Familiarity breeds confidence, sometimes to a fault, and it was 40 years and tens of thousands of incident-free cuts, into his career that one of Tim Sweeney's most seasoned, carpenters ran his thumb through a table saw.
“He didn't sever it, so you might say it's not that big a deal,” says the president of Sweeney Construction, in Madison, Wis. “But what you don't see is the residual effect on this individual” — the three or four months that the carpenter couldn't work, much less bowl or golf, two of his defining passions.
There's also the residual effect on the business. Sweeney Construction had enjoyed a stellar safety record since Tim and his brothers formed the company in 1986. A year after the carpenter's injury, another staff member slipped on a jobsite, tearing his rotator cuff. He was out for almost three months. The company's experience modifier (used to calculate workers' compensation rates) climbed from .73 — “about as low as you can go” — to .95, costing the company another $10,000 to $15,000 over a few years.
“Is that going to hurt our company? Probably not,” Sweeney says. But the emotional and physical scars remain, and the game of catch-up takes a toll on schedules, clients, and other employees.
When accidents happen, the moment of impact is often just the tip of the iceberg. In the course of assembling these reflections on real-life brushes with death and some lesser occupational risks of construction work, we learned not only of the individuals' renewed commitments to safety, but also of their coming to terms with mortality, fallibility, and, at least temporarily, dependence on others.
They hope you'll never learn the same lessons.
ONE STEP TOO MANY
Rob Mathews
Curb Appeal Renovations
Keller, Texas
“I fell 18 feet off a roof on August 9, 2006. We have a contract to maintain a Boys & Girls Club, and every summer we have seven days to do six to eight weeks' worth of work.
Rob Mathews (shown with wife and partner Robin Burrill) was inspecting a roof when he stepped off it. Thankfully, his 3 nancial and legal affairs were already in order.
Photo Credit: Michelle Thompson
“I was inspecting the A/C units on the roof, and I basically took one step too many backward. On my way down, I hit a metal handrail and flipped over, so that I landed on my head and shoulder.
“My guys were all inside painting, but I was able to drag myself up an incline, across the scorching sidewalk, and to a door that I banged on. In the hospital, I learned that I had a fractured sternum, two broken collarbones, a dislocated right shoulder, a collapsed right lung with bleeding into it, a concussion, and four broken ribs. By the time my project manager got to my truck, someone had broken into it and stolen my wallet, my tools and golf gear, and my handgun (it's Texas, and I have a license to carry).
“I was in the hospital for five days and out of work for a month or so, and I'm still having severe back problems a year later.
“We're now adamant that our staff stay off roofs, if at all possible. We're also holding monthly safety meetings, and we even hired a third-party safety inspector to review our facility and practices. At his recommendation, we replaced some ladders, which we were using to access a storage area, with a permanent step structure, and created a pulley system instead of handing things down from this elevated area.
“We've always had good insurance, but we also decided to start paying 100% of our employees' medical premiums, instead of 50%, and 100% of everyone's long- and short-term disability insurance as well.
“In hindsight, I'm lucky to be alive, and also lucky that the business was able to operate without me. Our staff was phenomenal, and our trades, vendors, and clients were very supportive. But the most important thing was that my wife and business partner Robin and I had gotten our financial affairs in order years ago — wills, medical powers of attorney, durable powers of attorney. She was able to take care of insurance and other matters, as well as to cancel my credit cards and call the bank when my wallet was stolen.
“I think that's the moral of my story. Every remodeler needs a backup plan, whether they have a partner or not. An accident could be catastrophic if the company hinged on you alone.”
U.S. residential remodelers had 16 fatal falls and 37 fatalities overall in 2006. Framing contractors had 17 fatal falls. Construction in general accounted for 1,226 fatal falls in 2006 — more than any other industry sector (U.S. Department of Labor).
STILL RINGING IN MY EARS
Michael Mills
Michael Mills Construction
Aptos, Calif.
“In 1977, as a middle-aged hippie learning how to be a contractor, I had recycled some hard maple flooring from a fire-damaged gymnasium to floor my own house. It worked well, so I figured that what's good for the floor should be good for the kitchen counter. I decided to use my beautiful new Makita electric hand planer to plane the boards prior to installation.
“Working away at removing the varnish and getting a nice new finish, I noticed that the planer seemed to be making more noise, and my ears were beginning to hurt. I'm almost done, I thought; a few more minutes won't matter. I didn't go get my ear protectors (that might have taken 5 minutes), or replace the dull blades (not more than 10 minutes), or sharpen the blades (maybe 15 or 20 minutes). I just kept working until I finished.
Simple precautions would have prevented the permanent damage Michael Mills did to his hearing.
“The next morning, I noticed a ringing in my ears. I figured it would go away soon. Well, 30 years later the ringing still hasn't gone away. I can't hear the sweet nothings my wife occasionally whispers; I can't follow the talk at parties; I can't distinguish the birds singing from the noise in my head. I find myself ‘tuned out' in many situations. I hear the sounds, but I can't understand the words because I've lost the high frequencies.
“I have spent more than $10,000 on hearing aids, most of it out-of-pocket. My current set is certainly a help, but it's no substitute for undamaged hearing. I can't begin to count the number of hours I have spent with audiologists, ear/nose/throat doctors, and so on. Worst, however, is the sense of isolation that not hearing well imposes.
“Here's what I tell my staff: If sound causes pain, it is causing damage. That kind of damage does not heal; in fact, it gets worse each time you do it. Protect your ears with plugs and headphones, which I supply on every jobsite. And keep your cutting tools sharp. Not only can they harm your ears if they're dull, but they're much more likely to cause accidents.
“The countertop I installed 30 years ago? It's still in service, after just one refinishing. Wish I could say the same for the ears.”
By age 25, the average carpenter's hearing is comparable to that of a 50-year-old who has worked in a quiet job. Construction tools with the highest sound levels include belt and orbital sanders; circular, jig, miter, and reciprocating saws; grinders; and drills (National Institute for Occupational Safety and Health).
DRIVING WHILE DROWSY
Steve Chmelar
Carroll Distributing
Ottumwa, Iowa
One July afternoon in 1999, while driving an almost new, heavy-duty, ¾-ton pickup down a four-lane highway, I blacked out and ran into an 18-wheeler that was stopped at an intersection. My truck was pulling around 18,000 pounds of construction equipment (I work for a supplier), and the wreckage it created by slamming into the tail end of a fully loaded grain transporter was a pile of twisted steel.
“The emergency crews worked for 90 minutes, in temperatures well over 100 degrees, to remove me from what remained of the truck. Miraculously, I escaped with just a broken arm and some cracked ribs. Everyone was amazed that I was out of the hospital in three days.
“Early one morning three months later, I blacked out again on the same highway. This time, I was going about 60 when I rear-ended a farmer who was slowly pulling his harvest uphill. Again, there were no serious injuries, but I totaled a second new truck. My company almost lost its insurance.
Steve Chmelar's undiagnosed medical conditions led to two horrific crashes, including one involving this truck.
Photo Credit: Michelle Thompson
“My questions turned from ‘How did this happen?' to ‘What's causing me to black out?' At 46 years of age, I was 6 feet tall, 185 pounds, and in relatively good physical shape. I hadn't been drinking, and I had an otherwise good driving record.
“Medical tests revealed that I had a heart condition, sleep apnea, and narcolepsy, a condition that can trigger sleep at any time. I was equipped with a pacemaker and a C-PAP, a device that regulates airflow and prevents sleep apnea. I also began to take a medication for ‘excessive daytime sleepiness.'
“In the meantime, my company's insurance carrier forbade me from doing any driving for company-related purposes. I used to drive about 50,000 miles a year for my job, but for almost 12 months, my wife had to drive me to work, and my co-workers had to drive me to all work-related activities. Imagine functioning as a remodeler if your driving privileges were pulled!
“Today I'm healthy and driving again. But I learned the hard way that some health problems are less obvious than others, and that many of them, if left untreated, will take their toll. Looking back, my only real symptoms were being a little tired and having a tendency to snore, a fact that my wife often noted. Now I know that even drowsiness alone is a risk factor. When you're fatigued, your reaction time is slower.
“I consider myself fortunate to have survived not one, but two horrific accidents. As with many who make it through near-death experiences, I think I might be alive for a reason. I believe that lives will be saved if I can help others be aware of their own health risks and consult with the appropriate medical specialists.”
The U.S. had 1,329 fatal work-related highway incidents in 2006 (Dept. of Labor). People with untreated medical disorders have up to seven times the risk of falling asleep at the wheel (National Sleep Foundation).
LIVING UNDER A SHADOW
Michael Mitchell
Government project manager
Fairbanks, Alaska
As a college student 25 years ago, I worked summers as an apprentice machinist. We had parts-cleaning tanks full of solvent, along with squirt bottles of MEK (methyl ethyl ketone) for degreasing parts. Like most of the other machinists, I would take the part and swish it around using my bare hands. The boss encouraged us to use gloves, but we were young and robust and invincible. Gloves were awkward, and there were no ramifications for not wearing them or listening to other warnings.
“One time, not long after I cleaned out a long-neglected parts-washing tank, I developed an excruciating headache. The doctors thought it was meningitis and wanted to do a spinal tap. I thought it was overexposure to chemicals, and I resisted. They were clueless about industrial chemical overdoses and didn't believe me, but they held off on the tap. After two days, the headache subsided.
Michael Mitchell still works with dangerous materials, but he's now vigilant about using proper safety gear and procedures.
Photo Credit: Michelle Thompson
“I'm no longer in the trade, though I did construct my own house (as is common in Alaska) and continue to do a lot of woodworking. To this day, I live with an ominous, overshadowing concern that cancer will shorten my life, especially whenever a new health problem arises. I'm vigilant about using proper safety gear and procedures when working with power tools and paints, and I insist that my sons do the same. I do not let them work if they are not wearing the right gear or are performing a task in an unsafe manner.
“Yes, I agree that some of OSHA's rules seem overzealous and lack common sense. But a ‘sixth sense' of safety awareness, and a desire to run a safe business, is true common sense.
“Superintendents and owners must not only encourage safety, they must insist on it. Supply your crew with comfortable gear (the quality has come way up from 20 years ago) and train them. If possible, use testimonials from those who learned the hard way. If you can convert the hearts of young, ‘invincible' crews to embrace a safety mindset, and educate them on how to work safely, they will follow the rules even when you're not watching them.
“Either work safe, or get off the job.”
Acute exposure to high concentrations of MEK can irritate the eyes, nose, and throat. Long-term MEK exposure in animals has led to problems including fetal malformations and slight neurological, kidney, liver, and respiratory effects (U.S. Environmental Protection Agency). Other chemical hazards found in construction work include asbestos, lead, plaster and silica dust, and vapors from solvents, paints, and glues.
Getting Acquainted With OSHA
Residential remodelers have traditionally flown beneath the radar screen of the Occupational Safety and Health Administration (OSHA), the government agency charged with issuing and enforcing rules meant to prevent work-related injuries, illnesses, and death. Like modern Paul Reveres, however, safety experts warn that “the OSHA inspectors are coming” to more remodeling sites, triggered by economic and regulatory factors.
On the economic front, disgruntled ex-employees may be more inclined to file complaints about their former employers' safety practices. “We just had OSHA show up on a residential site because a past employee complained,” says safety consultant Catherine Applegate of Applegate Associates (www .applegateassociates.com). “With layoffs happening, this could occur more frequently.”
Efforts to do more with less could also lead to more jobsite accidents that trigger OSHA visits. The risks may be greatest for small companies that aren't up to speed on the law, says Wayne Niles, safety director for Scherer Brothers Lumber Co. (www .schererbros.com). “They're trying to survive in a down economy,” tempting some to skip fall protection, use poorly maintained tools, or do without proper safety gear.
On the regulatory front, OSHA's “local emphasis programs” (LEPs) are focusing attention on regionally prevalent hazards. LEPs in some regions are as broad as “residential construction” and “fall hazards in construction.” (For current LEPs, go to www .osha.gov/dep/local_emphasis_ programs.html.) “It used to be that OSHA could only get into those sites if they drove by [and spotted an obvious hazard] or somebody complained,” Applegate says. Blanket LEPs such as “residential construction” effectively let inspectors stop by unprovoked, within certain guidelines.
Remodelers' best defense against OSHA and, of course, against accidents, is having and enforcing a strong written safety program.
The law can be Byzantine, so let an expert help you create a program. Start with your insurance company, Niles says. Those with risk management/loss control departments are often happy to perform a free risk assessment. OSHA itself might also be enormously helpful. Programs vary by state, but in Minnesota, for instance, “they have a division called OSHA Consultation and all they do is help businesses with safety issues,” Niles says. “It is free and they cannot fine you for any finding.”
Retaining a skilled safety consultant can also mitigate the risk of both accidents and OSHA fines or shutdowns. Contact Niles or Applegate at wniles@schererbros.com or capplegate@applegateassociates.com, respectively.