSC: International Association of Foundation Drilling ADSC: International Association of Foundation Drilling Laborers Health and Safety Fund of North America Laborers Health and Safety Fund of North America Mason Contractors Association of America Mason Contractors Association of America National Fire Protection Association National Fire Protection Association National Institute for Occupational Safety & Health National Institute for Occupational Safety & Health Sealant, Waterproofing and Restoration Institute Sealant, Waterproofing and Restoration Institute Washington Group InternationalWashington Group International

Five DfCS TrajectoriesFive DfCS Trajectories1.1. Increased prefabricationIncreased prefabrication

2.2. Increased use of less hazardous Increased use of less hazardous materials and systemsmaterials and systems

3.3. Increased application of construction Increased application of construction engineeringengineering

4.4. Increased spatial investigation and Increased spatial investigation and considerationconsideration

5.5. Increased collaboration and Increased collaboration and integrationintegration

Increased PrefabricationIncreased Prefabrication Shift site work to safer work site Shift site work to safer work site

environmentenvironment• elevation to groundelevation to ground• underground to gradeunderground to grade• confined space to open spaceconfined space to open space

Shift site work to factoryShift site work to factory• Allows use of safer, automated equipmentAllows use of safer, automated equipment• Provides safer, engineered environmentProvides safer, engineered environment

Increased Use of Less Hazardous Increased Use of Less Hazardous Materials and SystemsMaterials and Systems

Coatings, sealants, cleanersCoatings, sealants, cleaners

Building systemsBuilding systems• Steel, concrete, masonry, woodSteel, concrete, masonry, wood

Increased Construction EngineeringIncreased Construction Engineering Examples of construction engineeringExamples of construction engineering

• Soil retention systemsSoil retention systems• Crane liftsCrane lifts• Temporary loadsTemporary loads• Temporary structuresTemporary structures• Fall protection anchorage pointsFall protection anchorage points

Why are designers increasingly involvedWhy are designers increasingly involved• Growth of design-buildGrowth of design-build• Their understanding of structure and siteTheir understanding of structure and site

Increased Spatial InvestigationIncreased Spatial Investigation Communicating site hazards on Communicating site hazards on

project documentsproject documents Working distances for each tradeWorking distances for each trade

• Cranes and powerlinesCranes and powerlines• Excavation dimensions for work withinExcavation dimensions for work within• Steel connectionsSteel connections• Raceways and plumbing pipesRaceways and plumbing pipes

Ergonomic issuesErgonomic issues• OverheadOverhead• Awkward anglesAwkward angles

Example DfCS ProcessExample DfCS Process

Design Kickoff Design

Internal Review

Issue for Construction

External Review

Trade contractor involvement

• Establish design for safety expectations

• Include construction and operation perspective

• Identify design for safety process and tools

• QA/QC

• Cross-discipline review

• Focused safety review

• Owner review

Facilitating CollaborationFacilitating Collaboration

Having designers interact with Having designers interact with constructorsconstructors

Having specialists interact with Having specialists interact with generalist plannersgeneralist planners

Implications for contracting/delivery Implications for contracting/delivery methodmethod

Implications for Education of Implications for Education of Design EngineersDesign Engineers

Shift in mindsetShift in mindset Holistic viewHolistic view Exposure to DfCS fundamentalsExposure to DfCS fundamentals Training in system-specific DfCS Training in system-specific DfCS

opportunitiesopportunities Engineering course-specific DfCS Engineering course-specific DfCS

modulesmodules

Implications for ContractingImplications for Contracting

New contract terms neededNew contract terms needed Design-Bid-Build typically hinders Design-Bid-Build typically hinders

collaboration during designcollaboration during design Design-Build and Design+Negotiated Design-Build and Design+Negotiated

construction better facilitate construction better facilitate collaborationcollaboration

Implications for Use of Information Implications for Use of Information TechnologyTechnology

IT represents efficient means for IT represents efficient means for providing designers with information providing designers with information needed to perform DfCSneeded to perform DfCS

Manufacturers must make DfCS Manufacturers must make DfCS information availableinformation available

All entities will need IT to facilitate All entities will need IT to facilitate communication, collaboration, communication, collaboration, integrationintegration

What do you think? What do you think? How can we reduce barriers to DfCS?How can we reduce barriers to DfCS?

• Designers’ fear of liabilityDesigners’ fear of liability• Designers’ lack of knowledgeDesigners’ lack of knowledge

Where Do You Fit In?Where Do You Fit In? Initiate or expand DfCS in your Initiate or expand DfCS in your

companycompany Share information about your DfCS Share information about your DfCS

programprogram Provide data to make the business Provide data to make the business

case for DfCS case for DfCS Serve as a case studyServe as a case study Participate in the OSHA workgroup Participate in the OSHA workgroup

and/or the ASCE-CI PtD Committeeand/or the ASCE-CI PtD Committee

SummarySummary Designing for construction safety is:Designing for construction safety is:

• the right thing to do, andthe right thing to do, and• the smart thing to do.the smart thing to do.

Many countries require or promote Many countries require or promote designing for safetydesigning for safety

National organizations are working to National organizations are working to create tools, eliminate barriers and create tools, eliminate barriers and facilitate adoption of this important facilitate adoption of this important process in the United Statesprocess in the United States

Your participation is needed!Your participation is needed!

Thanks for Participating!Thanks for Participating!

Questions? Comments?Questions? Comments?

[email protected]@oregonstate.edu [email protected]@bucknell.edu [email protected]@wgint.com

The following slides are just in case The following slides are just in case someone asks….someone asks….

Barrier: Contract TermsBarrier: 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 Barrier: Increased Designer Costs Associated with DfCSAssociated with DfCS

While DfCS results in decreased total While DfCS results in decreased total project life cycle costs for the owner, project life cycle costs for the owner, DfCS processes will increase both DfCS processes will increase both direct and overhead costs for direct and overhead costs for designers. designers.

Potential solution: Educate owners : Educate owners that they must be willing to pay that they must be willing to pay slightly higher design fees to save slightly higher design fees to save themselves money in the long run.themselves money in the long run.

Barrier: Designers' Fear of LiabilityBarrier: 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 Barrier: Designers' Lack of Safety ExpertiseExpertise

Barrier: Few design professionals Barrier: Few design professionals possess sufficient expertise in possess sufficient expertise in construction safety.construction safety.

Potential solution: include : include construction safety in construction, construction safety in construction, engineering and architectural engineering and architectural curricula.curricula.

Potential solution: Develop and : Develop and promote 10-hour and 30-hour OSHA promote 10-hour and 30-hour OSHA courses for design professionals.courses for design professionals.

The Washington Group’s The Washington Group’s Training InitiativeTraining Initiative

The Washington Group International The Washington Group International provides safe design training to:provides safe design training to:• EngineeringEngineering• DesignDesign• ProcurementProcurement• ContractsContracts• EstimatingEstimating

WG’s Safety Qualified Supervisor WG’s Safety Qualified Supervisor TrainingTraining

2 Day Training2 Day Training 10-Hour OSHA Construction Safety10-Hour OSHA Construction Safety Economics of SafetyEconomics of Safety Safety Res. & AccountabilitySafety Res. & Accountability Work Planning & Job Hazard AnalysisWork Planning & Job Hazard Analysis Safety Construction & DesignSafety Construction & Design

An Ounce of Prevention An Ounce of Prevention is Worth a Pound of Cureis Worth a Pound of Cure

Order of precedence for addressing Order of precedence for addressing safety hazardssafety hazards1.1.Design to eliminate or avoid the hazardDesign to eliminate or avoid the hazard

2.2.Design to reduce the hazardDesign to reduce the hazard

3.3.Incorporate safety devices after the factIncorporate safety devices after the fact

4.4.Provide warning devicesProvide warning devices

5.5.Institute training and operating proceduresInstitute training and operating procedures

(Source: Manuele, F.A., “On the Practice of Safety.” Wiley and Sons, Inc. New York, NY, 1997.)(Source: Manuele, F.A., “On the Practice of Safety.” Wiley and Sons, Inc. New York, NY, 1997.)

Documents

The Future of Design for Construction Safety 18 th Annual Construction Safety Conference Rosemont, IL February 12, 2008 John Gambatese, PhD, PE Chair,