How a Multi-Site GC Reduced OSHA Recordables by 78% and Achieved 6.1× ROI in a Single Season
The Challenge
A mid-sized general contractor managing 6 active construction sites simultaneously had a safety manager responsible for compliance across all locations — an impossible span of control. Fall protection violations were chronic. Subcontractor PPE compliance was tracked only through weekly site walks. Two recordable incidents in the prior season had triggered insurance premium increases of $42,000/year. A third recordable would have triggered OSHA Enhanced Enforcement.
What VivyaSense Found — First 30 Days
- 1
31 fall protection violations per week across all sites — workers removing harnesses after morning safety walk
- 2
Subcontractor PPE compliance at 58% — dropping within 20 minutes of supervisor leaving the zone
- 3
Active struck-by hazard at Site 4 (steel erection) — workers beneath crane lifts with no exclusion zone enforcement; near-miss captured Week 2, never reported
- 4
4 unauthorized after-hours site accesses — two near equipment areas
Results — 6 Months
- ✓
Recordables: 9 → 2 (▼ 78%)
- ✓
Fall violations: 31/week → 5/week by Month 2 → 96% reduction by Month 6
- ✓
Subcontractor PPE: 58% → 91% — no new safety headcount hired
- ✓
Site 4 crane zone: enforced within 48 hours → zero crane incidents remainder of season
- ✓
OSHA walkthrough: zero citations
- ✓
Insurance premium increase: reversed — $42,000/year credit applied at renewal
ROI Summary
“One safety manager cannot physically be at 6 sites at once. VivyaSense gave us eyes everywhere simultaneously. Our insurance carrier asked us to document what we were doing so they could use it as a model for other GC clients.”— VP of Safety & Operations, General Contractor, Southeast US