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NIOSH Reports! Studies on Heavy Equipment
Blind Spots and Internal Traffic Control
Presented by
David E. Fosbroke
NIOSH, Division of Safety
Research
2004 Roadway Work Zone Safety & Health Conference
Baltimore, Maryland
November 4, 2004
Outline
Background
NIOSH Research
Worker Deaths
Blind Area Diagrams
Internal Traffic Control Plans
Doug Ammons, Steve Berardinelli, Jennifer Beaupre,
Dave Fosbroke, Chris Griffin, Robert Hammer, Mat
Hause, Scott Hendricks, Gary Mowrey, Brad
Newbraugh, Kara Perritt, John Powers, Stephanie
Pratt, Justin Tolpa, Todd Ruff, Bill Schiffbauer
Evaluating Roadway Construction Work
Zone Interventions
Project Organization
State Transportation Departments
Construction Companies
Engineering Consultants
Labor Unions
Construction Trade Associations
Equipment Manufacturers
FHWA, OSHA
Roadway Work Zone Intervention Evaluations
Morgantown, WV
Worker Exposure Measurement
Blind Area Determination
Internal Traffic Control Plans
Site Access / Partnering
Case Definition
HSRB/OMB/Photo Release
Research Staff Safety
Pittsburgh, PA
HASARD
Work Zone Analysis System
Spokane, WA
Proximity Warning Devices
Detection Zones
The Problem
Preventing workers from
being run over by
construction trucks and
equipment.
The Project Goals
Limit exposure of workers-on-foot to
construction traffic.
Focus on blind areas around
construction vehicles and equipment.
Develop exposure monitoring system(s)
Evaluate injury prevention measures
The Interventions
Proximity Warning Systems
Internal Traffic Control Plans
Proximity Warning Systems
Evaluate off-the-
shelf technology
including:
Radar
Sonar
Cameras
Tag-based
systems
Camera Systems
Radar Sonar
Sensors
Camera and Radar
Camera
Radar
Proximity Warning Systems: Data
collection methods
Warning system alarms
• Video
• Alarm overlay
• Alarm data
HASARD
INTERNAL TRAFFIC CONTROL PLANS
Paving Model Plan – Site #1
Field Trials
Direct Observation
GPS
Video
GPS Installed on Equipment including:
Asphalt Trucks
Paver
Rollers
GPS receivers worn by workers
Vermont GPS Data Overlaid in Map Point
Vermont GPS Data Paving Around a Rest Area
910 worker deaths in
work zones from 1992-
2000
826 (91%) were vehicle
or equipment-related
(traffic vehicle,
construction vehicle, or
both)
Background: Worker Deaths in Work Zones
Worker Fatalities in Roadway Construction
0
20
40
60
80
100
120
140
1992 1993 1994 1995 1996 1997 1998 1999 2000
Year
Deaths
Trend from 1992-2000
(n=910)
Source: Census of Fatal Occupational Injuries,
special research file (excludes NYC)
Worker Fatalities in Roadway Work Zones,
by Vehicle Type and Year, 1992-2000 (n=797)
0
10
20
30
40
50
60
70
80
1992 1993 1994 1995 1996 1997 1998 1999 2000
Year
Deaths
Construction vehicle
Traffic vehicle
Both
Source: Census of Fatal Occupational Injuries,
special research file (excludes NYC)
Workers on Foot – Construction
Vehicle Only
0 20 40 60 80 100 120
Other vehicle/other source
Other machine
Other/unspec truck
Excavating machine
Grading/surfacing machine
Semi-truck
Dump truck
Vehicle
Deaths
Source: Census of Fatal Occupational Injuries,
special research file (excludes NYC)
Deaths by Construction Vehicle Type, 1992-2000 (n=258)
41%
14.3%
14%
7.7%
10.4%
6.5%
6%
Blind Areas
Definition of Blind Area
A blind area is the area around a vehicle
or piece of construction equipment that is
not visible to the operators, either by
direct line-of-sight or indirectly by use of
internal and external mirrors.
Vehicle Blind Spots
Running over people
Running over materials
Striking other equipment and vehicles
Rollovers
Contact with utilities
Area of fully
obstructed view
Non-Construction Vehicle Blind Spot
Measurements
Methods
International Organization
for Standardization (ISO)
5006
Manual methods
Light Bar
Operator
Computer methods
Design Drawings
Laser Scans
Photographs
Manual Light Bar Method
Dump Truck (Manufacturer
and Model) Ford 880
GVW 54,000 lb
Serial # V00131
Machine Dimensions 7' 10" wide 23' 2" long
Operator Enclosure Closed ROPS
Attachments None
Other Information None
Measurement Technique Physical
Blind Area Diagrams - Ford 880
Ground Construction Barrel Worker
~3ft partially bent over
~5ft
Manual Operator Method
Marking Blind Areas Within a Polar Grid
Caterpillar 672CH Blind Area at 900mm
above Ground Plane
Blind Area Diagram Ford 880 Dump Truck
Not Visible to
Operator
Visible in mirrors
only
Comparison of Manual Methods
Field Crew Light Bar
Virtual Reality Method
Blind Area Diagrams
Photo Generated
Blind Areas
Contract Deliverable
Center for Disease Control and Prevention
Contract 200-2002-00563
“Construction Vehicle and Equipment
Blind Area Diagrams”
Final Report
Blind Area Diagrams
Caterpillar Contract
Shadow Method
and Computer
Generated Blind
Areas
Web Page of Blind Area Diagrams
Internal Traffic Control Plans
Why Develop an Internal Traffic
Control Plan?
Coordinate
vehicle/equipment
movement inside the
work zone
Limit exposure of
workers on foot to
construction traffic
Reduce hazards for
equipment operators
Definition of Internal Traffic Control
Plans (ITCP)
“STRATEGIES TO CONTROL THE FLOW OF
CONSTRUCTION WORKERS, VEHICLES AND
EQUIPMENT INSIDE THE WORKZONE”
Traffic
Control
Plans
TCP – ITCP PARALLELS
TCP
TYPICAL
RESPONSIBLE
PERSON
REQUIRED BY
MUTCD
ITCP
MODEL
COMPETENT
PERSON
CONCEPT
⇒
⇒
⇒
PRINCIPLES OF SAFE CONSTRUCTION
TRAFFIC CONTROL
Reducing the need to back up
equipment
Limiting access points to work zones
Establishing pedestrian-free areas
where possible
Establishing work zone layouts
commensurate with type of equipment
Providing signs within the work zone to give
guidance to pedestrians, equipment and
trucks
Designing buffer spaces to protect
pedestrians from errant vehicles or work zone
equipment
PRINCIPLES OF SAFE CONSTRUCTION
TRAFFIC CONTROL
ITCP COMPONENTS
NOTES PAGE
LEGEND
WORK AREA
DIAGRAMS
NOTES PAGE
SAFETY POINTS
PERSONNEL
EQUIPMENT
SAFETY POINTS
1. Truck spotter stays at paver
2. Stage trucks to minimize backing
3. No walking behind backing
trucks, in front of paving
machine, across hot mat, or
over trailer tongue.
PERSONNEL
Truck Drivers
Truck Spotter
Paver Operator
Roller Operators
EQUIPMENT
Oiler Trucks
Dump Trucks
Pavers
Rollers
Inspector
Superintendent
Test Personnel
Detailed
Notes
No workers in traffic zone
Spotter uses hands free radio to talk to
trucks
No workers on foot between a backing
truck and the paver
Truck spotter remains at paver until truck
stops
Inspectors remain away from paving train
and notify spotter before obtaining
samples
Safety Points
PEDESTRIAN-FREE ZONE
TRUCK MOVEMENT
DIRECTION OF TRAFFIC
DIRECTION OF TEMPORARY TRAFFIC OR DETOUR
CHANNELING DEVICE(S)
SIGN (SHOWN FACING RIGHT)
- On foot personnel classes -
OTHER CLASS
SURVEYORINSPECTOR
FLAGGERSPOTTER
FOREMANPEDESTRIAN WORKERP
D
I S
F
A
LIGHT(S)
BARRIER
PORTABLE LAVATORY
WATER TRUCKOIL TRUCK
DUMP TRUCK (FULL)
DUMP TRUCK (EMPTY)
DOZER
BACKHOE
FRONT LOADERGRADER
PAVING MACHINEROLLER
OIL WATER
CRANE FORKLIFT
SWEEPER
- Vehicle Types -
BOTTOM DUMP
PICKUP TRUCK MILLING MACHINE
Paving Model Plan – Traffic Adjacent
Paving Model Plan –
Site #1
Paving Model Plan – Site #2
Ingress
Paving Model Plan – Site #2
Egress
STEPS IN PREPARATION OF ITCPS
Review TCP and other contract
documents
Determine site-specific ITCP needs
Draw work space
Add pedestrian and equipment paths
Locate staging areas
Prepare notes and plan
Internal Traffic Control Plans – Questions
Can the need for backing be reduced or
eliminated?
Can the number of vehicle access points
into the work space be reduced?
Can pedestrian-free zones be
established?
Can the work space accommodate the
equipment being used?
Do any physical features of the site place
operators at risk?
Internal Traffic Control Plan: How-To Guide
Internal Traffic Control PlanInternal Traffic Control Plan
Draft Development GuideDraft Development Guide
Internal Traffic Control Plans forInternal Traffic Control Plans for
Asphalt Paving OperationsAsphalt Paving Operations
On Freeway SegmentsOn Freeway Segments
Task 8.1Task 8.1
Contract No. 200Contract No. 200--20022002--0059600596
Submitted to theSubmitted to the
CENTERS FOR DISEASE CONTROLCENTERS FOR DISEASE CONTROL
and PREVENTIONand PREVENTION
CONTRACTS MANAGEMENT BRANCHCONTRACTS MANAGEMENT BRANCH
Submitted bySubmitted by
C.L. Williams Consulting, Inc.C.L. Williams Consulting, Inc.
4720 W. Maverick Lane, Suite #1034720 W. Maverick Lane, Suite #103
Lakeside, Arizona 85929Lakeside, Arizona 85929
June 19, 2003June 19, 2003
Revised Internal Traffic Control PlanRevised Internal Traffic Control Plan
Site 2Site 2
Internal Traffic Control Plans forInternal Traffic Control Plans for
Asphalt Paving OperationsAsphalt Paving Operations
On Freeway SegmentsOn Freeway Segments
Task 7.1Task 7.1
Contract No. 200Contract No. 200--20022002--0059600596
Submitted to theSubmitted to the
CENTERS FOR DISEASE CONTROLCENTERS FOR DISEASE CONTROL
and PREVENTIONand PREVENTION
CONTRACTS MANAGEMENT BRANCHCONTRACTS MANAGEMENT BRANCH
Submitted bySubmitted by
C.L. Williams Consulting, Inc.C.L. Williams Consulting, Inc.
4720 W. Maverick Lane, Suite #1034720 W. Maverick Lane, Suite #103
Lakeside, Arizona 85929Lakeside, Arizona 85929
May 16, 2003May 16, 2003
ITCP Concrete Plans
Fatality Investigations
http://www.cdc.gov/niosh/face/faceweb.html
Participating FACE States
Example Fatality Cases
Case 1:45-year-old boom truck driver run
over by dump truck that was backing
during a repositioning maneuver.
Case 2: 31-year-old worker run over by
front-end loader at the site of a crushing
machine.
Case 3: 35-year-old laborer run over by
dump truck at roadway resurfacing
operation.
Case 1
Minnesota Face Program
(MN9207)
Turn-around
Paver
Truck Line
Concrete Paving Operation Layout
XX
Truck Line
Turn-around
New
Truck
Last
Truck
Truck Queue Repositioning
Case 2
Minnesota FACE Program (98MN030)
Original Site Layout
Redesigned Site Layout
Two-lane County Road -- Four-lane State
Highway
Case 3
Two-
lane
County
Road
Paving
Machine
Roller
Truck
Victim’
s Work
Area
Victim
Flagger
View from the
Street
View from Inside the Cab
Bug
Shield
Stickers
Fan
Air Cleaner and Door
Post
Mirror
Evaluating Roadway Construction WorkEvaluating Roadway Construction Work
Zone InterventionsZone Interventions
Highway paving operations (probably major
recon or new const)
Separated from traffic by more than cones
and barrels
Asphalt paving
Daytime operation
Control and treatment sites being
paved by different crews
Room for research trailer
Three weeks of paving at site
Contractor and DOT cooperation
David E. Fosbroke
NIOSH
Division of Safety
Research Morgantown,
WV
(304) 285-6010
dFosbroke@cdc.gov

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NIOSH Heavy Equipment Blind Spots and Internal Traffic Control

  • 1. NIOSH Reports! Studies on Heavy Equipment Blind Spots and Internal Traffic Control Presented by David E. Fosbroke NIOSH, Division of Safety Research 2004 Roadway Work Zone Safety & Health Conference Baltimore, Maryland November 4, 2004
  • 2. Outline Background NIOSH Research Worker Deaths Blind Area Diagrams Internal Traffic Control Plans
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  • 4. Doug Ammons, Steve Berardinelli, Jennifer Beaupre, Dave Fosbroke, Chris Griffin, Robert Hammer, Mat Hause, Scott Hendricks, Gary Mowrey, Brad Newbraugh, Kara Perritt, John Powers, Stephanie Pratt, Justin Tolpa, Todd Ruff, Bill Schiffbauer Evaluating Roadway Construction Work Zone Interventions
  • 5. Project Organization State Transportation Departments Construction Companies Engineering Consultants Labor Unions Construction Trade Associations Equipment Manufacturers FHWA, OSHA Roadway Work Zone Intervention Evaluations Morgantown, WV Worker Exposure Measurement Blind Area Determination Internal Traffic Control Plans Site Access / Partnering Case Definition HSRB/OMB/Photo Release Research Staff Safety Pittsburgh, PA HASARD Work Zone Analysis System Spokane, WA Proximity Warning Devices Detection Zones
  • 6. The Problem Preventing workers from being run over by construction trucks and equipment.
  • 7. The Project Goals Limit exposure of workers-on-foot to construction traffic. Focus on blind areas around construction vehicles and equipment. Develop exposure monitoring system(s) Evaluate injury prevention measures
  • 8. The Interventions Proximity Warning Systems Internal Traffic Control Plans
  • 9. Proximity Warning Systems Evaluate off-the- shelf technology including: Radar Sonar Cameras Tag-based systems
  • 13. Proximity Warning Systems: Data collection methods Warning system alarms • Video • Alarm overlay • Alarm data
  • 15. INTERNAL TRAFFIC CONTROL PLANS Paving Model Plan – Site #1
  • 17. GPS Installed on Equipment including: Asphalt Trucks Paver Rollers GPS receivers worn by workers
  • 18. Vermont GPS Data Overlaid in Map Point
  • 19. Vermont GPS Data Paving Around a Rest Area
  • 20. 910 worker deaths in work zones from 1992- 2000 826 (91%) were vehicle or equipment-related (traffic vehicle, construction vehicle, or both) Background: Worker Deaths in Work Zones
  • 21. Worker Fatalities in Roadway Construction 0 20 40 60 80 100 120 140 1992 1993 1994 1995 1996 1997 1998 1999 2000 Year Deaths Trend from 1992-2000 (n=910) Source: Census of Fatal Occupational Injuries, special research file (excludes NYC)
  • 22. Worker Fatalities in Roadway Work Zones, by Vehicle Type and Year, 1992-2000 (n=797) 0 10 20 30 40 50 60 70 80 1992 1993 1994 1995 1996 1997 1998 1999 2000 Year Deaths Construction vehicle Traffic vehicle Both Source: Census of Fatal Occupational Injuries, special research file (excludes NYC)
  • 23. Workers on Foot – Construction Vehicle Only 0 20 40 60 80 100 120 Other vehicle/other source Other machine Other/unspec truck Excavating machine Grading/surfacing machine Semi-truck Dump truck Vehicle Deaths Source: Census of Fatal Occupational Injuries, special research file (excludes NYC) Deaths by Construction Vehicle Type, 1992-2000 (n=258) 41% 14.3% 14% 7.7% 10.4% 6.5% 6%
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  • 29. Definition of Blind Area A blind area is the area around a vehicle or piece of construction equipment that is not visible to the operators, either by direct line-of-sight or indirectly by use of internal and external mirrors.
  • 30. Vehicle Blind Spots Running over people Running over materials Striking other equipment and vehicles Rollovers Contact with utilities
  • 32. Non-Construction Vehicle Blind Spot Measurements
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  • 34. Methods International Organization for Standardization (ISO) 5006 Manual methods Light Bar Operator Computer methods Design Drawings Laser Scans Photographs
  • 36. Dump Truck (Manufacturer and Model) Ford 880 GVW 54,000 lb Serial # V00131 Machine Dimensions 7' 10" wide 23' 2" long Operator Enclosure Closed ROPS Attachments None Other Information None Measurement Technique Physical
  • 37. Blind Area Diagrams - Ford 880 Ground Construction Barrel Worker ~3ft partially bent over ~5ft
  • 39. Marking Blind Areas Within a Polar Grid
  • 40. Caterpillar 672CH Blind Area at 900mm above Ground Plane
  • 41. Blind Area Diagram Ford 880 Dump Truck Not Visible to Operator Visible in mirrors only
  • 42. Comparison of Manual Methods Field Crew Light Bar
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  • 52. Blind Area Diagrams Photo Generated Blind Areas
  • 53. Contract Deliverable Center for Disease Control and Prevention Contract 200-2002-00563 “Construction Vehicle and Equipment Blind Area Diagrams” Final Report
  • 54. Blind Area Diagrams Caterpillar Contract Shadow Method and Computer Generated Blind Areas
  • 55. Web Page of Blind Area Diagrams
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  • 59. Why Develop an Internal Traffic Control Plan? Coordinate vehicle/equipment movement inside the work zone Limit exposure of workers on foot to construction traffic Reduce hazards for equipment operators
  • 60. Definition of Internal Traffic Control Plans (ITCP) “STRATEGIES TO CONTROL THE FLOW OF CONSTRUCTION WORKERS, VEHICLES AND EQUIPMENT INSIDE THE WORKZONE”
  • 62. TCP – ITCP PARALLELS TCP TYPICAL RESPONSIBLE PERSON REQUIRED BY MUTCD ITCP MODEL COMPETENT PERSON CONCEPT ⇒ ⇒ ⇒
  • 63. PRINCIPLES OF SAFE CONSTRUCTION TRAFFIC CONTROL Reducing the need to back up equipment Limiting access points to work zones Establishing pedestrian-free areas where possible Establishing work zone layouts commensurate with type of equipment
  • 64. Providing signs within the work zone to give guidance to pedestrians, equipment and trucks Designing buffer spaces to protect pedestrians from errant vehicles or work zone equipment PRINCIPLES OF SAFE CONSTRUCTION TRAFFIC CONTROL
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  • 68. NOTES PAGE SAFETY POINTS PERSONNEL EQUIPMENT SAFETY POINTS 1. Truck spotter stays at paver 2. Stage trucks to minimize backing 3. No walking behind backing trucks, in front of paving machine, across hot mat, or over trailer tongue. PERSONNEL Truck Drivers Truck Spotter Paver Operator Roller Operators EQUIPMENT Oiler Trucks Dump Trucks Pavers Rollers Inspector Superintendent Test Personnel
  • 70. No workers in traffic zone Spotter uses hands free radio to talk to trucks No workers on foot between a backing truck and the paver Truck spotter remains at paver until truck stops Inspectors remain away from paving train and notify spotter before obtaining samples Safety Points
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  • 72. PEDESTRIAN-FREE ZONE TRUCK MOVEMENT DIRECTION OF TRAFFIC DIRECTION OF TEMPORARY TRAFFIC OR DETOUR CHANNELING DEVICE(S) SIGN (SHOWN FACING RIGHT) - On foot personnel classes - OTHER CLASS SURVEYORINSPECTOR FLAGGERSPOTTER FOREMANPEDESTRIAN WORKERP D I S F A LIGHT(S) BARRIER PORTABLE LAVATORY
  • 73. WATER TRUCKOIL TRUCK DUMP TRUCK (FULL) DUMP TRUCK (EMPTY) DOZER BACKHOE FRONT LOADERGRADER PAVING MACHINEROLLER OIL WATER CRANE FORKLIFT SWEEPER - Vehicle Types - BOTTOM DUMP PICKUP TRUCK MILLING MACHINE
  • 74. Paving Model Plan – Traffic Adjacent
  • 75. Paving Model Plan – Site #1
  • 76. Paving Model Plan – Site #2 Ingress
  • 77. Paving Model Plan – Site #2 Egress
  • 78. STEPS IN PREPARATION OF ITCPS Review TCP and other contract documents Determine site-specific ITCP needs Draw work space Add pedestrian and equipment paths Locate staging areas Prepare notes and plan
  • 79. Internal Traffic Control Plans – Questions Can the need for backing be reduced or eliminated? Can the number of vehicle access points into the work space be reduced? Can pedestrian-free zones be established? Can the work space accommodate the equipment being used? Do any physical features of the site place operators at risk?
  • 80. Internal Traffic Control Plan: How-To Guide Internal Traffic Control PlanInternal Traffic Control Plan Draft Development GuideDraft Development Guide Internal Traffic Control Plans forInternal Traffic Control Plans for Asphalt Paving OperationsAsphalt Paving Operations On Freeway SegmentsOn Freeway Segments Task 8.1Task 8.1 Contract No. 200Contract No. 200--20022002--0059600596 Submitted to theSubmitted to the CENTERS FOR DISEASE CONTROLCENTERS FOR DISEASE CONTROL and PREVENTIONand PREVENTION CONTRACTS MANAGEMENT BRANCHCONTRACTS MANAGEMENT BRANCH Submitted bySubmitted by C.L. Williams Consulting, Inc.C.L. Williams Consulting, Inc. 4720 W. Maverick Lane, Suite #1034720 W. Maverick Lane, Suite #103 Lakeside, Arizona 85929Lakeside, Arizona 85929 June 19, 2003June 19, 2003 Revised Internal Traffic Control PlanRevised Internal Traffic Control Plan Site 2Site 2 Internal Traffic Control Plans forInternal Traffic Control Plans for Asphalt Paving OperationsAsphalt Paving Operations On Freeway SegmentsOn Freeway Segments Task 7.1Task 7.1 Contract No. 200Contract No. 200--20022002--0059600596 Submitted to theSubmitted to the CENTERS FOR DISEASE CONTROLCENTERS FOR DISEASE CONTROL and PREVENTIONand PREVENTION CONTRACTS MANAGEMENT BRANCHCONTRACTS MANAGEMENT BRANCH Submitted bySubmitted by C.L. Williams Consulting, Inc.C.L. Williams Consulting, Inc. 4720 W. Maverick Lane, Suite #1034720 W. Maverick Lane, Suite #103 Lakeside, Arizona 85929Lakeside, Arizona 85929 May 16, 2003May 16, 2003
  • 84. Example Fatality Cases Case 1:45-year-old boom truck driver run over by dump truck that was backing during a repositioning maneuver. Case 2: 31-year-old worker run over by front-end loader at the site of a crushing machine. Case 3: 35-year-old laborer run over by dump truck at roadway resurfacing operation.
  • 85. Case 1 Minnesota Face Program (MN9207)
  • 88. Case 2 Minnesota FACE Program (98MN030)
  • 91. Two-lane County Road -- Four-lane State Highway Case 3
  • 94. View from Inside the Cab Bug Shield Stickers Fan Air Cleaner and Door Post Mirror
  • 95. Evaluating Roadway Construction WorkEvaluating Roadway Construction Work Zone InterventionsZone Interventions Highway paving operations (probably major recon or new const) Separated from traffic by more than cones and barrels Asphalt paving
  • 96. Daytime operation Control and treatment sites being paved by different crews Room for research trailer Three weeks of paving at site Contractor and DOT cooperation
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  • 98. David E. Fosbroke NIOSH Division of Safety Research Morgantown, WV (304) 285-6010 dFosbroke@cdc.gov