Examining Safety at Top Contractors

The Engineering News Record recently published a list of the Top 400 Contractors.  At companies with $10-$30 billion in revenue, the number and size of contracts justifies a dedication to worker safety that small to mid sized businesses can emulate to help shorten the learning curve. Safety is deeply integrated into each of the Top 3 contractors’ day to day business policies and organizational culture.  Contracting firms that strive to achieve success may observe this theme as motivation to implement safety at the highest level to increase revenue and support growth.

Bechtel

At Bechtel, the safety goal is Zero Accidents.  Safety is integrated into each project via technical field procedures and extensive training.  Each employee has ‘stop-work authority’ if they feel a job responsibility is potentially unsafe.  To incenitivize safety and communicate its importance to employees, Bechtel provides multiple awards for exceptional safety performance and innovation.

Fluor

Fluor’s commitment to safety includes a “ZERO incidents” policy. Fluor has received recognition as one of America’s top safety companies by demonstrating excellence in “support from management and employee involvement, innovative solutions to safety challenges and effective training programs.” One such program is the Field Audit system, a proactive approach to identify and mitigate work hazards.

Kiewit

Kiewit has instituted and follows a ‘Nobody Gets Hurt’ policy.  Kiewit is focused on preventing even the most minor injuries through  employee engagement throughout the organization coupled with a supporting management commitment.  “Safety training, observation programs and job hazard analyses” help to support this vision.

Innovative Access Solutions

Innovative Access Solutions provides safety equipment to each of the Top 3 contractors listed above.  In addition to the Trucker series of trailer access products, IAS provides custom access solutions for remote locations, unique jobsite requirements and more, in support of construction work safety policies.  To request information about safety equipment from Innovative Access Solutions, click here.

Preventing Falls in Construction

Falls in construction are a well known cause of work injury.  A common misconception is that fall injuries are primarily of concern to individuals that work at heights.  This is not an accurate representation of the danger presented by slips, trips, and falls, even at minimal height.  In heavy and highway construction, also known as horizontal construction, falls account for approximately 25% of workers compensation claims.  These consist of falls from trucks, trailers, and construction equipment (45%); ladders, stairs, and scaffolding (20%); and walking or working surfaces (5%). Fortunately, a recent national focus on fall prevention has raised awareness of the issue and improved the quality of resources available to safety professionals.  Resources are published daily at sites like OSHA’s Stop Falls Initiative, CDC’s Campaign to Prevent Falls in Construction, and StopConstructionFalls.com in support of this important work safety trend.

Source: Tennessee Road Builder Magazine

Falls from Trucks, Trailers, & Equipment

As a leading cause of injury in the workplace, the risk of falls from trucks, trailers, and equipment is an important hazard for which to mitigate risk.  Communicating the need to maintain three points of contact, wear proper footwear, and clean debris from ladders and steps is a good first step.  For many types of equipment, upgrading to access ladders that provide three points of contact and durable weight support can provide additional injury risk management.  United Rentals is one example of a company that has provided a Safety Best Practice document recommending all employees at their 800+ locations upgrade to the Trucker portable side truck mount ladder.  The Trucker ladder provides 3 points of contact, ANSI rated weight support, and slip resistant tread in a sturdy, lightweight design.

Indirect Costs from Fall Injuries

It is important to remember the indirect costs of work injuries when considering falls from minimal heights.  It is easy to take for granted the risk of a fall from a 4′ flatbed trailer, particularly under the stress of work timelines.  Nevertheless, while these may not always be a fatality risk, the consequences of a work injury extends far beyond broken bones and injury claims.  Individuals can suffer long term complications that affect their ability to work and your company’s ability to excel.  Even when injuries are minor, your company’s workers’ comp EMR (Experience Modifier Rate) is affected, causing insurance rates to go up and potentially limiting your ability to win valuable contracts.  Clearly, the national focus on construction fall protection is a worthy cause for the sake of workers and the industries that employ them.

OSHA Top Five: Industrial Truck Citations by Industry

Powered industrial trucks are common across industries for transporting, storing, and staging materials, as well as many other practical uses.  Considering the wide range of applications and utility for trucks and trailers, it is not surprising that they are commonly cited for OSHA safety citations.  The sheer size and power of the truck combined with the variety of transported materials are the focus of regulations for OSHA standard 1910.178.

The Top Five industries cited for Powered Industrial Truck violations sheds light on the importance of truck safety risk management in the workplace.

  1. Manufacturing (665 Citations)
  2. Wholesale Trade (165)
  3. Transportation, Communications, Electric, Gas, and Sanitary Services (145)
  4. Construction (105)
  5. Retail Trade (70)

Powered Truck Safety in Industry

OSHA has structured Industry Standard 1910.178 to ensure businesses focus on operating properly equipped trucks, consider the safety factors of transported materials and operating environments, and generally to protect against the power and size of industrial truck equipment. Fire hazards, chemical considerations, and proper labeling are the focus of the standard.

Trucks are common in many industries, particularly those with material transport needs and at construction job sites.  Not surprisingly, each of the top 5 industries cited regularly conduct these activities.  The standard does not apply to “compressed air or nonflammable compressed gas-operated industrial trucks, nor to farm vehicles, nor to vehicles intended primarily for earth moving or over-the-road hauling.”

Fall Protection for Truck Trailers

In addition to standards related to Powered Industrial Trucks, truck trailers provide safety risks to consider when loading, unloading, staging, and performing related work requirements.  Providing safe access to trailers as well as an adequate work area for loading dock employees is a vital element to complete trucking protection.  Trailer access products such as Trucker safety ladders and portable work platforms will trucking fall protection on the road, loading dock, and job site.

Integrate Ergonomics into Shipyard Health & Safety

The shipyard environment is complex and unique.  Workers often perform awkwardly positioned tasks in unique and varying environments and have a history of forming musculoskeletal disorders (MSDs). Nonadjustable work stations, enclosed or confined spaces, and diverse repair activities can be job requirements which contribute to health and safety risk.

Ergonomics is the study of efficiency in work environments.  Shipyards that have systematically addressed ergonomics in the work environment have been effective at reducing injury and reducing MSDs.  As a result, many companies have recognized the value of integrating ergonomics into existing safety and health programs.  Companies invested in safety policy should take general steps for initiating ergonomical improvements in the work environment, and always remember that each work environment will have different needs and limitations to consider.

Shipyard Work Environments and MSD Injuries

Shipyard Work EnvironmentA shipyard is composed of three main work environments.  Shop work, with conditions similar to manufacturing and maintenance; and Yard and Vessel work, where tasks include assembly, welding, and repair. Shoulder stress, lower back strains, and symptoms including numbness, pain and swelling can indicate a work environment for which ergonomic improvements can reduce work injuries.

In addition to reduced worker’s comp and lost worker time, ergonomic risk management initiatives can improve morale, reduce absenteeism, and increase production efficiency.

General Steps for Systematic Improvement

Integrating ergonomics into a health and safety plan can follow the following process.

OSHA Shipyards Ergonomics Report
OSHA 2008 PDF Report
  • Providing Management Support
  • Involving Employees
  • Providing Training
  • Identifying Problems
  • Implementing Solutions
  • Addressing Injury Reports
  • Evaluating Progress

These general initiatives can lead to programs and activities across departments to accomplish injury prevention goals.

Equipment Solutions and Guidelines

Ergonomics solutions can be implemented site-wide and evaluated on a task basis for unique work hazards.  Consider three equipment options and related ergonomic guidelines.

  •  Standing Platforms: Provide stability and reduce shoulder and neck fatigue, particularly for overhead work.  Ideally workers should operate with hands between waist and shoulder height.  Lightweight platforms can be utilized site-wide.  
  • Racks and Shelves: For staging, moving, storing materials, tools, equipment.  Wheeled racks simplify maneuverability.  Position between knee and shoulder.
  • Tractor Trailers: Reduce trips between work areas for transport handling and time savings.  Avoid load shifting or tipping by considering stability and balance.

For details about Systematic Improvement Measures, additional Equipment Solutions and Guidelines, and a complete summary of Shipyard Ergonomics and MSDs, view the Ergonomics for the Prevention of Musculoskeletal Disorders report online at OSHA.gov.

Ergonomic Assessment at your Shipyard

OSHA recommends setting up a plan for achieving the cost, efficiency, and morale advantages associated with ergonomics process improvement.  In unique and varying shipyard environments, operational or safety teams may need assistance to develop a plan and engineer custom equipment.

Ergonomic improvements have resulted in an 80% accident rate reduction on some shipyards, and are accompanied by operational and morale benefits that can be of great value.  OSHA provides free consultation services, and workplace access specialists also assist with recommendations and equipment design.  Contact Innovative Access Solutions to get started designing custom access equipment to meet your ergonomic safety program equipment needs.

OSHA Top 10: Guarding Floor and Wall Openings and Holes

Floor openings are a broad OSHA standard covering stairwells, ladderways, hatches, skylights, pits, manholes, and other walking or working surfaces that workers can fall into.  In industrial workplaces, floor openings commonly provide multi-level access or access to storage or materials, and are often found when labor or construction is underway.  Consider the Top 10 citations for OSHA safety standard 1910.23 in 2012.

  1. Manufacturing (302 Citations in 2012)
  2. Wholesale Trade (71 Citations)
  3. Transportation, Communications, Electric, Gas, and Sanitary Services (61 Citations)
  4. Services (49 Citations)
  5. Mining (38 Citations)
  6. Retail Trade (30 Citations)
  7. Construction (12 Citations)
  8. Agriculture, Forestry, and Fishing (5 Citations)
  9. Public Administration (3 Citations)
  10. Finance, Insurance, and Real Estate (2 Citations)

Source: OSHA 2012 Statistics and Data

Safety managers and operations personnel must keep in mind OSHA guidelines including proper railings, floor opening covers, toe boards, manhole guards, and platforms.  Industries with the most frequent violations include manufacturing, transportation/energy, and mining.  The common thread among these industries?  Material storage, operational setting variations, and multi-level access.

Wall Opening Ladder for Material Access
Storage Access
Walkway Across Floor Opening
Floor Opening Walkway
Manhole Guard with Spring Latch
Manhole Guard

 

 

 

 

If your work area provides access to multiple levels for which standard equipment will not safely facilitate, custom solutions may be necessary.  Proper equipment will protect your employees, manage worker’s comp safety risk, and prevent OSHA citations.

Innovative Access Solutions, LLC

For custom access design, Innovative Access Solutions is an experienced and knowledgeable producer of OSHA safe solutions, across industries.  For more information about IAS, visit IAScustom.com or call (800) 388-6884.