Top 5 Mistakes We See in Work Zone Safety - and How to Avoid Them
Every day, crews set up work zones with good intentions. But even experienced contractors can overlook small details that lead to major safety issues, citations, or project delays.
At our company, we’ve supported thousands of traffic control setups. These are the top five mistakes we see again and again and how to avoid them.
1. Missing or Improper Advance Warning Signs
The mistake:
Crews forget to place advance warning signs like “Road Work Ahead” or “Flagger Ahead”. Or they set them too close to the work area for drivers to respond.
Why it matters:
Drivers need time to see, process, and react to changes in the roadway. If your first sign is 100 feet from the lane closure on a 45 mph road, that’s not enough.
How to avoid it:
- Follow the MUTCD’s required signs and recommended spacing based on speed
- Use a 3-sign sequence when required: Alert, Inform, Direct (Road Work Ahead, One Lane Road Ahead, Flagger Ahead)
- Drive the setup before considering the the traffic control “finished”.
2. Improper Taper Length or Device Spacing
The mistake:
Using too short a taper when shifting traffic or not spacing cones and barrels correctly (too far apart or uneven).
Why it matters:
A poorly built taper can confuse drivers or cause unsafe merging. Incorrect spacing makes the work zone look unprofessional — or worse, unpredictable.
How to avoid it:
- Use proper formulas to calculate taper length (e.g., L = WS²/60 for high-speed lanes)
- Space channelizing devices consistently. Here’s the trick for most tapers: the space between cones (in feet) should be the same as the speed limit (in miles per hour). A taper on a 45 MPH road will have cones spaced 45’ apart.
- Reference MUTCD Table 6C-4 or ask your traffic control provider for help
3. No Pedestrian Accommodation
The mistake:
Contractors block sidewalks or curb ramps without providing a detour or alternate pedestrian route.
Why it matters:
This is a violation of ADA requirements and often results in job shutdowns, citations, or public complaints — especially in urban areas or near schools.
How to avoid it:
- If you block a sidewalk, provide a safe alternate route with barriers and signage
- Include pedestrian routing in your traffic control plan
- Make sure temporary paths are firm, stable, and accessible for people with mobility devices
4. Flaggers Without Proper Positioning or Equipment
The mistake:
Flaggers stand in unsafe positions (e.g., too close to moving traffic) or lack required gear like STOP/SLOW paddles and high-vis apparel.
Why it matters:
Flaggers are critical to safety for the crew and the public. A distracted or poorly equipped flagger can cause crashes or injuries.
How to avoid it:
- Train your flaggers to position themselves with clear sight distance and escape routes
- Require MUTCD-compliant clothing and tools. Class 2 is required for all workers in the right of way (and maybe even more depending on your state).
- Conduct a brief pre-shift safety check and communication test
5. No Plan or Not Following the Plan
The mistake:
Some crews work from memory or guesswork. Others receive a stamped traffic control plan but don’t follow it in the field.
Why it matters:
Inspectors, DOT reps, and municipalities expect compliance with approved plans. “Winging it” can lead to failed inspections, fines, or job shutdowns. That plan has been created for a reason.
How to avoid it:
- Make sure your crew receives a copy of the approved traffic control plan
- Review the layout before setup begins
- Call your traffic control provider if conditions in the field require adjustments
Final Thoughts: Safety Isn’t Optional
Work zone safety isn’t just about checking a box. It protects lives, reputations, and your bottom line. The good news? Most of these mistakes are preventable with a little planning and the right partner.
If you're not sure whether your next setup is compliant, let us help. We design clear, compliant plans and supply the gear and guidance crews need to get it right the first time.