From Research to Practice:A Collaborative Approach to Prevention

through Design

John GambateseSchool of Civil and Construction Engineering

Oregon State University

20th Annual Willis Construction Risk Management ConferencePlano, TX

September 16-17, 2014

Source: Las Vegas Sun, December 29, 1998

Safety Headline

Safety Headline: Caring

Source: Las Vegas Sun, December 31, 1998

Source: Las Vegas Sun, December 29, 1998

Safety Headline: Taking action

Source: Las Vegas Sun, December 29, 1998

Safety Headline: Results

Why do accidents (still) occur?

Source: Construction Industry Institute, “Making Zero Accidents a Reality,” EM160-21, 2006

Safety Performance of Construction Industry

• Why do some companies perform better than others?

1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012325 413 477 497 527 613 644 770 518 765 995 936 1,117 1,073 1,129 1,195 1,333 1,297 1,766 2,085 2,403 2,272 2,086 2,637

0

2

4

6

8

10

12

14

16

14.3 14.2

13.0 13.1 12.2 11.8

10.6 9.9 9.5

8.8 8.6 8.3 7.9 7.1 6.8 6.4 6.3 5.9

5.4 4.7 4.3 4.0 3.9 3.7

7.19

6.125.32

4.313.44

3.00 2.66 2.301.60 1.59 1.67

1.03 1.02 1.23 1.16 0.88 0.72 0.58 0.68 0.57 0.64 0.81 0.43 0.40

Industry*

CII

Year and Work-hours (MM)

Tota

l Rec

orda

ble

Incid

ence

Rat

e (T

RIR)

*OSHA Construction Division, NAICS 236-238 (SIC 15-17) Reflects OSHA reporting change

Source: Construction Industry Institute, Austin, TX, 2013

Models of Accident Causation

Planning

Design

Construction

Inspection

Source:Reason, J., “Human Error: Models and Management.” British Medical Journal, Vol. 320, 768-770, March 2000

Accident and Risk Pictures

Source:Hale, A., “Construction Safety Management: Do we know what works?” CIB W099 Construction Safety Conference, Lund, Sweden, June 2-3, 2014.

System Failures

Active failures: Unsafe acts committed by people who are in direct contact with the system.

Latent failures: Inevitable “resident pathogens” within the system.

Source: Behm, M. and Powell, D. (2014). “Problem Solving: Are Higher-Order Controls Ignored?” ASSE Professional Safety, Feb. 2014, pp. 34-40.

“Risk reduction recommendations … are shifting slightly to include additional higher-order controls.”

However, the “results suggest that safety professionals may be stuck in an administrative control rut, fixated on identifying single causes close to the work operation.”

Accident Influences

• Hierarchy of influences in construction accidents• Loughborough ConCA

Model

• Safety Culture• “The organizational

principles, norms, commitments, and values related to the operation of safety and health” (NORA 2008)

Hierarchy of influences in construction accidents

accident

work team workplace

materials equipment

actions behaviour capabilities

communication

layout/space lighting/noise hot/cold/wet local hazards

suitability usability condition

attitudes/motivations knowledge/skills

supervision health/fatigue

site constraints work scheduling housekeeping

design specification

supply/availability

Immediate Accident

Circumstances

Shaping Factors

permanent works design, project management, construction processes safety culture, risk management

client requirements, economic climate, construction education

Originating Influences

Shaping Factors

permanent works design, project management, construction processes safety culture, risk management

client requirements, economic climate, construction education

Originating Influences

Wo

rke

r Fa

cto

rs

Sit

e F

ac

tors

Material/ Equipment

Factors

Originating Influences(Client, industry, design, safety culture)

Shaping Factors(Project, worker)

Immediate Accident Circumstances

Sources:Gibb et al., Civil Engineering, ICE, London, 2006.

“National Construction Agenda for Occupational Safety and Health Research and Practice in the U.S. Construction Sector.” NORA Construction Sector Council.

Accident

Designing a Safety Program

• How to further reduce the number of injuries and fatalities on projects?

• Suggestions from current research……

Source:Hagan, P.E., Montgomery, J.F., and O'Reilly, J.T. (2009). “Accident Prevention Manual for Business & Industry: Engineering & Technology.” Itasca, IL, National Safety Council.

Designing a Safety Program

• A starting point……Hierarchy of Controls

Reliability of the Control

EliminationEliminate the hazard during design

SubstitutionSubstitute a less-hazardous material

or form during design

Engineering Controls“Design-in” engineering controls,

Incorporate warning systems

Administrative ControlsWell-designed work

methods & organization

PPEAvailable, effective,

easy to use

Prevention through Design (PtD)

Low

High

Designing a Safety Program

• Balancing priorities• Axioms (self-evident truths that require no proof) of safety?

High

Low

Preliminary Design

Front-End Design

Startup

Infl

uen

ce

Maxim

um

re

turn

on

eff

ort

s

Maxim

um

resou

rce

deplo

ym

en

t

I nitiation

Engineering

I nfluence

Management of Change

Detailed Design

Costs

Res

ourc

es

Dep

loye

d

Construction

High

Low

Preliminary Design

Front-End Design

Startup

Infl

uen

ce

Maxim

um

re

turn

on

eff

ort

s

Maxim

um

resou

rce

deplo

ym

en

t

I nitiation

Engineering

I nfluence

Management of Change

Detailed Design

Costs

Res

ourc

es

Dep

loye

d

Construction

High

Low

Preliminary Design

Front-End Design

Startup

Infl

uen

ce

Maxim

um

re

turn

on

eff

ort

s

Maxim

um

resou

rce

deplo

ym

en

t

I nitiation

Engineering

I nfluence

Management of Change

Detailed Design

Costs

Res

ourc

es

Dep

loye

d

Construction

Source: Heinrich, H.W. (1931). “Industrial Accident Prevention: A Scientific Approach”

(Graphic courtesy of Bechtel Corp.)

Design of Constructor’s Safety Program

“Making Zero Accidents a Reality” – Safety Management Best Practices:

1. Demonstrated management commitment2. Staffing for safety3. Safety planning – pre-project/pre-task planning4. Safety training and education5. Worker involvement and participation6. Recognition and rewards (Caution!)7. Subcontractor management8. Accident/incident reporting and investigation9. Drug and alcohol testing

Source:Construction Industry Institute, “Safety Plus: Making Zero Accidents a Reality,” Research Summary 160-1

A Focus on Workers: Situational Awareness (SA)

Sources:Artman, H. (2000). “Team Situation Assessment and Information Distribution.” Ergonomics, 43(8), 1111-

1128.Hallowell, M. (2013). “Human Factors Engineering: Situational Awareness and Signal Detection Theory.”

• A motivated, active, and continuous extraction of information from an environment and the ability to use knowledge to anticipate trajectories and act effectively (Artman 2000).

State of the environment

SITUATIONAL AWARENESS

Decision Actions

Feedback

Level I:Detection

Level II:Comprehension

Level III:Projection

Environmental awareness

Risk perception

Analysis under uncertainty

“Addressing occupational safety and health needs in the design process to prevent or minimize the work-related hazards and risks associated with the construction, manufacture, use, maintenance, and disposal of facilities, materials, and equipment.” (www.cdc.gov/niosh/topics/ptd/)

Prevention through Design (PtD) = “Safety Constructability”

Designer Involvement: “Prevention through Design”

Why Prevention through Design (PtD)?

22% of 226 injuries that occurred from 2000-2002 in Oregon, WA, and CA related to design1

42% of 224 fatalities in US between 1990-2003 related to design1

60% of fatal accidents resulted in part from decisions made before site work began2

63% of all fatalities and injuries could be attributed to design decisions or lack of planning3

1 Behm, M., “Linking Construction Fatalities to the Design for Constr. Safety Concept” (2005)2 European Foundation for the Improvement of Living and Working Conditions3 NSW WorkCover, CHAIR Safety in Design Tool, 2001

Barriers to PtD Implementation

• No or minimal construction safety in designer education and training

• Competing priorities (e.g., safety vs. cost/schedule)

• Lack of knowledge of how to design for safety

• Unclear authority and responsibility for PtD

• Difficult for assess risks during design

• Contractual separation of design and construction

• Cost/time required to implement PtD

• Fear of increased liability

Enablers of PtD Implementation

• A committed owner/client

• Positive safety culture

• Design engineer experience and training

• Construction and safety

• Integrated project delivery methods

• Design/construction visualization tools

Source:Everett, J.G. and Slocum, A.H. (1994). “Automation and Robotics Opportunities: Construction versus Manufacturing.” Journal of Construction Engineering and Management, ASCE, Vol. 120, No. 2, pp. 443-452.

• Integrated production system similar to manufacturing industry• Design of the process

coincident with design of the product

Design and Construction Integration

What are the impacts of PtD on projects?

Survey of design and construction professionals in the UK:• Change as a result of implementing PtD (% of respondents)

Item DecreaseNo

Change Increase

Design cost (n=35) 6% 46% 49%

Construction cost (n=38) 34% 24% 42%

Design duration (n=37) 8% 57% 35%

Construction duration (n=39) 38% 44% 18%

Construction quality (n=39) 8% 28% 64%

Construction worker productivity (n=30)

13% 33% 53%

Construction worker health & safety (n=45)

4% 9% 87%

End-user health and safety (n=42) 5% 10% 86%Source: NIOSH PtD in the UK study, 2010

• Bechtel’s steel design process

• PtD elements:• Temporary access platforms

• Lifting lugs

• Shop installed vertical brace ladders

• Bolt-on column ladders and work platforms

PtD Example – Steel Design

Temporary ladder, platform, and safety line

Photos courtesy of Bechtel Corp.

Modular Platforms

Photos courtesy of Bechtel Corp.

Brace Lifting Clips and Rungs

Photos courtesy of Bechtel Corp.

Photos courtesy of URS/Washington Division

PtD Example – Prefabrication and Modularization

PtD as a National and International Initiative

• NIOSH PtD National Initiative• NORA Construction Sector Council CHPtD

Workgroup

• OSHA Construction Alliance Roundtable

• ANSI/ASSE PtD Standard Z590.3-2011

• U.K.: Construction (Design and Management) Regulations

• Singapore: Design for Safety Pledge, 2012

• Other EU countries, Australia, South Africa, and more

PtD in Planning and Design

Example PtD Program

The Haskell Co.: “Safety Alert System” (SAS)

• Designer safety education, training, awareness

• Safety reviews during design• All disciplines• Identify hazards• Incorporate safety suggestions into design

• Safety symbols on design drawings• Alert constructors to safety hazards• Include reference to related OSHA standards

PtD Process – Detailed Design

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

Source: Hecker et al., 2005

www.construction-institute.org

PtD Tools – Databases and Checklists

www.safetyindesign.org

PtD Tools – Databases and Checklists

www.dbp.org.uk

PtD Tools – Databases and Checklists

PtD Tools – Visualization, 4D CAD, BIM

PtD Tools – Design Risk Assessment

www.constructionsliderule.org

Which is safer to build? How much safer?

Steel-framed building

Concrete-framed building

SliDeRulE Website

SliDeRulE Website

SliDeRulE Website

Design Option Evaluation

Option Evaluation Sheet Intel D1D Programming

Option Title Subfab vs Basement Opion #1

Option Description D1B (Similar) Basement W/ 14' SubfabDescription of Issue:

Evaluation Criteria ScoreFSCS GOALS wt. worse better total Comments

5- *0 5+

C1 Dollars / Sq Ft 1 1 1 1 1 1 -5 11.9 M Impact to Base Build Cost

C2 Tool Install Cost 1 1 1 2 1.9 M Cost Savings

E1 Energy Conservation 1 1 -1 added building Volume

E2 Reduce Emissions 1 1 -1 More materials

S1 Support 2 Technology and 1 1 1 1 3 Move Available space

5 HVM Generations

S2 Maintain Existing Reliability and 1 1 1 More room for maintenance

Maintainability

S3 Improved Life Cycle Safety 1 1 1 2 Ergonomics - Cable Instalation

S4 Maximize Reuseability and 1 1 1 0 Small Benifet to Electrical

Fungibility Only adapts to Copy D1b

B FABS

D1 Overall Construction Duration 1 1 1 2 w eeks faster than POR ( Trench)

D2 Consructability 1 1 1 Better than Trench

D3 Tool Install Duration 1 1 1 2 More space available

5 Total Score

Comments:

Source: Intel Corporation, Lifecycle Safety Process

Multi-criteria Alternative Analysis Tools

1. Hazard identification• What construction safety

hazards does the design create?

2. Risk assessment• What is the level of safety and

health risk associated with each hazard?

3. Design option identification and selection• What can be done to eliminate

or reduce the hazards?• Remember the hierarchy of

controls……

PtD Design Review

PtD Design Review: Energy Mnemonics

• A condition or action that has the potential for an unplanned release of, or unwanted contact with, an energy source that may result in harm or injury to people, property, or the environment

Source:Fleming, M.A. (2009). “Hazard Recognition.” By Design, American Society of Safety Engineers.Construction Industry Institute, “Strategies for Improving Hazard Recognition,” Research Summary 293-1, July 2013.

“Follow the Energy”

PtD Design Review: Guidewords

Dimensions• Size, weight, height, depth, shape, clearance

Actions/Interactions• Access, support, sequence, placement, connection,

human-machine interface

Position• Orientation, location

Surroundings• Perimeters, openings, surfaces (coatings), obstructions

Dimensions: Size/Weight

Dimensions: Height/Depth

Dimensions: Shape

Source:“Detailing Guide for the Enhancement of Erection Safety,” National Institute for Steel Detailing and the Steel Erectors Association of America

Actions/Interactions: Access

Erector Friendly Column• Holes at 21” and 42” above

floor levels for guardrail cables

• Holes at high locations for fall protection tie-offs

• Column splices and connections at reasonable heights above floor

• Seats for beam connections

Source:“Detailing Guide for the Enhancement of Erection Safety,” National Institute for Steel Detailing and the Steel Erectors Association of America

Actions/Interactions: Connection

Actions/Interactions: Machine-user Interface

Source: Construction Industry Institute, “Real-time Pro-active Safety in Construction,” safety training course

Position: Ergonomics

Surroundings: Perimeters

Surroundings: Openings

Surroundings: Coatings

• Non-isocyanate

• Low volatile organic compounds (VOC)

Benefits of PtD

• PtD as a driver of innovation

Source: Culvenor, J. (2006). “Creating Transformational Change through Innovation in Risk Management Keynote Address: ‘Creating transformational change through innovation in risk management’.” Risk Management Research and Practice: An Educational Perspective, Welsh Risk Pool and University of Wales, Bangor, Trearddur Bay Hotel and Conference Centre, Holyhead, Anglesey, UK, March 30-31, 2006.

Additional Motivation

• Sustainable development

Source: http://sustainablesafetyandhealth.org/scsh-overview/

Safety and Owners

• Strong safety leadership and culture• Recognize business value of good safety performance• Procure based in part on safety performance

• Contractor and Designer

• Project delivery methods that integrate design and construction

• Safety in contracts• Construction and design contracts

• Promote PtD• Select design alternatives higher on the hierarchy of controls

• Participate in safety

Source:Toole, T.M. and Gambatese, J.A. (2014). “PtD Program Guidelines,” www.designforconstructionsafety.org.Construction Industry Institute, “The Owners’ Role in Construction Safety,” Research Summary 190-1, March

2003.

www.designforconstructionsafety.org

More PtD info…

Current and Future Research

• Precursor analysis to prevent low-frequency, high-impact events

• Impacts of degree of connectivity on construction worker safety

• Worker risk tolerance and behavior assessment

Graphic source: NASA Accident Precursor Analysis Handbook, NASA/SP-2011-3423

Current and Future Research

• Safe and effective speed reductions for freeway work zones

• Connection between lean design/construction and construction worker safety

• Use and re-use of formwork: safety risks and reliability assessment

From Research to Practice: A Collaborative Approach to Prevention through Design

• Thank you for your interest!

• Questions? Comments?

• For more information:• john.gambatese@oregonstate.edu