An article from the AGC California "Constructor" / Volume 32, Number 8 /
August 2001
A comprehensive safety program designed and implemented by FCI Constructors,
Inc./Cleveland Bridge California, Inc. for its construction of the New
Carquinez Bridge project has resulted in an outstanding safety record
since the project began in early January of 2000. AGC of California awarded
FCI Constructors, Inc. top honors in the special category of Safety Excellence
on a High Hazard Job for its achievement on this project, which creates
one of the first major suspension bridges built in the U.S. in 35 years.
The project will replace an existing bridge, originally built in 1927,
which carries westbound traffic on Interstate 80 across the Carquinez
Strait navigation channels about 20 miles northeast of San Francisco.
Construction is slated for completion in 2003.
Key project highlights include:
The three span, 3,465-foot-long structure will be one of the nation’s
first major suspension bridges to be built in several decades.
The bridge features two 400-foot high concrete towers, supported by driven
piles. Each tower will have 12 foundation piles, 3 meters in diameter
by 51 meters long, with an additional 42-meter rock socket.
The superstructure is a steel orthotropic deck section. Fabricated in
Japan, it will be shipped in three ocean going barges. Bridge sections
up to 50 meters long will be jacked into place off the bridge main suspension
cables.
The new 82-foot wide deck will accommodate four vehicle lanes (including
one HOV lane), a bicycle/pedestrian lane, and wide shoulders.
The project features an aggressive schedule bid in 1,200 days, with every
day a working day.
As of December 31, 2000 the project team had worked 197,000 hours with
zero serious injuries and no lost time accidents. FCI Constructors/Cleveland
Bridge developed several key safety areas of emphasis to achieve that
record, starting with a comprehensive new employee orientation program,
which is CD-Rom interactive. Every new employee must participate in and
pass a written test for each module. The focus of the training is behavior
based.
A second major component of the safety program is the weekly management
training programs geared towards increasing both technical knowledge as
well as managerial skills. The format takes place during a weekly site
safety coordination meeting, where subjects covered include results of
site inspections, observations and independent third party safety audits.
Another key component of the project is the mandatory completion of a
JSA, to be completed by the foreman in charge and prior to the commencement
of work activity. Once that is completed, a safety meeting is conducted.
For complex or high-risk activities, such as critical picks or deep pile
work, a formal safety review process takes place with the management team
to ensure that all aspects of the activity have been well planned and
prepared for prior to commencement of work.
In addition, monthly performance in both numbers of accidents, near misses,
as well as safety activities are measured and are factored into whether
or not a safety BBQ is held for everyone on site, including subs, the
owner and medical partners. Other incentives include T-shirts, hats and
jackets to reward the safe worker or crew.
While the various components of the comprehensive safety program have
added up to success, FCI President Tom Rademacher notes in the Safety
Award application that the total commitment and cooperation from the Joint
Venture Board and senior site management have been key to the project’s
success as well. “No safety issue is overlooked due to budgetary concerns,”
he says. “The investments made today will ensure continued success and
profitability now and in the future.”
Wow! What a great safety record! The 800 employees working on the NM 44
project work very safely. Since the project began in May 1999, workers have
logged 1,300,000 man hours, with a recordable incident rate of only 4.13,
and a lost time incident rate of 1.43. (Flatiron itself has had only one
recordable injury.) The national average for recordable incident rates is
9.6, and for lost time incident rates is 4.4.
Safety manager Sal Torres reports that the cost per man hour for workers
comp on the project is 10 cents, while the national average runs 30-50 cents.
"Many companies run upwards of 70 cents," says Sal. NM 44 has been designated
as the sixth most deadly highway in the U. S. During November and December
of 2000, not one private vehicle accident occurred in the entire 188 miles
of the project.
Hats off to Sal, and to safety coordinator Marvin Snook, safety technician
Michelle Palmer, and all the safety conscious workers at NM 44!
Heads up! To help you become more aware of the safety hazards at your project
site, we are now performing regular safety audits. These audits will occur
monthly on large projects, and on a regular basis on smaller ones.
Audit results are being shared with employees on specific sites, as well
as senior management at HBG and the particular division involved. A tool
for fact finding, not fault finding, the audits will be as objective as
possible.
Safety is the responsibility of everyone, and the safety manager is there
to help you develop safe habits and to assist in hazard reduction. As safety
manager Chris Peck points out, "In the summer season we hire more people,
and it is important we all watch out for each other. Our goal is for all
of our employees to return home each day with no injuries."
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