Preventing accidents on mega-facility construction & installation projects
Following on from our recent post 'EYE ON SAFETY' - DATA CENTRE CONSTRUCTION SUCCESS STORY' - today's article focusses on prevention of workplace accidents in mega-facility construction and installation environments, taking lessons from multiple design & build projects and subsequent accident investigations. We hope the following key points can contribute to a safer workplace for you and your colleagues.
Biyat Energy & Environment Ltd prides itself on its commitment to safety and environmental protection from the conceptual design phase of advanced industrial facility projects through to full volume production launch / operational readiness.
Biyat also has several years' experience implementing safe working systems and processes for facility engineering packages of work, plus QHSE assurance services throughout all project stages.
Construction traffic & vehicular access
It's no surprise that many accidents can and do occur relating to large construction vehicles such as concrete pump trucks and mixers, bobcats, forklifts and the like.
A solid vehicular management plan is a must with strong (dynamic) management on the ground. Well trained traffic marshalls stationed at key ingress/egress/choke points etc. with means of communication between them should help adherence to the intended means of managing traffic on your construction site.
Key questions you can ask yourself whilst walking around site.
Q: Are there any potential clash points with what is being built / or has been built already? I.e. Concrete/steel structural beams, external building doorways, temporary electrical cables at height, national infrastructure such as pylons and their respective overhead lines.
Structural elements: fixed or otherwise may still be in the process of installation and can pose a massive risk to vehicles if they clash i.e. concrete mixers as they enter the building to commence works relating to the building shell.
Traffic marshalling / escorting, speed controls etc. with warning signage indicating the height of the relevant opening(s) plus highly visible clatter bars should put you in good stead to mitigate such risks.
Overhead electrical cables, temporary or otherwise, are also at risk of vehicular clashes even though they may be several metres high. It's important to identify such areas - if they cannot be rerouted via safer means, they should be clearly identified and visible by use of telescopic goal posts / cross bars etc. Coloured flags (bunting) can also help enhance the visibility of such areas for the benefit of construction vehicle drivers and workers alike.
Q: Do the ground conditions and access routes enable safe movement of construction machinery around the site?
Large areas of newly compacted soil and those which have recently received heavy rain need to be properly assessed prior to siting construction machinery upon them. Even concrete pump trucks can topple if one or more of their outrigger legs start to sink, which can often happen in an instant and cause serious injuries or fatalities to workers in the vicinity who are involved in the pumping operation.
Beware of unprotected excavations, large or otherwise, as smaller vehicles such as bobcats may feel inclined to circumnavigate narrow ridges around their periphery and inadvertently fall in. A keen eye should remain on the site conditions in accordance with the intended logistics plan. It may be that unplanned work or unexpected additional manpower/resource is needed in remote areas of the site, thus attracting construction vehicles to places not previously expected.
If earthworks and excavations continue to shape the terrain of your site - a sharp eye is continuously required to identify any changes that can often occur dynamically within the course of an hour or even less. Watch out for potential ridges, dips, and uneven surfaces in soil terrain that can be a cause for both small & large construction vehicles to either fall, flip and overturn.
Excavations
Large area excavations and also deep narrow trenches each present an extremely dangerous work environment unless well planned and controlled from the outset.
Key things to consider include:
Excavation permits to work and identifying underground services. Sounds easy to do, but also easy to miss if not done right. Special consideration should be given to identifying temporary systems i.e. power lines that may be redundant but still live. It's important to document / mark all existing services during the construction phase whether they be temporary or permanent. Calibrated underground surveying equipment should be available from the get-go.
Access and egress requirements are a mandatory part of the planning for such activities and shouldn't be an afterthought.
The use of shoring and proper reinforcement to prevent collapse. This is a critical step to avoid injury and potentially multiple fatalities in the event the structure of the excavation and/or trench fails. Large volumes of soil and even rock / concrete debris can partially or totally cover those inside the trench - making escape or rescue extremely difficult. Shoring should be engineered based on the on-site conditions. Manual digging or use of hand-held machinery inside the excavation/trench should consider potential vibration effects that can lead to destabilisation and failure of the surrounding terrain. The combined use of excavation machinery i.e. crawler excavators whilst people are inside the trench/excavation should also be avoided for the same reason in addition to potential clashes.
The use of barriers i.e. jersey barriers to segregate the excavation/trench from other areas of the work site is also of paramount importance and should be inspected regularly for their presence.
Machinery delivery & installation
For sites receiving multiple loads of large machinery, i.e. during the installation phase - it pays dividends to devise a strategy where phased introduction of these goods can be carefully controlled onto your site. Multi-lingual instructions can be relayed to vendors beforehand on the delivery expectations, i.e. off-site parking / lay-by locations, arrival time slots, site delivery manager contact names / numbers, induction & site access requirements etc.
Needless to say, when larger items make their way to site - pre-planned routes should already be free from debris and obstacles. The dimensions should be verified taking into account the delivery vehicle - i.e. can it make it past the gatehouse, is the turn radius sufficient on roadways, can the road surface / factory floor take the anticipated load, is there delivery access already pencilled into the building design. etc.
Methods of material movement for final positioning should also be meticulously planned to avoid damage to expensive plant, equipment and the building asset itself. Companies may well benefit from employing a skilled machinery movement and installation contractor to assist on this point. Reference should also be made to manufacturer's instructions regarding the intended means of moving their equipment and their designated lift points and loads, etc.
Structural elements such as building columns need to be protected from the outset before machinery installation commences. It may be provident to bring forward the installation of permanent condition column protection systems to further prevent i.e. forklift clashes during machinery movement.
Attention should be given to the working hours of the 'lift & shift' teams to help ensure they are not fatigued whilst performing maneuverers of any kind. Especially after weekends and celebratory holidays, it is important to stipulate alcohol consumption prohibitions and/or restrictions from the outset and if need be, inspect and enforce such expectations.
As with any safety training programme, positive change can be brought about via positive coaching, mentoring and reinforcement rather than draconian rule.
Lifting operations, load fixation & manual handling
It goes without saying, carefully planned lifting operations with their associated RAMS, lifting plans and permits are a must before commencing works of this nature, in addition to the default requirement for lift zone segregation, spotters, tag line ropes, etc.
When working in a fast-paced environment against tight deadlines, an urge to take shortcuts can begin to manifest itself. Such urges need to be curtailed immediately and carefully supervised.
It is critical to use correctly rated accessories for forklifts and telehandlers such as extendable jib crane attachments, wheelie bin lifters/tippers, auto-locking telehandler skips, etc. Also, when lifting light poles and the like, proper slinging techniques should be employed to prevent slippage and potential loss of control of the load during the lift operation.
For heavier loads that need to be located at height, a single or set of genie lifts can be sited to provide the relative lift assistance enabling proper fixation of the load.
To reduce the risks associated with working at height, itself a highly dangerous activity, pre-assembly on the ground should always be considered as part of the installation planning phase.
For large fixtures such as overhead signage / television screens in manufacturing halls, consideration should be given to secondary restraints / fixtures to provide the necessary protection in the event the primary system fails.
Fixtures and Unistrut installations relating to bus-runs, overhead cable carriers, lighting, etc. need to be carefully designed, rated and validated to ensure the highest quality materials have both been procured and installed correctly to avoid potential overloading and sagging issues during the lifetime of the installation.
Installation operators should be trained in manual handling techniques and not underestimate the value of robust, task specific (i.e. cut resistant, tactile, extra-grip) gloves. In instances where longer loads are being transported or being passed from the ground to a higher level - adequate precautions such as a two-person handling, or enhanced PPE / use of machine assists should be considered to avoid accidents during movement to passers-by or the operators themselves.
Challenging tasks such as cable pulling should always seek to use either automated or assisted means to reduce potential injuries to operators. Also, the correct manpower resource should be provided with regular breaks to prevent exhaustion. Typical accessories to reduce manual handling can include electric cable pushers, cable pulling winches, pulling socks and cable rollers of different arrangements.
Working at height
During both the construction and installation phases, expect to find a plethora of MEWPS including scissor lifts, boom lifts and the like across the site.
It goes without saying the standard procedures such as permits to work, proper segregation/barriers, spotters, tethering of tools and the like should not be compromised.
Where many MEWPS are operating in close proximity, or in a tight narrow corridor - it is imperative to maintain tight safety supervision and controlled access through these areas. Pre-work planning and coordination between trades can also mitigate many risks and avoid people working up, over and under each other to get things done. In such cases, it is important to brief workers on the expected safety distances / exclusion zones required to avoid collision, entrapment and potential material falling onto workers in the case something falls from height.
MEWP operators should also follow strict procedures whilst working on the MEWP or at height; wearing the appropriate PPE i.e. harnesses, fall restraint, lifelines, etc. A risk assessment should also consider the need for helmet chinstraps and bump caps in cases where above-head installations can cause the helmet to fall, or in tight confined spaces.
The cleanliness of MEWP baskets should also be maintained and enforced - to avoid potential slips, trips and falls and to contribute to the overall mantra 'A Clean Site is a Safe Site'. Needless to say, disassembly of the MEWP structure and DIY add-ons, etc. are a No, No.
Consideration should also be given to potentially sharp objects and obstacles above the MEWP. Many accidents and even fatalities are caused due to inadvertent raising of the MEWP platform and subsequent crushing of the operator against existing installations. Also, sharp objects such as Unistrut fixings, ceiling tile rods, and edges of ventilation ducts should all be risk assessed and mitigated. Rubber protection can be added, rough edges filed, etc.
Toolbox Talks / safety briefings should be given regularly to work teams - one particular hazard is the tempted use of cable trays as walkways to access other installation zones. They are not designed as such and can give way / become weakened thus jeopardising their primary function.
Finally, regular checks should be conducted at height, focussing on installed items that have potential to fall and cause harm. Examples include ceiling tiles that may have become dislodged due to other installation works, or installed items that haven't been properly fixed, and even work tools / pipes / work materials that have been inadvertently left at height.
Electrical safety
Electrical safety is paramount during any installation phase project. Clear briefings should be given to the workforce ahead of site energisation plus follow-up targeted training as required.
The establishment, communication and training of a finely tuned LOTO protocol is a critical part of ensuring safety is maintained, with a clear chain of command and responsibilities for electrical supervision, permit to work, application and removal of LOTO etc. Such protocols also need to take into account the supervision / responsible person requirements in event of sickness, holiday and night working to prevent potential non-compliance with the intended processes.
Where multiple contracting parties / project management teams are involved, cohesion is necessary between all parties with full visibility required of each other's workstreams on the ground.
Temporary and permanent energised power cables should be clearly marked, secured, glanded and insulated as necessary to prevent unintended clashes with people/equipment or movement from their secured position. Special care should be taken relating to installation work in close proximity to any energised cables and circuits with a full survey plus safety precautions taken before work commences. Risk activities include wet core drilling through concrete facades and the use of reciprocal saws during drywall cutting - where both may lead to accidental penetration, clashes or water intrusion to existing installations.
It is also important to use the correctly rated tools and equipment when working in a live environment, for example, non-conductive step ladders such as fibre-glass variants.
Temporary power distribution boards and portable splitter boxes are commonly found on construction sites. It is important to perform regular certified electrical inspections on such installations and ensure they have the correct IP rating plus weather protection when used outdoors. Cables running externally should be kept away from areas liable to flood or pond during wetter weather. It is important not to add connections beyond the capacity of the unit(s) to prevent failure and potential fire risks.
Where LOTO has been applied - regular inspection of the tags / locks applied should check for signs of vandalism and to validate conformance. Live areas with restricted access should be locked, clearly signed referencing the potential risks with steps required for entry, etc.
In cases where temporary or redundant cables are being removed and replaced with permanent installations. A full survey of these systems should be jointly conducted and documented with the relevant authorised person(s) plus the installation project teams to minimise miscommunication and potential confusion that may lead to inadvertent electric shock.
Finally, a special focus should be given to the quality of construction tools used across the site that they are in good condition, double insulated, with no damaged cabling and that the required safety devices/trips are functional. For construction sites, limiting the voltage of hand tools to 110v can also go a long way in reducing potential electric shock risks.
Slips, trips and falls
These kinds of accidents are very common and, in most cases, can be avoided. Construction sites are a common source of hazards in this category. A strong focus from the get-go should be given to site cleanliness with efforts to maintain this from day 1. This will also send the right message to the workforce on the expectations required plus contribute to higher levels of productivity, job satisfaction and welfare.
Examples of accidents include misjudging steps leading from portable cabins, slipping on muddy patches on walkways, portable toilets capsizing due to being sited on unstable ground, tripping over roof lightning protection runs during installation, etc.
A focus should be directed on nurturing both high levels of cleanliness and general awareness whilst on site - to be aware of your surroundings. Phone use should be limited or even restricted to 'safe areas' of the site to drive a continuously improving safety culture. Designated walkways should be inspected regularly and kept meticulously clean and free of obstacles - any changes to these should be communicated in advance.
Step changes in levels i.e. between concrete plinths or cabin steps should be visually indicated with anti-slip tape, visibility paint/tape and signage etc.
The above is not limited to slips, trips and falls. General awareness and heightened risk perception can contribute to higher levels of safety amongst the workforce, project management team and project site as a whole. Improving this aspect should be a core element of any safety improvement strategy.
Site welfare
Here comes the 'elephant in the room'. The welfare and logistics requirements of a busy construction site should enter the conversation early on during the project planning phase.
In addition to ensuring there is a place to 'put stuff', i.e. incoming materials in close proximity to the construction site - the welfare of the project team and workforce as a whole is extremely important and a critical success factor in achieving the project's mission objectives.
The provision of adequate welfare facilities such as toilets, changing rooms, eating areas, smoking areas, prayer rooms, laundry facilities, mobile kitchens, etc. can either make or break a project if not done correctly and significantly impact morale - which in many cases needs to be maintained over a long period with various waves of work teams.
In a nutshell, they need to be provided, be plentiful and be maintained to a high standard due to their continuous use. Daily food trucks and even weekly specialised catering services to give that end of week 'buzz' can really keep things moving.
Machinery Design
In parallel to the design and build of industrial facilities as a building - advanced engineering teams are more often than not simultaneously designing manufacturing systems ahead of the production system installation phase. In this aspect, safe machinery design is a key factor and covered in a previous article.
Typical focus areas include provision of safety interlocks, hydraulic protection, accessible isolators, visible guarding, hazard signage, safety control systems & LOTO placards.
During design & commissioning; PUWER assessments, LOLER inspections and DSEAR risk assessments or their national equivalent can be conducted to ensure compliance with the various regulations and validate safe operation.
We hope you found this article useful!
If you are looking for enhanced confidence and EHS assurance during your next flagship industrial facility design & build project from concept to completion...
Contact — Biyat Energy & Environment Ltd (biyatenergyenvironment.com)
This article was written by Luay Zayed, founder of Biyat Energy & Environmental Ltd. A global energy and environmental consultancy specializing in turnkey engineering solutions that protect the environment and improve energy efficiency in the manufacturing & industrial sectors.
