Key areas covered
- Falling Object and Overhead Hazard Control
- Vehicle and Equipment Struck-By Prevention
- Flying Objects, Projectiles, and Swinging Load Control
Struck-by incidents are the second leading cause of construction fatalities. Supervisors must plan for falling objects, moving vehicles and equipment, flying debris, and swinging loads before work begins. Effective control requires PPE enforcement, traffic control planning, load path management, and daily inspection of tools, equipment, and work zones.
Falling Object and Overhead Hazard Control
Falling objects account for a significant share of struck-by fatalities. As a foreman, your responsibilities begin at the planning stage: identify every overhead work activity, establish exclusion zones beneath elevated work, require toeboards (minimum 3.5 inches high) on all scaffolds and elevated platforms per 29 CFR 1926.502(j), and ensure tools and materials are secured when not in use. Hard hats (ANSI Class E or G) are required for all workers in areas where falling object risk exists per 29 CFR 1926.100(a). When working below other crews, post warning lines and barricades at least 6 feet from the edge of the overhead work zone. Debris nets under elevated work areas and tool lanyards on elevated hand tools are engineering controls that should be the first line of defense before relying on PPE alone. During crane picks, establish a clearly marked load path exclusion zone and prohibit workers from standing beneath suspended loads per 29 CFR 1926.753(e).
Why it matters
A dropped wrench from 30 feet strikes with the force of a hammer blow regardless of whether the victim is wearing a hard hat. Engineering controls that prevent the drop are more reliable than PPE that absorbs impact. Plan no-drop zones as a primary control.
Field note
Use tool lanyards on all hand tools used above 4 feet. Before a multi-story pour, identify every floor opening above ground-level work and install debris nets or plywood covers rated for the expected load. Brief the ironworker and carpenter foremen on the overhead zones every morning.
Vehicle and Equipment Struck-By Prevention
Vehicle and equipment struck-by incidents kill more construction workers than any other struck-by category. OSHA 29 CFR 1926.601 and 1926.602 establish requirements for construction vehicles: working brakes, horns, reverse alarms, adequate lighting, and rollover protection. As a foreman, your traffic control responsibilities include: separating pedestrian and vehicle traffic routes with physical barriers wherever feasible, requiring high-visibility vests (ANSI/ISEA 107 Class 2 minimum) for all workers in roadway and equipment traffic zones per 23 CFR 634, designating trained spotters for all reversing equipment in congested areas, and establishing a site speed limit enforced by physical controls (speed bumps, one-lane choke points). Never allow workers to ride on equipment not designed for passengers. Establish clear equipment exclusion zones around active work areas and enforce them with cones, barriers, and flagging. For dump trucks and concrete trucks on sites with pedestrian workers, a banksman/spotter must guide every reversal.
Why it matters
Most equipment struck-by fatalities occur in the blind spot behind reversing equipment. A reverse alarm alone does not protect a worker who cannot hear it over site noise. Physical separation and a dedicated spotter are the only reliable controls in congested work zones.
Field note
Map vehicle and pedestrian routes on the site plan before mobilization. Review the map at the weekly safety meeting and update it when new equipment is brought on site or work zones shift. A worker who does not know the traffic plan cannot follow it.
Flying Objects, Projectiles, and Swinging Load Control
Flying object struck-by hazards arise from power tool ejections (saw kick-back, nail gun misfires, grinder disc failures), pressurized system failures, and crane/rigging load swing. OSHA 29 CFR 1926.102 requires eye and face protection when there is risk of flying particles. As a foreman, control these hazards by: enforcing safety glasses and face shields during grinding, cutting, and nail gun operations; requiring grinder guards at all times per 29 CFR 1926.303(c); ensuring nail guns are operated in contact-trip mode only when sequential fire is the required method for the task; inspecting all rigging hardware before each lift for cracks, deformation, or wear beyond discard criteria per 29 CFR 1926.251; and requiring that crane loads are rigged to prevent rotation, shifting, or uncontrolled swing during picks. Establish load exclusion zones equal to the load radius plus a buffer, and enforce them with barriers and spotters. Powder-actuated tools require a permit, operator certification, and a spotter per 29 CFR 1926.302(e).
Why it matters
Grinder disc failures at 11,000 RPM turn disc fragments into projectiles with energy equivalent to rifle rounds. A missing guard is not a minor violation — it is an imminent danger condition. Stop work on any grinder operating without its guard.
Field note
At the start of every shift, require grinder operators to show you the guard is installed and the disc is within its use-by date. Inspect rigging slings for cuts, abrasions, and heat damage before the first lift. A two-minute rigging check prevents fatalities.