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A Guide to Traffic Control Zones

4/9/2025

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With nearly 4 million miles of roadways in America, proper maintenance and upkeep is an important task to local, state, and federal governments. With billions being spent each year to build and maintain these roadways, a pivotal task is providing safe working space for road workers while allowing pedestrians to safely navigate around the construction. In this blog, we will explore Traffic Control Plans and specifically review the areas that are found within traffic control zones.

What is a Traffic Control Plan?
A Traffic Control Plan or Temporary Traffic Control Plan is a plan that describes the safety measures used to guide pedestrians through a traffic control zone. These plans, typically diagrams or sketches, will describe all safety measures that will be used to warn pedestrians of incoming roadwork, guide them through the work zone, and eventually notify them of where the work zone ends. 

Traffic Control Zones
There are four main areas to a traffic control zone with each providing specific elements that keep both workers and pedestrians safe. Let’s review each area and what they provide to complete the control zone:

Advance Warning Area – section of the roadway where pedestrians are informed about the upcoming work zone. Many will utilize bright orange signage or sometimes flashing signals to warn pedestrians to prepare to slow down

Transition Area – if traffic needs to be shifted for the work ahead, a transition area is used to combine traffic lanes or direct traffic to a new path around the work zone. These areas are to be clearly marked, typically with traffic cones or barriers to allow traffic flow to properly and safely pass the work zone

Activity Area – section of the roadway where work is taking place. This area is made up of the work space, traffic space, and buffer space; designated areas for workers and equipment to safely operate separately from the pedestrian traffic. Buffer spaces between the work space and traffic space are free of any people, vehicles, or equipment and typically begin with an arrow board directing traffic away from the work zone

Termination Area – section of the road to safely return pedestrians to the normal path. This area typically extends well past the work zone and is completed by an ‘End Road Work’ sign.

With over 100,000 crashes estimated to happen each year within work zones, proper Traffic Control Plans help facilitate safe passage for both workers and pedestrians. Knowing the control zones and how to navigate through them as a worker and pedestrian will keep everyone safe. To keep the conversation going, download the Work Zone Toolbox Talk (TBT) or comment below.
CAT - Work Zone Traffic TBT
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Power Tool Safety

3/5/2025

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Power tools are the equipment that propels over 8 million construction workers on a daily basis. With thousands of tools available, these pieces of equipment make our jobs easier, but when used incorrectly can become hazardous in an instant. Below we will review the safety features of power tools and the hazards you need to be aware of when working with them.
 
Safety Features
Most power tools have new safety features to reduce the risk of injuries. Depending on the type of power tool, you may need to make sure each feature is available and in working condition. Let’s review some common safety features of power tools and what OSHA recommends:
  • Guards – all exposed moving parts of tools must be guarded to protect from rotating parts, sparks, flying chips, and pinch points. Commonly used in circular saws and grinders, OSHA requires a machine guard at all times for blades/discs greater than 2 inches
  • Pressure Switches and Shutoffs – switches that shut off power when released. OSHA requires most hand-held tools to have pressure switches including drills, drivers, grinders, sanders, and saws. Larger tools such as disc sanders, routers, and planers are required to have a control switch or pressure switch to shut off power
  • Accessory Safety Clips – locks or mechanisms that keep tool accessories from being ejected during operation. Commonly used with saw blades, chisels, and drill bits, OSHA requires all clips to be in working condition prior to use
 
Power Tool Hazards
Even though power tools are used on a regular basis, employers are still required to provide training and hazard recognition for power tools that employees will use. Below we will review the three common types of power tools and the most common hazards associated with them:

Electrical​
  • Shocks and burns – caused when the electrical current is disrupted and flows incorrectly through the body. To prevent, electrical tools should have a three-wire cord and be grounded through the receptacle. Additional best practices include inspecting cords for worn or frayed insulation and to not use in wet or damp locations unless rated properly
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Battery Operated
  • Fires – occur when the battery or tool are overworked or used incorrectly. Best practices include using compatible batteries with select tools, inspecting to make sure batteries have no damage or leaks, and store batteries in a dry area off charging stations

Pneumatic
  • Misfires or explosions – caused when the compressed air is improperly traveling through the hose. To prevent, locking attachments for tools and additional safety valves to gauge pressure flow should be installed on hoses 

Power tools help us build efficiently and reduce strains on workers. Making sure you select proper power tools and use their safety features to reduce hazards will help keep all employees safe on the job. To keep the conversation going, download the Power Tools Toolbox Talk (TBT) or comment below.

Power tools TBT
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Using Scaffolds Safely

2/5/2025

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In construction, millions of workers use scaffolds to erect building envelopes and finishes. Scaffolds can be a cost-effective solution for large scale projects and where heavy loads are required to reach new heights. When scaffolds are in use, it is important to remember that many need to be designed and erected by professional, competent employees. Let’s review some of the ways scaffolding can be erected and used in a safe manner.

Erecting Your Scaffolding
Before erecting your scaffolding, you will need to make sure it is designed by either a Qualified Person or an Engineer. An Engineer is required to design your scaffolding system when:
  • Scaffolds will be moved while employees are working from them
  • When pole scaffolding reaches over 60ft in height
  • When tube or frame scaffolding reaches over 125ft in height
  • When cantilevered or outrigger components are required

After the design has been made, your major scaffold components will include:
  • Guardrails – used as part of fall protection system for employees over 10ft above lower level; must be between 38-45 inches in height
  • Midrails – part of the fall protection system; must be between 20-30 inches from platform
  • Toeboards – prevent falling hazards to surfaces below
  • Platforms – planks or decks as the floor of the scaffold; must completely cover the surface with no more than 1inch of space from the uprights
  • Footings – known as base plates or mud sills; must be leveled and support entire scaffold load
  • Braces – when the height to base ratio exceeds 4:1 bracing/tying must be used to support scaffold from tipping
When all these components are combined, your complete scaffolding system will be in place and is required to support at least 4 times the maximum intended load. Now workers will need to know how to work safely while on the scaffold system.

Safe Scaffold Use
Before beginning work from a scaffold, an inspection will need to be completed by a Competent Person to check for defects or changes to the structural integrity of the system. When an inspection has been completed, be sure to tag the system so workers know it is safe to use. When using a scaffold system, some safe working tips include:
  • Know your scaffold load rating and do not overload
  • Do not use ladders, blocks, or other methods to increase your working height on a scaffold
  • Inspect all platform planks to make sure none are warped, cracked, or have holes
  • Make sure the scaffold is clear of all overhead power lines and energized electrical devices
  • Do not work from scaffolds that are covered with snow, ice, or other slippery materials

Scaffolds are a common solution when working at heights but falls and load failures will always be a hazard. Make sure your scaffold is designed by a Qualified Person or Engineer, inspected by a Competent Person, and workers are trained and know how to safely operate from a scaffold. To keep the conversation going, download the Scaffold Safety Toolbox Talk (TBT) or comment below.
Scaffold Safety
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Hazards in the Cold

1/8/2025

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The New Year has officially begun and the cold front has made itself a home for the next few months. As winter is in full swing, new hazards related to the weather are rearing their ugly heads. Let’s take a look at some of the potential winter hazards you may face and some ways to prevent injuries from occurring.
 
Cold Stress
Cold Stress occurs when the body loses heat faster than it can be produced. Common types of Cold Stress include:
  • Trenchfoot – swelling, redness, and blisters usually affecting the feet when exposed to prolonged cold/wet environments
  • Frostbite – injury where the body tissue freezes, typically from high wind chills and cold temperatures
  • Hypothermia – the most dangerous condition where the body’s internal temperature drops below 95 degrees causing confusion, loss of consciousness, and even death
When exposed to winter weather, the best ways to prevent Cold Stress are:
  • Wear multiple layers of loose-fit clothing
  • Change clothes if they become wet
  • Drink warm, sweet fluids full of electrolytes. Stay away from alcohol
  • Have a place where breaks can be taken to warm up when working long periods outdoors
 
Slip, Trip, & Fall Hazards
While these hazards continue to be the leading cause of injury, it is important to highlight the winter conditions that will intensify these hazards in the cold. Snow, sleet and ice make slips, trips, and falls a serious injury when working outdoors as simple tasks can become dangerous. Some ways to prevent these types of injuries in the cold include:
  • Salt all walkways, staircases, and ramps located outdoors
  • Wear proper footwear that includes treaded boots or even spikes for better traction
  • When wearing multiple layers make sure you still have a full range of motion
  • If a fall occurs, try to fall sideways to prevent any head/neck injuries
 
Heating Hazards
Heaters are a man’s best friend during the winter. While they allow us to keep warm and dry, additional hazards like electrical shock, burns, and fires are common when heaters are in use. When using heaters, be sure to:
  • Check to make sure the cord is not worn or frayed. Make sure the outlet is rated properly along with extension cords if needed
  • Keep all materials away from the heat source to reduce the risk of fires
  • Do not expose any skin or body parts to the heater for a prolonged period of time
  • Have a proper evacuation plan in case of fire or an emergency
 
While the snow makes for a beautiful scenery, knowing the hazards that come with the weather and knowing how to prevent them will keep everyone safe while working out in the cold. To keep the conversation going, download the Cold Stress toolbox talk (TBT) or comment below.
Cold Stress TBT
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Holiday Home Safety

12/4/2024

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During the holiday season, an estimated 47,000 fires claim more than 500 lives each year. This is why safety is not just important in the workplace, but also in your home. Let’s review some of the best ways to keep yourself safe from fires, decorating hazards, and even the invisible killer this season.
 
Holiday Decoration Safety
With over 7,000 fires from Christmas trees and holiday decorations each year, tis the season for safety. When choosing holiday décor, remember to:
  • ​Find decorations that are flame resistant or retardant
  • Keep decorations away from all heat sources and steer clear from doors and windows
  • Inspect all light strings for broken or worn cords
  • Do not hang strings with nails or something that can damage the cords
  • Do not use any decorations rated for the indoors in an outdoor setting
 
Smoke Alarms
When a fire breaks out, a smoke alarm can be the quickest way to alert the whole household of an emergency. Some helpful tips to remember regarding smoke alarms include:
  • Install a smoke alarm in every bedroom and on every level of your home
  • Connect alarms so when one is signaled, all of them will sound
  • Keep alarms at least 10ft away from your stove to reduce false alarms
  • Test alarms at least once a month and check batteries every year
  • Consider replacing alarms once they have been in service for more than 10 years
 
Carbon Monoxide Safety
Also known as the ‘Invisible Killer’, carbon monoxide (CO) is an odorless/colorless gas created when fuels don’t burn completely. With over 80,000 incidents each year, having a CO detector during the cold months is imperative to home safety. Consider these tips when looking to install your monitor:
  • Centrally locate your CO monitors around all sleeping areas and heat sources
  • Connect alarms so when one is signaled, all of them will sound
  • If alarm sounds, move immediately where fresh air is available
  • Keep all vents and exhausts clear of snow and clutter
  • Do not run any generators or fuel engines indoors without proper exhaust to the outside
 
Home fires can start and spread quickly. Remembering to keep decorations away from hazards and checking your alarms/monitors regularly can keep your family safe and ready to respond to an emergency. To keep the conversation going, download the NFPA Safety Tips or comment below.
NFPA Winter Holiday Safety
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Respirators on the Job

11/6/2024

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Workers are exposed to thousands of chemicals each day, many of which can be harmful. With nearly 200,000 injuries from chemical exposures each year, taking extra precautions when handling and working around chemicals begins with protecting your airways. Below we will review the different types of respirators that can be found on the job and when is the best time to use them.
 
What is a Respirator
A respirator is a device that protects you from inhaling dangerous substances, such as chemicals and infectious particles. They work by either filtering particles from the air, chemically cleaning (purifying) the air, or supplying clean air from an outside source. Before choosing a respirator, the airborne hazards and their concentration must be determined to make sure the device and filters will be sufficient.
 
Types of Respirators
There are four types of respirators, all of which filter, clean, or supply air to the individual. Let’s look at these types from the least protective to the most:
 
Particulate Respirator
Commonly known as “N-95” or “dust mask”, these respirators protect against dust particles, fumes, and mists. These are the most affordable respirators as they are typically disposable when finished. You will need to replace these respirators once they become discolored or the filter is clogged.
 
Air Purifying Respirator
Commonly known as “gas mask” or “half-face/full-face respirator”, air purifying respirators filter/clean the air as you breathe in. Equipped with filter cartridges, these respirators are secured to your face to create a seal around the mouth to prevent vapors and gases from entering the airway. These respirators typically require a medical examination and fit test to make sure the user is physically able to wear and breathe properly. Make sure you select the proper cartridges for the hazard at hand and replace them once they have expired or they reach their use limit.
 
Powered Air-Purifying Respirator (PAPR)
PAPRs use a fan to draw air through a filter to a helmet or hood. These are very similar to an air-purifying respirator, but do not require testing or a tight fit against the face. Filter cartridges are required and must be selected for the hazard you may face. Replace them once they have expired or reached their use limit.
 
Self-Contained Breathing Apparatus (SCBA)
SCBAs use an air tank to supply clean air to the user through a mask. They provide the highest type of protection from high concentrations of chemicals and require specialized training before use. SCBAs are typically used in atmospheres that are immediately dangerous to life and health (IDLH) or are very oxygen deficient. Since there is an air tank, there are no filters or cartridges to replace, but the air tank itself will need to be inspected regularly and removed from use once it has reached its expiration.
 
While there are many varieties of respirators, making sure you select the best option for the hazard you face will keep you and your lungs safe from exposure. Make sure you know the hazards at hand, have the proper filters/cartridges for said hazard, and are physically able to use the respirator without any medical issues. To keep the conversation going, download the Respiratory Protection Toolbox Talk (TBT) or comment below.

Respiratory Protection TBT
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Planning for an Emergency

10/2/2024

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An emergency or disaster can strike at any moment, causing injury and destruction along the way. This is why being prepared for any and all situations is necessary, so a response is effective. Below we will discuss some ways OSHA recommends preparing for an emergency and what you can do to keep your employees safe in a disaster situation.
 
OSHA Requirements for Emergencies
A workplace emergency is a situation that threatens workers, customers, or the public; disrupts or shuts down operations; or causes physical or environmental damage. In the construction industry, OSHA requires plans to be in place for means of egress, fire prevention, and emergency action:
  • Means of Egress: exits are to be free from obstructions at all times when occupied. Exits are to be marked by a readily visible sign on or pointing towards the exit route
  • Fire Prevention: all equipment shall be ready and maintained throughout the construction process. A proper water supply (temporary or permanent) must be present to operate firefighting equipment. Fire extinguishers are to be present for each 3,000ft² of space and may not be more than 100ft from each other
  • Emergency Action Plan: a well-organized plan that prepares workers with roles and responsibilities they are in charge of during an emergency. These plans are required when an employer wants to completely evacuate a facility during an emergency.
Emergency Action Plans (EAP) are required to have certain information available to employees. Below we will review how to begin an EAP and the requirements within.
 
Emergency Action Plan Review
Before writing an EAP, a hazard assessment must be completed to analyze any and all physical and chemical hazards present around the building. Once an assessment is completed, each hazard should have a plan on how to address the threat along with any specific workplace layouts or emergency systems that need to be included in remediating the hazard. Once hazards are identified and addressed, your written EAP should include the following information:
  • A method or procedures for reporting a fire or emergency (including authorities and project contacts)
  • Emergency egress routes posted and visible to show the nearest escape route
  • Procedure to account for all workers after an excavation (typically a rally point or refuge area)
  • Procedure for workers who are to remain to shutdown critical operations, execute fire extinguishers, or operate other essential functions
  • Rescue and medical duties that are to be performed by workers
If your facility is large and includes multiple buildings with multiple hazards, additional EAPs can be created for each specific area.
 
Preparing Your Workers
The best way to prepare your workers for an emergency is to provide training and practice all emergency responses so workers can act quickly when a disaster strikes. Emergency Preparedness Training should include roles, responsibilities, and any special tasks required by employees during an emergency. Annual training drills should be conducted to practice emergency procedures with emergency responders to keep knowledge fresh in all worker minds. Additionally, emergency systems need to be tested regularly to make sure notifications and alarms will properly alert employees during an emergency.
 
Knowing a disaster can strike at any moment, being prepared is paramount to the safety of yourself and your workers. Creating a proper Emergency Action Plan and preparing your employees will keep you ahead of anything that mother nature may throw your way. To keep the conversation going, download the Emergency Action Plan Toolbox Talk (TBT) or comment below.
EAP TBT
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Excavation Safety - Competent Person

9/4/2024

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When it comes to construction projects, your foundation excavation is important and yet the most dangerous aspect of the job. From the utilities underground to the shifting of soils, it’s important to have a competent person available to know these hazards and make sure everyone works safely around them. Let’s look at what it means to be a competent person on an excavation project.
 
What is a Competent Person?
OSHA defines a competent person as “one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.”
In short, a competent person has the knowledge and understanding to remove hazards. One can assume this role through experience in the field, proper training by the company, and through their knowledge and understanding of OSHA standards and practices. Once the competent person has been identified for a project, it’s important they review their duties and responsibilities each and every day as the job changes.
 
Duties of a Competent Person
Open trenches and excavations are a dangerous operation as they disturb the soil and surrounding areas in new ways each day. That is why the competent person must be prepared for any and all hazards you may see. Some responsibilities the competent person will need to be perform include:
  • Inspect the Excavation/Trench Daily
    • As the project progresses and the weather changes, the excavation needs to be inspected daily to ensure the safety of the workers. Checking for hidden hazards, damaged equipment, or eroded walls and address them immediately
  • Analyze the Soil
    • Knowing the type of soil and the surrounding area will help the competent person select the proper protective system. This will also assist in selecting areas for spoils and direct traffic flow away from the open excavations
  • Determine Proper Protective System
    • Bench, Slope, Shore, and Shield are the four main ways to protect workers in an open excavation. The competent person will decide which system will be the most beneficial for the site and also maintain any trench boxes or safety standards for spoils
  • Ensure Egress Routes are in Place
    • If excavations are taller than 4ft, an egress route needs to be added. All trenches also require an egress route accessible within 25ft of the work area
 
In Case of Emergency
Your competent person needs to be on the jobsite every day to assist with the job duties and safety inspections, but this doesn’t mean they can be everywhere all the time. For this reason you need to ensure all workers have proper training around open excavations and have the ability and confidence to stop work if something seems wrong. In the event of a cave-in or collapse, make sure everyone knows to dial emergency services immediately.
 
Excavations and trenching operations are paramount to the beginning of a project. Ensuring the safety of those working means you need to make sure your competent person is prepared and has the authority to keep everyone safe at all times. To keep the conversation going, download the Competent Person Toolbox Talk (TBT) or comment below.
NUCA Competent Person TBT
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Improving Your Company Training Program

8/7/2024

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This year, nearly 400,000 new workers entered the construction industry. While this is an increase from the previous year, the Bureau of Labor Statistics estimates there are over 700,000 job openings annually that need filled. With the influx of new employees and need for even more, a proper training program is paramount to make sure employees are safe and competent with their work. Below we will explore some ways to improve your training program and how you can properly implement these changes.
 
Assess Training Changes
As safety and technology continue to advance, new changes should be reviewed and assessed regularly to ensure your training meets the needs of the work at hand. Some changes that can affect your training needs include:
  • New Products or Services – as your company grows and work scopes change, employees need to be trained on all equipment and products that come along
  • Organizational Changes – if your building layout is updated, new processes are introduced, or additional hazards are exposed these may require updates to training and PPE requirements
  • OSHA/Law Updates – when new standards are imposed or laws update handling requirements, your procedures need to be updated as well
Once changes are reviewed and identified, your team needs to work together to update your training plan to create a well-rounded and effective program.
 
Update Training Plan
Once your training updates have been identified, your supervisors need to work on identifying ‘what’ needs changed and ‘how’ to implement these changes in your organization. Some of these examples can include:
  • Conduct Inspection/Investigations – identify any deficiencies, gaps, or improvements that can be made to ensure safety and compliance for the new process
  • Organize Employee Participation – provide workers with the training and materials needed to work with/around the new process safely
  • Ensure Emergency Procedures – update any Emergency Action Plans (EAP) and makes sure all emergency procedures aren’t impacted negatively by this new process
As your plan is being updated, make sure your workers are involved in this process to help measure preparedness and effectiveness. Once the plan is updated, these changes need to be implemented and tracked for their effectiveness.
 
Implement Training Changes
After your training plan is updated, the implementation process should include tracking training procedures, evaluating employees on their knowledge retention, and continuously monitoring the quality of training and updating as needed. If this training is something that is needed on an annual basis, make sure that your employees and their training are recorded and tracked to make sure they continue to receive their training on a regular basis. This type of training management is something that can easily be handled by STAC and our unique QR codes.
 
When updating your training plan, employers need to make sure that all parts of the organization are included in the assessment, update, and implementation process. When everyone is included, the most effective solution can be implemented. To keep the conversation going, download the Health & Safety Plan Toolbox Talk (TBT) or comment below.

H&S Plan TBT
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OSHA Emphasis – Powered Industrial Trucks

7/3/2024

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In July 2023, OSHA created a National Emphasis Program on Warehouse and Distribution Centers to evaluate high-risk workplaces. Since this program was enacted, over 600 inspections have been conducted by OSHA with nearly $2.5 million in penalties, most of which involve Powered Industrial Trucks (PIT). Below we will focus on the operation and training procedures of PITs and some hazards to be aware of when in use.
 
PIT Operation
Before operating a PIT some things to remember:
  • All operators must be over the age of 18
  • Inspect your PIT for any damage, leaks, or broken safety features
  • Inspect your work area for potential hazards that may be unsafe
  • Always wear a seatbelt (if applicable)
When operating a PIT some things to remember:
  • Never exceed the rated load requirements
  • Know your clearance for moving, picking up, and stacking your loads
  • Always yield for pedestrians. Check all walkways and aisles for foot traffic
  • When work is complete, set the brake, lower the forks, and park in a safe location
 
PIT Training Requirements
Before operating PITs, you need to be trained by a competent person. Training requirements include:
  • Training for each piece of equipment you will be operating
  • Written portion or knowledge check
  • Evaluation while using equipment
  • Store training documents/license for certification period (typically 3 years)
 
When it comes to PIT use in and around your workplace, making sure you have been properly trained is paramount to the safety of yourself and your coworkers. To keep the conversation going, download the Forklift Safety Toolbox Talk (TBT) or comment below.

Forklift Safety TBT
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