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Protecting Construction Workers: Targeting OSHA's Fatal Four with Smart Safety Investments

  • Writer: Costello Safety
    Costello Safety
  • Jun 16
  • 6 min read
Construction Fatal Four
Construction Fatal Four

In construction, hazards are a daily reality, and some of them are far deadlier than others. In fact, OSHA reports that over 60% of all construction-related fatalities result from just four categories of incidents. Known as the “Fatal Four,” these hazards—falls, struck-by incidents, electrocutions, and caught-in/between accidents—represent the most urgent and preventable threats to worker safety.


Understanding and addressing these core risks isn’t just good practice—it’s a moral and business imperative. If you’re responsible for worker safety on construction sites, prioritizing controls for these high-risk categories could be the most impactful decision you make this year.



Understanding the Pareto Principle in Safety

The Pareto Principle, or the 80/20 rule, suggests that roughly 80% of consequences come from just 20% of causes. In workplace safety, this principle is especially powerful. While construction sites are filled with hundreds of potential hazards, focusing efforts on the Fatal Four can prevent a significant majority of injuries and fatalities.

Applying this approach allows organizations to concentrate their limited time, money, and manpower on the hazards that are statistically the most lethal. It doesn’t eliminate the need for comprehensive safety programs, but it ensures that the foundational threats are aggressively addressed first.


OSHA’s Fatal Four: The Root of Most Fatalities

According to the latest data published by the U.S. Bureau of Labor Statistics (BLS), in 2022 alone, there were 1,056 construction worker deaths—an increase from the previous year. Of those, over 60% were attributed to the Fatal Four:

  1. Falls from heights

  2. Struck-by object

  3. Electrocutions

  4. Caught-in or between

Let’s explore each of these in depth, including the real-world risks and the most effective methods to eliminate or control them.


Employee falls from height
Employee falls from height

1. Falls from Heights: The Leading Killer

Falls have long held the unfortunate title of the top cause of death in the construction industry. In 2022, they accounted for over 35% of all construction fatalities. Common causes include:

  • Unprotected sides and edges

  • Improper use of ladders or scaffolding

  • Lack of fall protection systems

  • Open floor holes and shafts

  • Inadequate training or oversight


Effective Controls for Fall Hazards

Elimination and substitution are the most effective strategies in the hierarchy of controls. Can the task be performed from the ground? If so, redesign the process to remove the need to work at height.


If working at elevation is unavoidable, consider the following measures:

  • Guardrails: Install around unprotected edges. They physically prevent a fall and should be the first line of defense.

  • Fall Arrest Systems: Include harnesses, lanyards, and anchor points. All must meet ANSI/ASSE Z359 standards and be regularly inspected.

  • Scaffolding: Must be erected and maintained by a competent person. Planks should be at least 18 inches wide, include guardrails and toe boards, and provide safe access and egress.

  • Ladders: Ensure they are rated for the task, placed at a 4:1 angle, secured at both ends, and extend 3 feet above the landing surface.

  • Safety Nets: Used where guardrails or harness systems are impractical. Follow OSHA’s extension and drop-height guidelines.

  • Housekeeping: A tidy site is a safer site. Loose cords, tools, or debris are tripping hazards, especially on scaffolds or rooftops.

  • Weather Awareness: Postpone work at elevation during high winds, rain, or icy conditions.


Also critical is the presence of a competent person to oversee elevated work and verify compliance with OSHA 29 CFR 1926 Subpart M.



Employee stuck by debris
Employee stuck by debris

2. Struck-by Object Hazards: Silent and Sudden

Struck-by hazards are particularly dangerous because the victims are often uninvolved in the task that caused the incident. Workers might be hit by falling tools, flying debris, swinging loads, or rolling equipment.


Common Examples

  • Tools dropped from scaffolding

  • Nail gun misfires

  • Swinging crane loads

  • Rolling trucks or forklifts

  • Material collapsing from improperly stacked loads


Effective Controls for Struck-by Incidents

  • Tool tethering systems: Secure tools and equipment at height.

  • Barricading zones: Tape off areas around overhead work, crane lifts, or high-traffic equipment areas.

  • Toeboards and Screens: Prevent items from falling off platforms or roofs.

  • Qualified equipment operators: Only trained and certified personnel should operate cranes, forklifts, and heavy machinery.

  • Proper material storage: Secure stacked or bundled items against wind or vibration.

  • Blind spot controls: Use audible backup alarms, camera systems, and spotters.


Even with these controls in place, always enforce PPE rules—hard hats, safety glasses, and high-visibility vests are critical on active sites.


Employee electrocution
Employee electrocution

3. Electrocution Hazards: The Invisible Threat

Electrocutions remain one of the top killers on construction sites. According to OSHA, 8.6% of construction fatalities in 2022 involved electrocution. These incidents are particularly dangerous because electricity is silent, invisible, and often underestimated.


Real-World Risks

  • Contact with overhead or underground power lines

  • Use of damaged extension cords or tools

  • Poorly grounded temporary power systems

  • Wet environments and electric-powered equipment


Preventive and Control Measures

  • Maintain safe distances: OSHA requires minimum approach distances based on voltage. Use non-conductive barriers or de-energize the lines when working close.

  • Locate utilities before digging: Always call 811 before excavation. Use vacuum excavation if lines are close.

  • Lockout/Tagout (LOTO): Follow 29 CFR 1910.147 to ensure energized systems are properly locked and tested before work begins.

  • GFCIs on tools: Ground fault circuit interrupters are required on all temporary wiring setups.

  • Non-conductive PPE: Use fiberglass ladders, rubber-soled boots, and Class E hard hats when working around live electricity.

  • Water control: Never use cords or tools in wet environments. Elevate cables or drain water.

  • Routine inspections: Remove damaged cords and tag out defective equipment. Only qualified electricians should perform repairs.


Electrocution prevention requires vigilance. One moment of distraction can result in severe injury—or worse.


Employee caught between equipment
Employee caught between equipment

4. Caught-in/Between Hazards: Crushing Dangers

Caught-in or caught-between incidents involve crushing, pinching, or being compressed between two objects. These often involve heavy equipment, moving parts, or trench cave-ins.


Examples

  • Getting pinned between a moving truck and a wall

  • Being pulled into machinery

  • Trench collapses

  • Entrapment in rotating or reciprocating parts


Controls and Best Practices

  • Machine guarding: All moving parts must be guarded per OSHA 29 CFR 1910.212.

  • Trench safety: Use trench boxes or shoring for any trench over 5 feet deep. For trenches over 20 feet, a registered professional engineer must design the system.

  • Rollover protection systems (ROPS): Install on heavy equipment such as bulldozers or skid steers.

  • LOTO for maintenance: Disable machines before any service or inspection.

  • Proper PPE: Avoid wearing loose clothing or jewelry near moving parts.

  • Spotters and barricades: Always use trained spotters during equipment movement.


OSHA also recommends slope or bench excavations, depending on soil type, to prevent collapse. Never enter an unprotected trench.


Why Training Alone Isn’t Enough

Safety training is a critical component—but it’s not a silver bullet. Multiple studies have shown that while training is vital, it ranks behind engineering controls, management engagement, and worksite analysis in terms of effectiveness.

Training should be part of a broader safety system—not the only tool in the toolbox. Focus instead on eliminating hazards at the source, supported by strong policies and regular safety audits.


The Power of Management Involvement

No safety strategy is complete without committed leadership. Top-down support ensures that procedures are enforced, equipment is maintained, and safety isn’t sidelined when deadlines loom.


Key Roles for Management:

  • Developing and funding robust safety programs

  • Conducting regular site visits and walkthroughs

  • Empowering safety personnel and giving them authority

  • Setting a personal example of safety compliance

  • Ensuring that corrective actions from inspections are actually implemented


A culture of safety starts with what leadership models and mandates.


Leading vs Lagging
Leading vs Lagging

Leading vs. Lagging Indicators

Many companies rely on lagging indicators like injury rates, incident logs, or workers' compensation costs. While these are important, they reflect what has already happened.

Leading indicators, by contrast, help prevent incidents before they occur.


These include:

  • % of pre-task plans completed

  • Near-miss reports

  • Safety meeting attendance

  • Corrective action close-out rate

  • Frequency of equipment inspections

  • Number of safety observations


Tracking both types of metrics provides a more holistic view of safety performance and helps guide smarter interventions.


Creating a Safer Construction Site—One Hazard at a Time

There’s no one-size-fits-all solution to eliminating the Fatal Four. However, the following practices can dramatically reduce risk:

  1. Conduct regular hazard assessments

  2. Implement site-specific safety plans

  3. Invest in controls before investing in training

  4. Foster open reporting of hazards and near-misses

  5. Engage both supervisors and employees in daily safety huddles


Every improvement begins with awareness and commitment. By addressing the most dangerous risks first, you protect your workers, reduce liability, and boost your company’s reputation.


Conclusion: Safety with Purpose

Reducing injuries and fatalities in construction isn’t about achieving a perfect record; it’s about making daily progress toward a safer work environment. OSHA’s Fatal Four are well-known threats, and yet they continue to harm thousands of workers each year. That doesn’t have to be the case.


At Costello Safety Consulting, we specialize in practical, field-tested solutions for controlling high-risk hazards. Whether you need help with site inspections, training development, or full-scale safety program management, we’re here to help your team go home safe, every single day.


Let’s Eliminate the Fatal Four—Together

Whether you’re a general contractor, subcontractor, or project manager, our team can tailor safety solutions that work for your budget, your crew, and your job site.



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