Revanswood power plant

Site Visit Report

XXXX Construction Site

Introduction

The National Institute of Occupational Safety and Health (NIOSH) reports that construction workers have relatively high rates of work related injuries and death in comparison with other U.S. industry sectors. Based on 2006 data, construction workers experience the highest rates of fatalities, and though they comprise about 7% of the American workforce, they experience 21% of fatal injuries nationwide. In 2008, the BLS reports that the number of fatalities in private sector construction declined 20 percent, from 1204 cases in 2007 to 969 cases in 2008. Fatalities involving workers in the construction of buildings were down 21 percent form 2007. The leading causes of construction fatalities include falls to a lower level, electrocutions, struck-by events, and caught-in or crushed-by events. NIOSH reports that these three causes represent about 65% of total injuries and 43% of nonfatal injuries with days away from work. In 2005, the Bureau of Labor Statistics (BLS) reports that the rates of non-fatal injuries requiring days away from work in construction to be 2.4 per 100 full-time workers -- the second highest rate among all U.S. industry sectors, after Transportation and Warehousing with a rate of 2.9 per 100 full-time workers.

The construction industry is composed of a complex mix of different trades and activities. Much of the work is contracted out and each worker is typically present at the worksite for short durations and only a portion of the length of the project. This unique organization of construction makes the management of its occupational health and safety more challenging than other industries. The temporary nature of the work engenders a free, independent spirit in construction site personnel and has let to a disregard for authority and regulations[1].

Construction Hazards -- Leading Causes of Fatalities

· Falls: Construction workers are a high risk population for falls. BLS reports that in 2001, falls to a lower level accounted for the greatest number of fatal occupational injuries among construction workers (410 fatalities or 4.3 per 100,000 full-time workers). In 2003, the Occupational Safety and Health Association (OSHA) inspected 707 fatal construction incidents involving 730 fatalities. Of these, falls from/through roofs accounted for 76 events (10.7 percent), and falls from/with structures for 74 events (10.5 percent)[2].

· Electrocutions: NIOSH reports that during the ten year period from 1992-2002, the overall total of deaths associated with contact with electricity was nearly 3,400 with 47% of these occurring in the construction industry. About 1 in 8 construction industry deaths involved electricity versus 1 in 20 for all industry. The risk is not exclusive to electricians, and is important for many construction trades such as roofers, painters, laborers, operating engineers, and carpenters.

· Struck by Object: In 2001, BLS estimated the fatality rate of struck-by events in construction to be 1.2 per 100,000 workers.

Other Construction Hazards

· Biological

· Animals: Bites from animals can transmit disease, including rabies.

· Insects: Insects bites can result in localized itch, allergic reactions, and transmission of disease.

· Bacteria

· Lyme Disease is transmitted from a bite from an infected tick. It can result in a chronic disease characterized by flu-like symptoms. The bite typically results in a bulls-eye appearing rash at the site of the bite from 3-30 days after the bite.

· Viruses

· Protozoa

· Molds: Can cause a irritation of the upper airways (nose/throat), and in some people can affect the lungs and cause difficulty breathing.

· Chemical

· Silica: Breathing-in silica dust can increase the workers risk of developing lung diseases and cancer.

· Dust: Various types of dust can cause respiratory symptoms, including cough, nasal congestion, and difficulty breathing.

· Asbestos: Long term respiratory exposure is known to cause lung disease, and increase the risk of lung cancer.

· Carbon monoxide: Build-up of carbon monoxide can result in asphyxiation, and is a common cause of death in the construction industry.

· Welding fumes and gases: Inhaling welding fumes and gases are known to cause lung disease, and can result in disease from absorption of various types of toxic metals.

· Wood dusts: If inhaled, the dust formed from sanding and cutting wood is known to cause lung disease and cancer.

· Metals: Inhalation and absorption of various kinds of metals are known to cause serious disease in humans. The health effects of lead have been extensively studies, and are known to be found in some paints, and construction materials. Exposure is often encountered in older buildings.

· Man-made mineral fibers: Inhalation of man-made mineral fibers are known to cause lung diseases.

· Coal tar

· Epoxy resins

· Asphalts

· Cleaning products contain many chemicals that are irritants to the skin, eyes, nose, and lungs. Some chemicals are also known to cause cancer if the worker is exposed to sufficient quantities.

· Solvents: Various trades within the construction industry are associated with high levels of exposure to solvents, which can be immediately threatening to life, or cause chronic diseases.

· Physical

· Cold / Heat: Construction workers are often required to work outdoors in extreme climates. They are often exposed to high winds, and confined spaces. The large variety of work locations makes it difficult for construction workers to prepare for all exposures. Prolonged exposure to excessive heat or cold can result in the life threatening conditions of hyper/hypothermia.

· Hand tools: A large variety of hand tools are used in construction. Injury from hand tools can result from mechanical trauma as well as electrical burn and shock.

· Ergonomic: Construction work often involves physically demanding work, and workers are exposed to forceful exertions, static muscle contractions, and non-neutral postures.

· Noise: The construction industries reliance hand tools, portable energy sources, and heavy machinery results in significant exposures to noise levels in excess of that which is known to cause hearing loss. Without adequate protection, prolonged exposure will result in a characteristic premature loss of hearing.

· Sun: Prolonged or intense exposure to ultraviolet rays in sunlight is a known cause of skin cancer, including one of the most deadly cancers, melanoma.

· Stress

· Ionizing radiation exposure can occur when radiologic equipment is used to identify weak points in steel. The health effects of exposure are highly dependent on the dose of exposure, and can result in short and long term health consequences.

· Vibration: Workers can be exposed to vibration while using various kinds of hand tools and heavy machinery. It is a well established risk factor for a variety of musculoskeletal diseases.

XXX Construction Site

The XXX is a 21-story building construction project located in the neighborhood of XXX in New York City. The 662,000 sq-ft building is estimated to cost $316 million dollars. The project is being developed by XXX on the corner of North 111st Street and 20th Avenue. It is scheduled to be completed in early 2014. The construction project is managed by XXX. There are approximately 250 workers contracted at the site.

Previous OSHA settled violations to XXX over the past 2 years include:

· February 12th, 2008

· Standard cited: 19260404 F06 Wiring design and protection.

· Standard cited: 19260405 G02 IV Wiring methods, components, and equipment for general use.

· Standard cited: 19260404 F06 Wiring design and protection

· October 23th, 2005

· Standard Cited:19260416 E01 General requirements.

· Standard Cited:19260405 A02 IIE Wiring methods, components, and equipment for general use.

· August 12th, 2002

· Standard Cited:19260502 B03 Fall protection systems criteria and practices.

· August 8th, 2003

· Standard Cited:19260350 A01 Gas welding and cutting.

Walkthrough Inspection

On the date of the inspection, the building construction was partially complete. The structure of the building had been placed, and cement floors were in place. The glass exterior modules had not yet been placed on the upper half of the building. Many of the walls were not yet placed.

On the top floors several employees were involved with small modifications of the cement flooring. One employee was removing molding from the cement flooring at the edge of the structure using a crowbar. Management reports that the worksite abides by OSHA’s standard for utilization of tool lanyard’s, although this employee was not using a tool lanyard. Management reports that a cocoon system is utilized on the top floor. Full height vertical safety netting was in place on all floors without the glass modules in place. The employee was not attached to a drop line, although anchored attachments, drop lines, and lanyard equipment was available to all employees. Management reports that all anchored points meet the OSHA 5000lb rule for tying-off. Horizontal safety netting was in place surrounding the building at the 17th floor. A safety perimeter 15 ft from the edge was indicated by bright yellow tape. Workers are taught to take certain safety precautions when working beyond the indicated perimeter.

The top floors were exposed to relatively high winds, and the temperature drop was noticeable. The few workers that were actively working on the upper floors seemed appropriately dressed for the temperature. Portable kerosene heaters were available, although none were in use at the time of the visit. All heaters had fireguards underneath to collect leaking/excess kerosene. The workers were of course exposed to a mild degree of sunlight.

There were several (4x4’ and 18 x 18) holes in the cement flooring. They were cordoned off with casing and surrounded with brightly colored tape. The OSHA standard dictates that the casing extends 42” from the ground, but the management’s policy exceeds this standard, and uses casing that extends 60” from the ground. There was one wood board next to one of the floor holes that could have potentially been a trip/fall hazard. One hole was completely covered with a thick wood panel secured in place.

All floors had fire extinguishers -- reported to be one located at stations every 2500 sq-ft. Running vertically in a central location there was a compressed air cylinder per fire standard. The cylinder is primed and ready to transport water quickly in the event of fire. There is an elevator and two stairways that service all floors. Management policy dictates that the stairways not be blocked, and be free of debris at all times. Employees are given fire safety training. They are given instruction of a meeting place at the SW corner of the building in the case of emergency/fire. All employees performing hot work are required to take a special pre-training course prior to working on the site. Chapter 14 of the Fire Safety Code dictates the need for one personnel assigned to a dedicated fire safety position at every worksite.

Several workers were sweeping and collecting loose debris without wearing masks. There was very little noticeable dust at the time.

One worker was operating a jackhammer on cement. He was wearing gloves, protective eye-ware, ear plugs, a long sleeve sweatshirt, and boots. He was not wearing a mask, and the safety supervisor requested that he stop and obtain a particulate mask before continuing.

Although there was not an employee actively installing ventilation ducts at the time of our site-visit, there was a crank operated and tilting duct jack available at the site of planned ceiling and wall installation.

Four workers were working on transporting bundles of glass modules from there collection point to the staging area for installation. The glass modules were heavy, large, and not liftable by an individual worker -- approximately 5x10’ in size. Several of the workers were wearing gloves with some kind of grip enhancing beads on the palmar side. The modules were lifted using a forklift, and transported on a dolly. Several workers would assist the forklift operator by placing/removing cinder blocks under the loading panels. This process required relatively minimal ergonomic stress on the workers.

One worker was using a power tool with a damaged cord. This is a potential hazard, and could cause an electrical shock if the cord came into contact with water or other conductive surface. The cord had been repaired using electrical tape -- the safety officer requested that the worker stop using the device. To reduce the risk of electrical shock, Ground Fault Circuit Interrupter (GFCI) outlets are used exclusively at the worksite. These safety devices are able prevent serious injury by detecting when the electrical current has diverted, and automatically disconnecting the source of electrical conduction.

One worker was spraying support beams and other structures with a mineral based insulating material. The material was sprayed-on using an approximately 4 ft extension nozzle. The worker was elevated to his spraying position using a lift device, with safety rails within arms reach surrounding his standing position. The floor in which the spraying took place was contained with plastic to limit environmental/worksite contamination from the spraying material. There was no ventilation in place however, and this resulted in a build-up of particulate contaminant in the workspace. The employee performing the spraying was wearing an N95 particle filtering mask, and long sleeve clothing. The worker was not wearing safety glasses, and it would be recommended for this type of work. Nearby workers were not wearing protective masks despite visible particulates in the air resulting from the spraying process. The noise level seemed close to the threshold level. It was unclear if the employee was wearing hearing protection, or if it was required. Other workers in the area were not wearing hearing protection.

The management company does maintain a respirator fit testing program.

A crane was operational at the site. Winds were monitored to ensure safe operating conditions.

Noise hazards and equipment capable of generating dangerous levels of noise were present throughout the worksite. Much of the equipment was not in use at the time of the visit.

The elevator was operational to all levels of the building. There is a potential for workers to be injured if working near the elevator shaft. To limit this risk, management designated a controlled access zone for elevator shaft operation.

Multiple risks for head injury were present throughout the worksite. Head injury can result from falls, being struck by a falling object, flying debris/tools, or low-hanging structures/objects. All employees are required to wear an approved helmet while present on the worksite.

A tower crane was present on one side of the building. It was stabilized to the building to prevent tipping over and causing significant damage/injury.

Injury is more likely to occur later in the day, when there is not supervision present, and when it becomes dark. To mitigate this risk, the management has enforced a strict policy reducing/eliminating work being done after 3pm. Every day an inspector will periodically monitor the worksite for violations.

Compressed gas cylinders are used throughout the worksite. These cylinders are potentially dangerous due to the tremendous energy of compressed gas, and the volatility/flammability of the gas itself. They can potentially become projectiles, or explode if misused. Care must be taken to prevent rapid temperature changes or mechanical mishandling. Employees receive special training in the handling of gas cylinders, and it is management policy that the cylinders be brought to the ground floor for overnight storage. They are to be stored upright, and not laid on their side. At the time of our visit, there was one gas cylinder that was properly labeled and stored in its upright position.

Management policy dictates that all power tools are utilized with a guard.

Management reports that all scaffolding structures meet OSHA standards, and that all employees involved with constructing scaffolding are required to take a special 4hr course dedicated to that subject.

All employees are required to take the OSHA 10hr course. This course teaches basic hazard identification and injury prevention.

Operation of boom lifts is a significant falls/injury hazard, especially when used on an incline. All employees operating book lifts are required to take a special safety class.

A worksite inspector performs daily inspections, and uses a red/green tag system for determining if the worksite meets safety standards. All rigging equipment is inspected.

Safety of workers and the public walking along the sidewalks around the perimeter of the worksite are protected from debris by using sheds, and occasionally diverting traffic during crane operation in the area.

Management reports that a priority is placed on housekeeping. During the inspection there was relatively minimal loose debris.

Management reports that SOP’s and safety manuals/resources are available to the employees.

There is a full time paramedic at the worksite.

Overall Impression and Recommendations to Improve Worker Safety

Overall the construction site seems to have an efficient and effective safety program. The safety policy and practices observed appear to be operating at a near optimal level. During our site visit, the safety management was quick to identify hazards and make on-the-spot corrections. Balancing safety policy/enforcement and efficiency of work is a complex and dynamic process, requiring clear communication between all stakeholders and those charged with ensuring safety.

Our site visit provided the opportunity to identify potential safety hazards. Recommending remedies to these hazards would typically require a more thorough investigation of the proximal and ultimate cause leading to the hazard. Bearing this in mind, the following recommendations are made:

· Respiratory protection should be used when applying mineral based insulating material.

· Those employees working near the edge of the building should always be using the available secondary fall protection.

· When working near the edge, all tools should be securely fastened with a tool lanyard.

· It is recommended that those exposed to noise at near threshold levels, wear hearing protection.

· Loose materials and tripping hazards should be removed from the ground, especially those near holes in the floor.

· When possible, holes in the floor should be covered/closed.

Bibliography

1. Lingard, H.C. and S.M. Rowlinson, Occupational Health and Safety in Construction Project Management. 2005: Spon Press. 396.

2. Shriver, W., An analysis of fatal events in the construction industry 2003. 2005, Construction Industry Research and Policy Center.