The Safety Advantages of Prefabrication and Modular Construction

Chubb Global Risk Advisors Are You Aware of Modular construction, prefabrication, and offsite construction are terms which are often used interchangeably, although the Safety-Related they have subtle differences. All three are types of construction Benefits Associated in which techniques from manufacturing are being utilized with Prefabricated to improve the construction process. They also reflect the and Modular industrialization of construction. Construction? In prefabrication, a building or building components are made in a more controlled environment than is offered at a traditional construction site. Prefabrication has been defined as “a manufacturing process, generally taking place at a specialized facility, in which various materials are joined to form a component part of a final installation.”1 This approach typically involves a single trade, such as electrical, piping, or rebar. Prefabricated or modular construction allow various building components such as bathrooms to have pre-wired light fixtures and exterior walls built in a factory setting, and then transported to a construction site.

In terms of safety, think of modular or prefabricated construction as a construction process rather than a specific type of building. The key is how the building was constructed, not what the building is.

The construction industry is one of the most dangerous fields to work in. Out of every 5,000 private-industry worker fatalities, 20 percent are in construction. That means one out of every five worker deaths is construction-related. According to the Department of Labor (DOL), Construction workers accounted for 1,008 (47 percent) of all fatal work injuries in 2018. Utilizing modular or prefabricated construction should be considered as an approach that can reduce the likelihood of fatalities and injuries on the traditional construction sites. Construction’s According to the Bureau of Labor Statistics (BLS),2 in calendar year 2018 there were 4,779 worker fatalities in private industry; “Fatal Four” of those 1,008 or 21.1% were in construction. This equates to one in five worker deaths last year occuring in the construction industry. The leading causes of private sector worker deaths in 1. Falls the construction industry (excluding highway collisions) were falls, followed by struck by object, electrocution, and caught-in/ 2. Struck by object between. These “Fatal Four” were responsible for more than 3. Electrocution half (58.6%) the construction worker deaths in 2018, BLS reports. Eliminating the Fatal Four would save 591 workers’ 4. Caught-in/between lives in America every year.3

Falls are the number one cause of construction worker fatalities, accounting for one-third of all on-the-job deaths in the industry. In 2017, there were 366 fall fatalities out of 971 total fatalities in construction.2 Falls are a hazard found in many work settings, but construction has the most fatal falls out of all industries and represents 51% of all falls nationally.4

The “Fatal Four Causes of Injury in Construction Account for 591 Deaths (2018)3 400

350 338

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150 112 100 86 55 50

0 Falls Struck by Object Electrocutions Caught–In/Between The Safety Advantages of Prefabrication and Modular Construction

How Modular Construction Reduced Risk of Struck by Can Reduce Construction Risks and Caught-In/Between Injuries

With modular and prefabricated One of the most significant differences construction, much of the work being between traditional and prefabricated/ performed occurs in a manufacturing modular construction is that the latter setting, where the likelihood of fatality takes place away from the construction and serious injury is lower than in on-site site in a controlled factory environment. construction. Incorporating modular An assembly-line-like work process is set and prefabricated components into a up for the manufacturing of the building construction project can help to reduce components. Team members know their the top causes of construction site work area well, understand the areas of injuries and fatalities.5 caution, and are specialized in their tasks. Because of this well-organized Reduced Risk of Fall-Related Injuries workflow and process, there is a significantly reduced chance of being Performing much of the work offsite struck by machinery, equipment, or allows for the reduction of risky other objects — frequent occurrences construction site elements such as on traditional construction sites. scaffolding, ladders and working at Manufacturing construction components heights. With falls as the number one away from the jobsite can reduce the cause of workplace fatalities in amount of foot traffic occurring at the construction, maximizing the work job site. This simple change means fewer done at ground level can have a big workers onsite and fewer workers who impact. According to the Center for can potentially be injured, killed, or Construction Research and Training, otherwise involved in a caught-in/ ladders accounted for 24% of fatal falls between or struck by an object accident. in construction with scaffolding involved in an additional 15% of Reduced Risk of fall-related fatalities. Weather-Related Injuries To the extent possible, eliminating The controlled environment of an indoor or reducing the use of ladders can manufacturing setting keeps out any significantly reduce the risks in weather hazards that may present construction. Approximately 65% of all themselves in a traditional construction construction workers perform work on environment. When the process takes scaffolds, exposing workers to the risk place indoors no rain delays or slippery of falls, electrocutions, and falling surfaces should occur due to weather. objects. With prefabricated or modular The likelihood of slips, trips and falls is construction, more work is performed reduced inside indoor environments. at the ground level, and the need for Hazards such as temperature extremes working at heights is reduced in general. and high winds can be eliminated when Additionally, the prefabricated/modular building components are prefabricated construction process reduces the need indoors at an off-site location. for climbing to potentially dangerous heights to build each module. Reduced Risk of Inattention The typical height of a prefabricated Since the prefabricated component or modular unit ranges from 8 to 10 feet tall. structure is a module, workers have one This reduction in height alone can large object to focus solely on rather than prevent a significant number many moving parts. With employees’ of accidents that occur due to falls. attention centered on the modular structure, workers can focus on one thing at a time during the installation of the module and not be distracted 4 The Safety Advantages of Prefabrication and Modular Construction

by multi-tasking. Overall, these standardized workflows that encourage Rigging pre-assembled structures make the specialization and a better understanding Rigging of each modular component construction process more efficient and of duties and environments, allowing is another area where additional focus reduce site disruption and wasted time. for far fewer accidents to occur in is needed. In many cases customized comparison to a typical construction rigging is required when lifting the Reduced Time on Site site. Then when the structure is Due to Improved Efficiency modular components. Having the delivered to the project site, all that correct rigging equipment and trained In addition, with modular/prefabricated is left is installation. and qualified personnel is essential for components, the overall construction this type of work. process can often be quicker than Managing the Safety Hazards traditional, onsite construction. Associated with Modular and Moving Prefabricated Components By finishing the project roughly 30% Prefabricated Construction to and Around the Site to 50% faster, construction workers While modular and prefabricated Based on the accidents found in studies will be spending far less time in a construction processes can reduce of prefabricated/modular construction potentially hazardous situation, reducing some of the safety risks associated with sites, precise pre-job planning to 6 the chance of all potential injuries. traditional construction sites, this properly clear the work area around Increased Quality Control/ approach does have its own hazards that and under moving components should Reduced Exposure to Construction must be managed. The Rinker School be a primary concern for contractors. Defect Claims of Construction Management at the The OSHA standard 1926750(k)(I): states University of Florida, Gainesville, “Requirements for Lift-Slab Operations In addition to reducing the potential Florida conducted a study that closely can be considered as a basic safety for workplace injuries, prefabricated/ examined 125 injuries that occurred on practice for moving prefabricated/ modular construction can also help in manufacturing facilities and onsite modular components.” According to improve quality and efficiency. construction projects that installed or this standard “no employee, except those utilized prefabricated/modular building essential to the jacking operation, shall The controlled environment of a components. Their findings provide a be permitted in the building/structure manufacturing facility lends itself to blueprint for safety managers seeking while any jacking operation is taking more thorough quality control testing to control hazards associated with place unless the building/structure has and traceability of components that prefabricated/modular construction. been reinforced sufficiently to ensure allows the team to identify and correct its integrity during erection.” Ensuring glitches before the module arrives at Cranes employees do not work under or near a the worksite. Additionally, the factory Unlike most other traditional live suspended load is an area that will environment allows for more accurate construction sites, a job site with require additional focus. construction, tighter joints and better air prefabricated/modular installation Securing modular/prefabricated loads filtration, which in turn allows for better requires a large crane to lift modules wall insulation and an increase in energy (boxes) onto the foundation or structure. during transportation, lifting and storing, efficiency. Getting it right the first time An acute focus on crane safety is is another area of emphasis. saves all parties time and money and can required on job sites where prefabricated Most modular units are transported on help reduce exposure to construction modular units are being installed. a semi-trailer and are often oversized defect claims Having a clear understanding of the loads loads, requiring specialized planning involved and the capacity and reach of and routing to transport the large Overall, modular construction can the site crane will be paramount. Chubb components. Chubb Global Risk provide a variety of advantages over Global Risk AdvisorsTM suggests only Advisors suggests only hiring trucking traditional construction methods, but using highly experienced qualified crane and fleet specialists that have experience perhaps the most essential is the safety and rigging companies to perform these in large oversized load transportation. it provides the employees working on tasks. Pre-planning hoisting operations the project. The prefabricated/modular involving large modular units are construction process itself sets up essential to avoid significant incidents.

5 The Safety Advantages of Prefabrication and Modular Construction

Appropriate Temporary Connections The Majority of Injuries Associated with Modular Construction Occur During Installation Stabilizing and securing temporary 70% connections of modular/prefabricated structures during their installation is an 60% essential area contractors need to pay 57.6% attention to. Support connections with this type of construction require special 50% and innovative design, training, and preplanning. The table on the right 40% illustrates accidents related to prefabricated/modular construction. 30% The table focuses on the activities 20% taking place at the time of the incident, 16.8% showing 57.6% of the accidents associated 13.6% with prefabricated/modular construction 10% 4.8% occur during the installation phase on 2.4% 2.4% 1.6% 0.8% project work sites. Effective and thorough 0 preplanning of the installation process Installation Mfg. Process Moving On/O Inspection Preparing for Not Speci ed Disassembly is a critical part of a safety program. Loading Installation

Manufacturing Hazards “In general, it can be concluded that Risk management specialists can help you assess your workplace and work Modular/prefabricated building on-site working environments pose processes, identify risks to your construction is essentially the fabrication greater safety risks than off-site employees or gaps in your safety of building components in manufacturing construction operations. Safety can program, and create a tailored solution. plants. The intent is to improve quality, be expected to improve by fabricating For example, they can help you explore enhance safety, reduce construction as many components as possible in 7 the following questions: time, minimize waste and improve manufacturing facilities.” energy efficiency. The manufacturing Although the manufacturing environment • What are the specific loss drivers process involves risks that must be is generally a safer and more productive on your projects? addressed as well. Keep in mind that work setting, companies that perform work in the facilities fall under the • How does your data on the “Fatal Four” prefabricated/modular construction General Industry Standards OSHA 1910, compare to industry averages? should be aware of the hazards not OSHA 1926 (Construction). It is associated with this unique type of • How might incorporating modular or important to be aware of the potential construction. Chubb Global Risk prefabricated construction make your hazards and different regulations and Advisors has experience in both the worksites safer and reduce injuries? requirements in manufacturing as construction and manufacturing • What types of projects need an opposed to a construction environment. industries assisting our insured in onsite safety manager? How many? avoiding accidents by providing sound The Rinker School study demonstrated • What set-up requirements should loss control advice. that there is a significant difference in the be implemented for cranes working nature and severity of onsite and off-site Need a hand? on modular installation and other construction accidents. Approximately construction site work? What size, 62% of the accidents associated with Whether you already utilize prefabricated capacity and reach are necessary for prefabricated/modular construction or modular construction or are thinking a crane on your work site? occurred on construction sites, while of incorporating them into your • How are the modular units only 18% occurred at manufacturing construction process, it’s important to transported to the site? plants. The location was not clearly have a robust safety program that helps identified for 20% of the accidents. you address all the exposures associated • What process do you follow for with your projects. Business as usual can modular installation? Can the process make it hard to identify many exposures be improved to reduce risk? that often go unnoticed. New processes bring new hazards.

6 The Safety Advantages of Prefabrication and Modular Construction

• What are the risks at the Footnotes manufacturing facility? This process 1. SMART Reconfigurability Approach in Manufacture is often overlooked and should be of Steel and Façade Constructions, Dominik Tobias reviewed to reduce risk Matt, Erwin Rauch and Vittorio Franzellin 2. www.bls.gov/iif/oshwc/cfoi/cftb0322.htm Risk management specialists can also 3. www.osha.gov/data/commonstats evaluate the effectiveness of management control programs and operational 4. www.cdc.gov/niosh/construction/stopfalls.html controls in place to reduce or minimize 5. www.cpwr.com/sites/default/files/publications/ Quarter2-QDR-2019.pdf fall exposures and other risks to employees. They can work with you at 6. www.ishn.com/articles/106913-modular- construction-can-help-reduce-the-fatal- every phase of the prefabricated/modular four-accidents construction process from pre-job 7. Maryam Mirhadi Fard, Seyyed Amin Terouhid, planning and hazard assessments to Charles J. Kibert & Hamed Hakim (2015): Safety Job Safety Task Analysis ( JSTA) and fall concerns related to modular/prefabricated building construction, International Journal protection requirements in order to of Injury Control and Safety Promotion, DOI: eliminate, prevent, protect, and monitor 10.1080/17457300.2015.1047865 — controls and to identify additional Page 9, 12, 13, 14, 15 controls needed.

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