Attachment_J.3_-_Developing_Traffic_Control_Plans_(TCP’s).pdf

Guidance

March 2016

Work Zone Safety Consortium

This material is based upon work supported by the Federal Highway Administration Grant Agreement DTFH61-II-H-00029

Developing Internal Traffic Control Plans (ITCPs) for Work Zones mkumar Text Box

ATTACHMENT J.3 - DEVELOPING TRAFFIC CONTROL PLANS (TCP'S)

Preface

While the use of Internal Traffic Control Plans (ITCP) in work zones is not regulated by the U.S. Department of Transpor tation, Federal Highway Administration (FHWA) or by the U.S. Department of Labor, Occupational Safety and Health

Administration (OSHA), adoption of an ITCP approach is an effective method of organizing the work space to reduce work zone injuries and fatalities. The concepts described herein are best practices gathered and evaluated by government researchers and private contractors who have studied ITCPs for nearly two decades.

ITCPs align with regulations issued by both FHWA and OSHA that require development and execution of safety programs for construction workers. For example, the national Manual on Uniform Traffic Control Devices (MUTCD)1 contains the following description in Section 6B.01–Fundamental Principles of Temporary Traffic Control: “Road user and worker safety and accessibility in temporary traffic control (TTC) zones should be an integral and highpriority element of every project from planning through design and construction.”

Objectives

This document explains the concept of Internal Traffic Control Plans or ITCPs, as applied in roadway construction work zones. Construction contractors, contracting agencies, and others responsible for work zone safety face the challenge of providing a safe workplace while ensuring the safe movement of all road users through and around the work zone.

The concept of an ITCP involves coordination of construction traffic inside the activity area of a TTC zone. The purpose of an ITCP is to separate — to the extent possible — work vehicles and equipment from workers on foot.

Those involved in roadway construction are likely familiar with temporary traffic control plans (TTCPs), which describe how a specific work zone is to be set up to ensure the safety of the motoring public. However, workers, vehicles, and equipment within the work space are usually not addressed in the TTCP. The ITCP is a plan that project managers and others who have production responsibility for roadway construction projects can use to coordinate and control the flow of work vehicles, equipment, and workers operating in close proximity within the work space.

This document is organized into the following sections:

• ITCP Defined

• Need for ITCP

• ITCP Components

• Steps in Developing an ITCP

• Other Considerations

• Example ITCP Diagrams of Typical Work Operations and Worker Safe Zones

• Regulatory Background

Refer to http://www.workzonesafety.org for a copy of this document.

© 2016 American Road and Transportation Builders Association, Washington, DC

This material is based upon work supported by the Federal Highway Administration under Grant Agreement No. DTFH61IIH00029.

Any opinions, findings and conclusions or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the Federal Highway Administration. This publication does not constitute a national standard, specification, or regulation. No statement made in this booklet should be construed to convey an impression that any member of the consortium, its affiliates, or employees have assumed any part of the employer’s exclusive legal responsibility for providing a “safe and healthful workplace” as mandated by the Occupational Safety and Health Act. Nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

Developing Internal Traffic Control Plans (ITCPs) for Work Zones

Internal Traffic Control Plans Defined An ITCP is a method or protocol to coordinate worker, work vehicle, and equipment movements in the activity area of a work zone and to inform all parties operating within the activity area about the locations of others. The activity area is the section of the highway where the work activity takes place. It is comprised of the work space, the traffic space, and the buffer space. The ITCP goal is to minimize interaction between workers on foot and work vehicles and equipment. ITCPs also serve to reduce backing and other maneuvering by large trucks in the activity area.

The movement of workers, vehicles, and equipment within the work space should be planned in a manner similar to the way a TTCP (temporary traffic control plan) guides road users through the work zone. Whereas TTCPs focus on moving motorists safely through a work zone, ITCPs focus on keeping workers on foot from being struck by work vehicles and equip ment within the work space. TTCPs and ITCPs share common principles, including:

• providing clear direction about the proper travel path to follow,

• separating moving vehicles from workers on foot,

• using TTC (temporary traffic control) devices to mark traffic paths, and

• maintaining a smooth traffic flow.

ITCPs help accomplish these functions by:

• designating safe areas for workers and appropriate routes for work vehicles and equipment,

• establishing “no go” zones for workers as well as for work vehicles and equipment, and

• defining specific operating procedures for trucks delivering materials in the activity area.

Need for Internal Traffic Control Plans

Each year, 50 to 60 highway workers are killed and thousands more are injured when struck by vehicles or equipment at road construction sites.2 Although some of these fatalities are caused by motorists not paying attention or driving recklessly or impaired and intruding into the work space, an equal number of fatalities occur when work equipment or vehicles drive over or back over a worker.

ITCPs help protect workers on foot in the work spaces of an activity area. Because workers on foot often must work close to large vehicles and equip ment, the movements of workers, equipment, and vehicles must be well coordinated. The hazard of proximity to equipment and vehicles is compounded by blind spots. A blind spot (or blind area) is the area around a vehicle or equipment that is not visible to the operator, either by direct lineofsight or indirectly by use of internal and external mirrors.

Each vehicle has its own unique blind spots. When a worker on foot enters a blind spot, the worker is virtually invisible to the operator.3

ITCPs also help reduce risks for vehicle and equip ment operators by identifying hazardous locations

(i.e., dropoffs, overhead power lines, etc.) and safe travel paths around the job site.

An ITCP can use TTC devices to mark travel paths (Source: FOF/Kojadinovish).

Fatal Injuries at Road Construc�on Sites

VEHICLE TYPE

Cranes and Li�s Graders and Rollers Loader Bulldozer Backhoe Construc�on Dump Truck Pickup Truck Tractor Trailer Van Automobile

0 100 200 300 400 500 600 Source: U.S. Department of Labor Bureau of Labor Sta�s�cs: Fatal occupa�onal injuries at road construc�on sites by selected characteris�cs, 2003 - 2010

ITCP Components

The main components of an ITCP are:

• ITCP diagrams,

• ITCP legend, and

• ITCP notes.

The heart of the ITCP is the diagram showing the layout of the work space and the movement of personnel and construction vehicles within the work space. The ITCP will include the access and egress points for the work space, so it may also show portions of the overall work zone. While the diagram does not have to be to scale, it should be adequate to give those reviewing the plan a good concept of how the safety features will function.

The ITCP legend explains the symbols used on the

ITCP diagram. Standard symbols for devices and vehicles can be based on those used in the national MUTCD, if desired. However, additional details on classes of personnel

(e.g., spotters, other workers) and vehicle types are needed in developing an ITCP. In many cases, simple handdrawn sym bols are adequate such as those for the dozers, spotter, and dump trucks in the handdrawn example below.

The ITCP notes contain safety points, injury reduction measures, sitespecific provisions, and duties of various contractor personnel. The ITCP notes should include provisions for communication between workers, assignment of spotters for backing trucks and equipment, and site speed limits.

While some ITCPs can be fairly informal and quickly implemented as part of the daily work shift safety briefing (see example to the left), others may need to be more extensive and involve several hours of staff time to develop and implement.

The method of getting the information out to workers should be covered in the communications plan (see Step 8 on page 9). The level of detail included in an

ITCP should be consistent with the size of the project and the number and frequency of worker safety risks that will exist. For example, items that may be included in the ITCP notes and diagrams for a more complex jobsite might include the following:

• contact information for the general contractor and all subcontractors,

• designated worker and visitor parking areas,

• procedures for orienting independent truck drivers to the activity area/work space and ITCP,

• delineated areas around specific equipment and operations where workers on foot are prohibited,

• designated locations for storing materials and servicing equipment,

• schematic diagrams depicting movement of workers on foot, work vehicles, and equipment within the activity area,

• descriptions of internal signs and other internal traffic control devices that will be used,

• speed limit for operating vehicles and equipment within the activity area,

• specifications for any lighting that will be required in the activity area,

• description or drawing of how the ITCP relates to the TTCP,

• a training plan about the ITCP for all site personnel, and

• an operations communications plan including how the ITCP will be monitored and enforced (the development of this plan is discussed in greater detail in the following section).

The above ITCP diagram includes a legend and notes (Sources:

ARTBA and FOF Communications; clipboard drawing below: FOF).

Steps in Developing an ITCP

The following section describes an 8step approach that can be followed to achieve a safe and effective ITCP.

Step 1. Identify project and ITCP scope.

Ideally, the ITCP should be considered from the very beginning of a project because some important elements — such as the size of the work space — will be dictated by such things as the amount of rightofway available and the number of lanes that will be closed.

To facilitate proper separation between workers on foot and the required work vehicles and equipment, adequate space is necessary.

If such considerations are not anticipated from the beginning, it will be more difficult to organize a complete ITCP.

The sitespecific portion of the ITCP development will generally begin after the contract is awarded, but before construction work actually begins. This is an ideal time to negotiate responsibility for executing certain elements of the ITCP. Duties can be assigned to the roadway owner, project engineer, superintendent, foremen, and other personnel. Risk can be properly allocated and processes can be defined – such as participation in safety meetings, how and if law enforcement will be used, location of access and egress points, and the amount of lane encroachments.

Development begins with an assessment of what the ITCP needs to cover from the list of potential topics provided above. The ITCP designer should determine the limits of the project and also asses the amount and speed of traffic that will be passing by the work space. In addition, any equipment and materials staging areas, batch plants, etc., should be included. In many cases, these will have been identified during bid preparation activities for the project. The contract document most relevant to ITCP preparation is the project plan, which is annotated with information such as access points and work sequencing plans. Also, a plan and cross section of the site and the construction sequence should be reviewed.

The location of any hazardous areas should be identified at this time.

Hazardous locations to be identified and checked include, but are not limited to:

• areas where work will have to occur close to moving traffic without positive protection,

• overhead power lines,

• underground utilities,

• bridges and overpasses (especially if these are or will be near or below minimum height requirements), and

• any holes, trenches, or significant dropoffs that will exist during the project.

STEPS IN DEVELOPING AN ITCP

1. Identify project and ITCP scope.

2. Determine construction sequence.

3. Determine locations and safe move-ments for vehicles, equipment, and workers within each operation; draw diagram(s).

4. Determine vehicle and equipment movements to and from each operation.

5. Determine safe movements for workers to and from and within each operation.

6. Assess and resolve potential internal traffic conflicts.

7. Identify individuals who will need to understand and use the ITCP.

8. Develop the ITCP communication plan.

The ITCP should be completed and distributed before the work begins (Source: ARTBA).

Underground utilities are one example of the hazards to be identified in the ITCP (Source: Interserv).

Step 2. Determine the construction sequence during the project.

In this step, major work tasks or operations

(paving, trenching, or earthwork, etc.) should be identified. The over all space requirements for each operation during a particular work shift should be estimated, as should the frequency with which these operations move (e.g., daily, for each phase or stage of construction, etc.). Any significant suboperations for each task (such as sampling, watering, loading/offloading material and equipment, equipment cleanout, etc.)

and the locations of those suboperations should be identified as well.

Finally, the types of vehicles and equipment required for each operation and suboperation should be listed, along with an estimate of the numbers of workers on foot.

Step 3. Determine locations and safe movements for vehicles, equipment, and workers within each operation and draw the basic work area diagram(s).

This step is where the actual planning and design of the ITCP begins. For each operation and suboperation that will occur in the project, the following should be noted on a site drawing:

• layout of each vehicle and equipment used,

• typical location of each within the operation,

• typical range of movements,

• equipment swing radii,

• potential pinch points between work vehicles and equip ment during work activities, and

• blind areas around each vehicle or equipment.4

Long backing maneuvers for trucks, other work vehicles, and equipment should be avoided.

Workers on foot should be located as far as possible from vehicle paths. Parking, toilet, and break areas should be staged away from the principal conflict points.

Construction equipment is typically large and has an enclosed cab. These characteristics can make the blind areas very large.

Also, the size of construction vehicles and equipment often place truck drivers and equipment operators high above the ground.

They cannot see workers on foot passing close to them.

The National Institute of Occupational Safety and Health (NIOSH) has produced diagrams of the blind areas around a large number of vehicles. These diagrams provide information on where workers on foot cannot be seen directly and

Example blind spot diagram for a haul truck (Source:

NIOSH).

ITCP diagram for paving (Source: NIOSH/ARTBA).

Paving (Source: pavementinteractive.org).

Blind Area Diagram for Haul Truck

1.5 m Plane Euclid EH4500

LEGEND

Haul truck Blind area Mirror viewable area

Worker Area

Staging Area

Enter

Lane 1 10’

Lane 2 10’

Breakdown Lane 10’

Exit areas where they can only be seen through rearview mirrors.4 The diagrams can be accessed and downloaded at http://www.cdc.gov/niosh/topics/highwayworkzones/BAD/imagelookup.html). These diagrams can be placed directly onto a drawing, if desired.

Once the typical layout of vehicles and equipment is created for the operation, locations where workers on foot should and should not stand or walk (“workerfree zones” or “nogo” zones) can be determined and placed on the diagram.

These zones should include:

• locations of potential pinch points between vehicles,

• locations within equipment turn radii, and

• blind areas around vehicles and equipment. .

Similarly, equipment and vehicle nogo areas should be identified around the different hazards that may exist on site. An example of identifying unsafe areas is shown in Figures 1 and 2 on pages 6 and 7.

It should be noted that it is not necessary for an agency or contractor to perform this step each time it prepares an ITCP for a particular project. Rather, agencies and contractors can examine their common work operations and determine these typical vehicle and equipment layouts and movements for each one. Then, for future pro jects, these typical diagrams can be adapted as necessary on future project ITCPs, with attention focused primarily on how vehicles and workers move to and from the various work operations within each project.

Example blind spot diagram for a hydraulic excavator (Source: NIOSH).

Cat 325B (Source: cervettitractor.eu).

Blind Area Diagram for Hydraulic Excavator Cat 325B Ground Level

Symbol for worker free or nogo zone.

WA

TE

R

S

S

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

ITCP Diagram: Dirt Spreading Operation With Limited Backing Distance

Spo�er

Cones

Trucking area - Do not enter this area on foot.

If workers must enter this area to correct traffic control layout, it must first be approved by a supervisor. The employee shall not work alone.

While working, they shall not cross behind or immediately in front of trucks.

To Cut

From Cut

Crossing prohibited

Crossing prohibited

Figure 1. Example diagram of vehicle, equipment, and worker locations and movements for a dirt spreading operation (Source: Adapted from The Roadway Safety Alliance, Internal Traffic Control Plans, 2008)5

Keep the wai�ng trucks from the cut queued behind currently backing vehicles.

This helps limit backing distance.

Train workers on blind spots of each machine/truck and how to follow direc�ons from Spo�ers.

Traffic.

Dump truck access points and the amount of required backing are limited in this diagram.

The Spo�er and dirt spreaders control vehicle backing.

Truck Pulling in / Backing - Moving from traffic at fast speed.

Total rear blind spot and must back up.

Truck Backing - Large rear blind spots. Backing long distances required. Driver may lose focus while wai�ng.

Truck Backing - Total rear blind spot. No one is allowed to cross between this truck and the milling machine.

Crossing prohibited

Water truck Only present when milling with water.

Broom - Large rear blind spot and is always moving backward and forward.

Rubber�re or bobcat - Bobcat has large rear blind spot and can turn quickly. Rubber �re has rear blind spot at boom. Moves throughout job.

ITCP Diagram: Asphalt Milling Mainline1. Trucking area - Do not enter this area on foot. If workers must enter this area to correct traffic control layout, it must first be approved by a supervisor. The employee shall not work alone. While working, they shall not cross behind or immediately in front of trucks.

NOTE: Keep trucking area to a minimum to reduce backing.

If possible, consider staging arriving trucks in a holding queue parallel to and behind the truck being loaded (see Figure 1).

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equipment. A flash-light with cone is required at night. Spot from the driver’s side only.

NOTE: Consider deploying traffic control devices such as cones to help restrict worker access to areas where fast-moving, unpredictable brooms, rubber �res, or bobcats are opera�ng.

Figure 2. Example diagram of vehicle, equipment, and worker locations and movements for an asphalt milling operation (Source: Adapted from Barriere Construction, Safe Zones, 2014)6

Train workers on blind spots of each machine/truck and how to follow direc�ons from Spo�ers.

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

Spo�er

Cones

Traffic.

Step 4. Determine vehicle and equipment movements to and from each operation.

Access to and egress from the work space and to each operation/suboperation is the next activity to consider in ITCP development. Guidance on methods of providing good access and egress can be found in Guidelines on Work Zone Access and Egress.7 Once the vehicle or equipment enters the work space, the ITCP should illustrate how vehicles are to progress to the operation destination.

On major projects with multiple simultaneous operations, specific work vehicle and equipment travel lanes may be designated using TTC devices to provide clear path guidance to drivers and to warn workers on foot. In these situa tions, care should be exercised regarding the types and place ment of TTCDs used to ensure motorists passing through the traffic space either do not see the devices or do not clearly under stand that the devices are intended for work vehicles and equip ment, and not for the traveling public.

For certain operations, continuous deliveries and/or removals of materials by multiple vehicles are required. Establishing a safe location for such vehicles to queue and wait their turn is critical. In the example ITCP above, asphalt delivery trucks queue both in the opposite direction closed lane (1) and in the direction of paving (2), behind and to the left of the paving operation. (Proper temporary traffic control is used in the closed lane to create the queuing location via a temporary lane closure.) Backing maneuvers but one (3) are eliminated in this example ITCP.

Step 5. Determine safe movements for workers to/from and within each operation.

After determining vehicle and equipment locations and movements within each operation and the travel paths to and from the operations from the work space access and egress points, consideration must be given to how workers on foot will move, as needed, around the project. The following should be noted on the drawing:

• location of worker parking and visitor parking (if applicable),

• path workers will take from the parking lot/staging area to the work operation,

• location of portable toilets relative to work operation,

• location of break areas, such as shady spots, relative to the work operation, and

• staging areas.

Example ITCP diagram of material delivery vehicle queuing locations with legend. This lay out is designed to reduce backing (Sources: NIOSH/ARTBA/FOF).

The many elements of a project should be diagramed or noted in the ITCP (Source: Arkansas DemocratGazette).

Dozer

Truck Movement

Water Truck

Channelizing Device

Roller

Dump Truck (Empty)

New Pavement Existing PavementProhibited Area for Workers on Foot

Barrier

Traffic Direction

Foreman

Inspector Spotter

Flagger Worker on Foot Surveyor

Bottom Dump (Full)

Bottom Dump (Empty)

Dump Truck (Full)

Other Type of Worker

Paving Machine A D

Backhoe

I

F P S

A P

PP D

I +

Water

Water

1 2

The objective of this effort is to ensure that workers will not cross active work vehicle and equipment paths before or after work shifts, as part of normal work duties, or during rest breaks. In addition, workers should not have to cross active travel lanes. In more complex work zones, TTCDs may be needed to delineate the safe worker movement areas and travel paths.

Step 6. Assess and resolve potential internal traffic conflicts.

After all work operations, vehicle and equipment paths, and worker movements and paths have been laid out, the next step is to identify and resolve potential conflicts, such as the one in the photo on the left.

Many work operations move along the project, whereas others occur at a fixed loca tion for only a few days. Taking a critical overview of how work will progress will aid identification of potential ITCP conflict times and locations so that adjustments can be made to the task schedule and/or sequencing of work operations.

ITCP conflicts may also occur sporadically due to weather or other shifts in schedule as work progresses during a project.

The shift supervisor responsible for ensuring the implementation of the ITCP should perform a daily check of potential conflicts that could occur, make appropriate changes to the plan, and communicate those changes to all individuals who need to under stand and use the ITCP (see Steps 7 and 8).

Step 7. Identify individuals who will need to understand and use the ITCP.

The ITCP should be an integral part of the project’s safety plan and contractor planning phase. If safety professional(s) are employed, they typically will lead the creation of the ITCP, and the site supervisor will oversee implementation. In other situations, project managers, foremen, supervisors, and other lead persons may need to work together to come up with a safe ITCP. For this reason, they all should be taught the principles of safe construction traffic control. Some of these personnel will also be in charge of daily setup and monitoring of the ITCP. Table 1 on page 10 displays the personnel and their specific duties.

An internal traffic conflict between workers on foot and equipment (Source: pavementinteractive.org).

A variety of key people must understand and use the ITCP (Source: ARTBA).

For highprofile projects, there may be a number of visitors to the site from time to time. These could include surveyors, OSHA, senior management, and others. Ensuring that these individuals are properly and fully informed of the ITCP is an important consideration.

Step 8. Develop the ITCP communication, monitoring, and enforcement plan.

The final step in the ITCP development process is to establish the plan for communicating, monitoring, updating, and enforcing the implementation of the ITCP. Ultimately, the ITCP should fold into the overall safety plan for the site. One of the greatest contributions of ITCPs is improved communications.

Table 1. Personnel Who Need To Understand and Follow an ITCP

Personnel

Safety professionals (safety managers, safety coordinators, company safety directors, etc.)

Inspectors/quality control staff

Superintendent/project manager, project or area engineer

Workers on foot

Truck supervisors or managers

Truck drivers

(including independent drivers)

Equipment operators

Spotters

Specific Duties

Ensure sitespecific ITCP is created

Train onsite personnel in ITCP concepts

Ensure all construction supervisors are familiar with the plan

Consider ITCP needs during site operations phase

Assist and advise in plan execution

Communicate with road owner the importance of

ITCP implementation

Oversee ITCP implementation

Ensure subcontractor coordination and “buyin”

Assign personnel to carry out the plan

Coordinate among personnel and subcontractors

Ensure changes are made to ITCP as site conditions change

Learn ITCP elements and how to comply

Understand hazards of working around equipment

Take responsibility for personal safety and apply training lessons

Share ITCP instruction on where drivers should operate

Assist in communicating safe site procedures with all truck drivers

Receive ITCP instruction on where to operate

Receive navigation assistance (spotters) when appropriate

Never operate into a blind area without checking for hazards and workers on foot

Stay out of areas designated for workers on foot

Know blind area for equipment operated

Do not move until the blind area is checked or a spotter is designated

Do a 360 walkaround before moving equipment

Ensure equipment operators know where the spotter is located; make eye contact with the operator

Ensure the spotter knows his or her responsibilities.

Receive training in safe spotting procedures and know the signals

Stay in continuous communication with operator/driver and remain visible at all times o

A communications plan will likely include one or more of the following elements:

• specific notes regarding safe zones and unsafe (nogo) zones identified during development of the ITCP diagrams,

• statements of the consequences of violating the zones and other aspects of the ITCP (such as the internal vehicle path speed limits),

• statements on how violations of the ITCP will be identified and reported,

• notes on safe backing requirements, such as how workers will communicate with truck drivers during any backing oper ations (designating the spotter, common hand signals, etc.),

• procedures on how workers may enter any areas not desig nated for workers (QA or Quality Assurance tests, for example),

• protocols to be followed by workers in communicating with equipment operators and specific directions on where workers will stand when equipment is working,

• rules for workers to follow if they must cross vehicle or equipment paths (e.g., making eye contact and receiving confirmation from operator, maintaining 360 awareness while crossing, etc.),

• the chainofcommand review that will be followed regarding any necessary changes to the ITCP, and

• method(s) to be used to assess how well the ITCP is working and the steps that will be used to adjust the plan if necessary.

During this step, responsibilities for key personnel are assigned and any remaining training is conducted to implement the communications plan and educate project staff on its content. Onsite workers are provided training in both overall ITCP concepts and in specific implementation elements at their assigned work areas.

The methods by which all individuals requiring knowledge of the ITCP will be educated must be defined. These may include:

• preproject training of staff assigned to the project,

• drawings and bullet points regarding the acceptable vehicle and equipment access points and travel paths that will be provided to all delivery drivers, and

• daily updates of the ITCP as part of the preshift safety talks.

The process required for setting up an ITCP communications plan can translate into better communications and productivity for the overall project. Relevant

ITCP elements include:

• creating notifications for the chain of command,

• creating lists of key contact persons and emergency responders, and

• organizing daily communications with site personnel.

Such elements create a process for dealing with daytoday project management issues.

The ITCP communications plan requires specific items that may not be considered for other project communications. The ITCP will anticipate a means to communicate with workers, operators, truck drivers, etc., about routine changes to the plan. The ITCP communications plan will cover workertooperator/driver communications when internal traffic and worker paths cross. This includes hand signals, radio communications, lighting, etc. The ITCP will cover a process for communicating with the truck boss and drivers daily to explain the routes and precautions.

A very simple communications tool is an air horn, which can be sounded if there is a problem, with instruction to stop all operations.

An ITCP should provide rules for workers if they must pass vehicle paths (Source: ARTBA).

An ITCP may be communicatedxxxxx by phone (Source: FOF).

An air horn may signal to stop work (Source:

SlaterGartrell).

A radio may convey instructions (Source:

UTV Inc.).

o

To function properly, the ITCP must be reviewed and modified each day before the beginning of each shift so employees can receive instruction on how it will be implemented that day. In addition, ITCPs may be modified more frequently as conditions change throughout the day.

Other Considerations

In addition to the concepts discussed above, two other basic issues should be considered during ITCP development and implementation: worker visibility and human factors.

Worker Visibility.

Workers must be clearly visible to drivers and operators. Section 6D.03.04 of the 2009 MUTCD1 states that all workers, including emergency responders, within the rightofway who are exposed either to traffic or to work/construction vehicles in the TTC zone shall wear highvisibility safety apparel that meets the Performance

Class 2 or 3 requirements. High visibility garents are now required by both FHWA and

OSHA for all workers, not just those exposed to motorists/onroad traffic. These agencies require workers to be dressed in a minimum ANSI Class II vest. The composition of these vests is explained in a standard known as the ANSI/ISEA 107 "American National

Standard for HighVisibility Apparel."8 This standard describes three classes of vests.

An ANSI Class I or “unrated” vest is not appropriate for roadway construction workers.

The most common class of garment for road construction work is Class II. A Class II vest will not likely have sleeves, but is closed on the sides and must be fastened in front to provide coverage at 360 degrees. The background fabric must be fluorescent and have retroreflective tape on the front, back and sides.

A Class III garment is appropriate for night work and some daylight situations where workers need maximum visibility.

Class III garments may be created by adding pants (Class E) to a Class II vest, or by using a vest or jacket that covers the full torso and has full or partial sleeves.

When choosing a garment, consideration should be given to the appro priate fluorescent color. Some states have speciific regulations as to garment color. If a jurisdiction is not specific, follow the ANSI/ISEA standard that requires the worker to be distinguished from the background. In other words, if workers are near a lot of orange barrels and equipment, then yellowgreen might be the best color. If they work around green foliage and trees, then orangered would be best.

Human Factors.

When developing an ITCP, it is important to consider human behavior.

The checklist in the box to the right identifies some of the critical human factor elements for an ITCP. Radio and cell or mobile phone use poses unique safety challenges on the job site. When talking on the phone, people often plug the ear away from the phone and look to the ground so they can concentrate on the call in a busy, noisy environment. When they do so, they will not see dangers or hear alarms.

Example ITCPs

The following figures present some examples of how a contractor can establish “typical” diagrams of work operations for vehicles, equipment, and workers. Consistency is evident in the example diagrams so that the fundamental concepts are easy to grasp and maintain by the work crews on site. Notes that can be used to review these diagrams during each pre shift safety meeting are included.

Human Factor Considerations in ITCP Design and Implementation

Where are workers likely to stand or congregate?

On hot days, is shade nearby?

Where are the portable toilets?

Where might workers stand when cold? Or in the rain?

If workers are likely to walk to a location, is there a safe route?

Can workers use phones on the job?

Can a place(s) be designated for making and receiving calls?

How does the foreman communicate with all other parties?

Example Class III highvisibility garments (Source: ARTBA/FOF).

Truck Pulling In / Backing - Moving from traffic at fast speed.

Total rear blind spot and moves backward for long distances.

Do not stand between this truck and the excavator.

Truck Backing - Large rear blind spots.

Backing long distances required. Driver may lose focus while wai�ng.

Breaker - Do not enter the swing radius when machine is on.

Crossing prohibited

Truck Backing / Dumping Total rear blind spot. Do not stand on either side of a truck while it is dumping.

Bobcat - has large rear blind spot and can turn quickly. Moves throughout job.

Cross behind equipment only when it is at least 50 feet away (3 lengths of a roller).

Ensure you make eye contact with operators. Use only when necessary.

ITCP Diagram: Asphalt Patching Removal and Replacement With Breaker

Excavator - Total near blind spot and a blind spot at broom.

Dozer - Moves very quickly in all direc�ons.

Rollers - Smaller blind spots but the operator can look only in one direc�on at a �me and is always moving backward and forward. Stay clear of rollers changing direc�on.

Broom - Large rear blind spot and is always moving backward and forward.

Figure 3. Example diagram of vehicle, equipment, and worker locations and movements for asphalt patching re moval/replacement (Source: Adapted from Barriere Construction, Safe Zones, 2014)6

3. Train workers on blind spots of each machine/truck and how to follow direc�ons from Spo�ers.

5. Crews should stop visitors and inspectors and instruct them in safe places to cross.

4.

A. Discuss differences in the diagram and today’s plan.

B. Discuss addi�onal considera�ons:

Cleanout spots Break areas Cross streets U�li�es Ask for crew’s input.

1. Trucking area - Do not enter this area on foot. If workers must enter this area to correct traffic control layout, it must first be approved by a supervisor. The employee shall not work alone. While work-ing, they shall not cross behind or immediately in front of trucks.

NOTE: Keep trucking area to a minimum to reduce backing.

If possible, consider staging arriving trucks in a holding queue parallel to and behind the truck being loaded/ unloaded (see Figure 1).

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equipment. A flashlight with cone is required at night. Spot from the driver’s side only.

Move away from the truck while the truck bed is being raised. Once the asphalt breaks free, the spo�er can return to the truck.

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

Spo�er

Total rear blind spot and moves backward for long distances.

Do not stand between this truck and the excavator.

Truck Backing - Large rear blind spots.

Backing long distances required. Driver may lose focus while wai�ng.

Crossing is prohibited

Truck Backing / Dumping Total rear blind spot. Do not stand on either side of a truck while it is dumping.

Bobcat - Bobcat has large rear blind spot and can turn quickly. Moves throughout job.

Cross behind equipment only when it is at least 50 feet away (3 lengths of a roller). Ensure you make eye contact with operators. Use only when necessary.

ITCP Diagram: Asphalt Patching Removal and Replacement With Milling Machine

Rubber�re - Has rear blind spot at boom. Moves throughout job.

Dozer - Moves very quickly in all direc�ons.

Rollers - Smaller blind spots but the operator can look only in one direc�on at a �me and is always moving backward and forward. Stay clear of rollers changing direc�on.

Broom - Large rear blind spot and is always moving backward and forward.

Figure 4. Example diagram of vehicle, equipment, and worker locations and movements for asphalt patching re moval/replacement with milling machine (Source: Adapted from Barriere Construction, Safe Zones, 2014)6

Crossing is prohibited

4.

A. Discuss differences in the diagram and today’s plan.

B. Discuss addi�onal considera�ons:

Cleanout spots Break areas Cross streets U�li�es Ask for crew’s input.

5. Crews should stop visitors and inspectors and instruct them in safe places to cross.

1. Trucking area - Do not enter this area on foot. If workers must enter this area to correct traffic control layout, it must first be approved by a supervisor.

The employee shall not work alone. While working, they shall not cross behind or im-mediately in front of trucks.

NOTE: Keep trucking area to a minimum to reduce backing. If possible, consider staging arriving trucks in a holding queue parallel to and behind the truck being loaded/unloaded (see Figure 1).

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equipment. A flashlight with cone is required at night. Spot from the driver’s side only. Move away from the truck while the truck bed is being raised. Once the asphalt breaks free, the spo�er can return to the truck.

3. Train workers on blind spots of each machine/truck and how to follow direc�ons from Spo�ers.

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

Spo�er

When hitching stabilizer to water machine, radio contact must be maintained between the driver and the worker spo�ng the hitch. The hitch shall be done with extreme cau�on.

Hitching is the only �me people should be between the water truck and stabilizer.

Tanker Truck - Goes through jobsite and evenly spreads the soil cement. Do not stand in front or behind truck.

Crossing is prohibited unless hitching the water to the stabilizer. No one is allowed to cross here.

Sheep Foot Smaller blind spots but the operator can only look in one direc�on at a �me and is always moving backward and forward.

Stay clear of changing direc�on.

Rubber�re or Bobcat - Bobcat has large rear blind spot and can turn quickly. Rubber �re has near blind spot at boom. Moves through job. Does not have sta�onary place in job train.

Cross behind breakdown roller only when rollers are at least 50 feet away (3 lengths of a roller). Ensure you make eye contact with operators. Use only when necessary.

ITCP Diagram: Cutting Soil Cement

Rollers - Smaller blind spots but the operator can look only in one direc�on at a �me and is always moving backward and forward.

Stay clear of rollers changing direc�on.

Figure 5. Example diagram of vehicle, equipment, and worker locations and movements for cutting soil cement

(Source: Adapted from Barriere Construction, Safe Zones, 2014)6

5. Crews should stop visitors and inspectors and instruct them in safe places to cross.

4.

A. Discuss differences in the diagram and today’s plan.

B. Discuss addi�onal considera�ons:

Cleanout spots Break areas Cross streets U�li�es Ask for crew’s input.

Motor Grader Huge blind spots. Operators cannot see workers on foot. Extremely loud. Must use radio.

Workers stay clear when machine starts.

Makes wide turnarounds.

1. Trucking area - Do not enter this area on foot. If workers must enter this area to correct traffic control layout, it must first be approved by a supervisor.

The employee shall not work alone. While working, they shall not cross behind or immediately in front of trucks.

NOTE: Keep trucking area to a minimum to reduce backing. If possible, consider staging arriving trucks in a holding queue parallel to and behind the truck being loaded/unloaded (see Figure 1).

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equipment. A flashlight with cone is required at night. Spot from the driver’s side only. Move away from the truck while the truck bed is being raised. Once the asphalt breaks free, the spo�er can return to the truck.

3. Train workers on blind spots of each machine/truck and how to follow direc�ons from Spo�ers.

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

Spo�er

Truck Pulling In / Backing - Moving from traffic at fast speed. Total rear blind spot and moves backward for long distances.

Crossing prohibited

No one is allowed to cross between this truck and the MTV (mul� terrain vehicle).

Rubber�re or Bobcat - Bobcat has large rear blind spot and can turn quickly.

Rubber �re has rear blind spot at boom.

Moves throughout job.

Cross behind equipment only when it is at least 50 feet away (3 lengths of a roller). Ensure you make eye contact with operators. Use only when necessary.

ITCP Diagram: Asphalt Mainline Paving

QC Gator - Few blind spots but moves constantly.

Rollers - Smaller blind spots but the operator can look only in one direc�on at a �me and is always moving backward and forward. Stay clear of rollers changing direc�on.

Broom - Large rear blind spot and is always moving backward and forward.

5. Crews should stop visitors and in-spectors and instruct them in safe places to cross.

TAC Truck - Total rear blind spot and moves backward for long distances with spray bars extended.

Truck Backing / Dumping - Large rear blind spot. Do not stand on either side of a truck while it is dumping.

MTV and Paver - Large blind spots.

If you cannot see the operator, the operator cannot see you. 4.

A. Discuss differences in the diagram and today’s plan.

B. Discuss addi�onal considera�ons:

Cleanout spots Break areas Cross streets U�li�es Ask for crew’s input.

Limit distance between roller and paver to 30 feet or greater. If roller must get closer than 30 feet (twice the length of a roller) to the paver, remove workers from the screed deck.

Use obvious eye contact and radio the operators when crossing between MTV and paver. Wait for confirma�on. If operator loses sight of crew member, he must stop.

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equipment. A flashlight with cone is required at night. Spot from the driver’s side only. Move away from the truck while the truck bed is being raised. Once the asphalt breaks free, the spo�er can return to the truck.

Figure 6. Example diagram of vehicle, equipment, and worker locations and movements for asphalt mainline paving (Source: Adapted from Barriere Construction, Safe Zones, 2014)6

1. Trucking area - Do not enter this area on foot. If workers must enter this area to correct traffic control lay-out, it must first be approved by a supervisor. The employee shall not work alone. While working, they shall not cross behind or immediately in front of trucks.

NOTE: Keep trucking area to a minimum to reduce backing. If possible, consider staging arriving trucks in a holding queue parallel to and behind the truck being loaded/unloaded (see Figure 1).

3. Train workers on blind spots of each machine/ truck and how to follow direc�ons from Spo�ers.

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

Spo�er

Total rear blind spot and moves backward for long distances.

Truck Backing - Total rear blind spot and moves backward for long distances. May lose focus while wai�ng.

Crossing prohibited

Water Truck Only there when milling with water.

ITCP Diagram: Asphalt Milling Mainline

Broom - Large rear blind spot and is always moving backward and forward.

Figure 7. Example diagram of vehicle, equipment, and worker locations and movements for asphalt milling mainline (Source: Adapted from Barriere Construction, Safe Zones, 2014)6

5. Crews should stop visitors and inspectors and instruct them in safe places to cross.

4.

A. Discuss differences in the diagram and today’s plan.

B. Discuss addi�onal considera�ons:

Cleanout spots Break areas Cross streets U�li�es Ask for crew’s input.

Truck Backing - Large rear blind spot. No one is allowed to cross between this truck and the milling machine.

Rubber�re or Bobcat - Bobcat has large rear blind spot and can turn quickly.

Rubber �re has rear blind spot at boom.

Moves throughout job.

1. Trucking area - Do not enter this area on foot. If workers must enter this area to correct traffic control lay-out, it must first be approved by a supervisor. The employee shall not work alone. While working, they shall not cross behind or immediately in front of trucks.

NOTE: Keep trucking area to a minimum to reduce backing. If possible, consider staging arriving trucks in a holding queue parallel to and behind the truck being loaded/unloaded (see Figure 1).

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equipment. A flashlight with cone is required at night. Spot from the driver’s side only.

NOTE: Consider deploying traffic control devices such as cones to help restrict worker access to areas where fast-moving, unpredictable brooms, rubber �res, or bobcats are opera�ng.

3. Train workers on blind spots of each machine/truck and how to follow direc�ons from Spo�ers.

Unsafe area.

Do not enter.

People

Blind spots. You may be visible only through use of mirrors. Use cau�on.

Safe crossing area. Operators must stay out of these areas and watch for employees.

Spo�er

Total rear blind spot and moves backward for long distances.

Truck Backing - Large rear blind spots. Backing long distances required. Driver may lose focus while wai�ng.

Crossing prohibited

ITCP Diagram: Asphalt Drives and Turnouts

Broom - Large rear blind spot and is always moving backward and forward.

Figure 8. Example diagram of vehicle, equipment, and worker locations and movements for for asphalt drives and turnouts (Source: Adapted from Barriere Construction, Safe Zones, 2014)6

5. Crews should stop visitors and inspectors and instruct them in safe places to cross.

4.

A. Discuss differences in the diagram and today’s plan.

B. Discuss addi�onal considera�ons:

Cleanout spots Break areas Cross streets U�li�es Ask for crew’s input.

Truck Backing / Dumping - Total rear blind spot. Do not stand on either side of a truck while it is dumping.

No one is allowed to cross between this truck and the MTV.

Rubber�re or Bobcat - Bobcat has large rear blind spot and can turn quickly. Rubber �re has rear blind spot at boom. Moves throughout job.

TAC Truck - Total rear blind spot and moves backward for long distances with spray bars extended.

Use obvious eye contact and radio the operators and crew when crossing between MTV and paver.

Must receive confirma�on. If operator loses sight of crew member, he must stop.

MTV and Paver - Large blind spots. If you cannot see the operator, the operator cannot see you.

Cross behind equipment only when it is at least 50 feet away (3 lengths of a roller).

Ensure you make eye contact with operators.

Use only when necessary.

2. Spo�er shall maintain clear line of sight with drivers. Stay out of the path of truck and equip-ment. A flashlight with cone is required at night.