Road Construction Injury Prevention: Practical Strategies for Safer Crews

By Cale Chaltron, MS, ATC
Injury Prevention Specialist, Fit For Work

Key Insights

• Road construction crews face unique challenges and hazards on the job, many of which are preventable.
• Situational awareness is essential to injury prevention in work zones.
• Practicing good ergonomics helps road crews safely perform intense physical labor.
• Conducting regular personal protective equipment (PPE) checks ensures equipment is in good working condition.

Road construction crews face unique challenges and hazards, from working at night to distracted drivers in work zones. While the majority of fatal worker injuries involve vehicles, the most common non-fatal injuries are related to ergonomics, awareness of conditions, and communication. Many of these injuries are preventable with a few simple steps, keeping crew members safe on the job and moving the project forward.

Common Injuries and Hazards Facing Road Crews

According to the U.S. Bureau of Labor Statistics (BLS), these are some of the most frequent work-related injuries and their common causes among road crews:

• Sprains, strains, contusions, and lacerations are often due to physical labor and incorrect ergonomics such as bending, overreaching, and incorrect hand placement.
• Heat illness is a serious risk for crews working during hot weather with minimal access to shade, especially when working with heavy machinery that radiates significant heat and high-temperature materials such as asphalt.
• Slips, trips, and falls can easily occur when climbing on and off equipment or due to uneven surfaces on site, with risk increased during wet, icy, or dark conditions.
• Falls from heights become dangerous quickly due to tall machinery and ground conditions including hot asphalt, wet concrete, chemicals, or uneven ground.
• Electrocution can occur if appropriate lockout/tagout (LOTO) practices are not followed during maintenance on equipment.
• Machinery entanglement, which occurs when a person or item gets caught in moving machinery, can result in serious injury. The risk is increased by poor LOTO practices and inadequate PPE.
• Ground collapses under equipment weight can quickly become catastrophic, so careful inspection of sites is essential.
• Hearing loss and respiratory issues are common due to equipment noise and frequent inhalation of dust and smoke.
• Crushing, being caught between, or getting struck by equipment can occur if communication between crew members and general awareness of surroundings are poor.
• Vehicle collisions, including workers on foot struck by vehicles and workers driving or riding in a vehicle, are responsible for over 75% of fatal worker injuries at road construction sites, but they also cause non-fatal injuries. Distraction and general lack of situational awareness are significant contributors.

6 Road Construction Injury Prevention Strategies 

The most effective injury prevention strategies are simple to implement and easy to remember:

1. Start a pre-shift stretching routine to warm up muscles. Most road crews are performing physically intense work, and proper stretching can reduce musculoskeletal injuries.
2. Check ergonomics and biomechanics regularly. Good ergonomic practices and biomechanics—the science of how the body moves and responds to physical demands—significantly reduce strain on the body, allowing crew members to remain safe and healthy on the job. If supervisors notice a trend of poor biomechanics, an injury prevention specialist can provide coaching that supports site safety initiatives and crew member well-being.
3. Ensure that PPE is available and functional. Supervisors may not be able to control or mitigate every hazard on a job site, but adequate PPE significantly reduces the likelihood and severity of injuries. Implement regular checks of high-visibility clothing, helmets, and boot treads (long hours can wear down treads quickly). Make sure adequate ear plugs, masks, and goggles are available to reduce hearing loss, respiratory issues, and eye injuries.
4. Maintain situational awareness. From remaining attentive in the work zone to evaluating site conditions, situational awareness is key to avoid vehicle collisions, accidents with machinery, and ground collapses. Remind crew members to stay alert and avoid distractions, including mobile phones, when onsite.
5. Remain weather aware. Use tools like the OSHA-NIOSH Heat Safety Tool to check the heat index, and make sure crews are staying hydrated. If no shade is available, a work vehicle with air conditioning can serve as a cooling station. Slippery conditions also increase risk, so follow local weather outlets for information on precipitation and freezing temperatures.
6. Emphasize communication within the crew. Calling out position changes and machinery use raises awareness of crew member location and movement. Communication is one of the best ways to prevent machine entanglement, crushing, and strike injuries.

Safety in Action

Sometimes working safely takes a little more time but the result is worthwhile. A road crew member working on a smaller paving strip at the edge of a roadway was observed using a hand roller. Given the size of the paved area, a larger roller appeared to be the more efficient choice.

However, the employee had carefully assessed the area, determining that the large roller would be operating on an angle. Due to its weight, it would be at risk of sinking the low side and tilting further. Should the ground shift or collapse, the equipment could roll over and cause serious damage. Using the hand roller would take longer, but it was the safer choice for the situation.

Conclusion

Injuries and accidents on the job can have long-term impacts on crew members’ lives, both at work and personally. Simple steps, including improved ergonomics, situational awareness, and communication, can significantly reduce the frequency and severity of onsite injuries onsite. Investing time and energy to mitigate the unique risks and hazards present in work zones keeps crew members safe and projects on track.

Looking to build a safer workforce? Fit For Work provides injury prevention and ergonomic solutions that help keep employees healthy, productive, and on the job. Contact us to learn more.

Cale Chaltron earned bachelor’s degrees in kinesiology and athletic training from Michigan State University, followed by a master’s degree in exercise science from the University of Toledo. From 2020 to 2023, he served as an athletic trainer at the University of Kentucky. Cale joined Fit For Work in 2023 and provides onsite injury prevention, ergonomics and employee wellness services for clients across the Upper Midwest.