Lessons from the Field: Common Mistakes in Site Setups — and How to Avoid Them
Real-world compliance and safety slip-ups from traffic management crews — and how proactive verification keeps them in check.
1. Mistake #1: Insufficient Risk Assessments
One of the most common issues seen in traffic management planning is the use of generic Traffic Management Plans (TMPs) that don’t reflect the unique risks of the site. For example, site-specific decisions — like temporary speed zones or after-hours barriers — are often included without any supporting rationale.
How to avoid it:
Perform a physical site inspection and take geo-tagged videos
Document specific risks and the “why” behind design decisions
Use drive-through video verification after setup to record safe implementation
Source:
AusQ Training, “7 Most Common TMP Design Mistakes,” accessed July 2025. Summary of top issues in traffic management plan creation and execution.
2. Mistake #2: Poor Signage and Barrier Placement
Improper placement of signs and barriers is not just a technical error — it’s a safety risk. Whether it’s spacing, height, angle, or visibility, poor signage contributes to confused motorists and increased accident risk. This is one of the most common non-compliance issues on real-world sites.
How to avoid it:
Rigorously follow MUTCD or AGTTM spacing and placement standards
Use daily drive-through verification video to confirm correct setup
Conduct supervisor spot-checks during setup and at peak traffic times
Source:
AWP Safety, “6 Most Common Construction Site Safety Violations and Prevention Tips,” published 2024.
3. Mistake #3: Inadequate Crew Training and PPE Use
Traffic controllers must be trained, certified, and wear the right PPE. This includes high-visibility clothing, hard hats, safety boots, and gloves. Lack of compliance here has led to fines, work stoppages, and near-miss incidents.
How to avoid it:
Verify all workers have up-to-date tickets before work starts
Conduct toolbox talks that include a PPE checklist
Record site crew setup (including PPE) via short video on arrival
Sources:
Safe Work Australia, “Traffic Management Guide for Construction Work,” 2022.
AusQ Training, “Industry Events and Webinars,” 2023.
4. Mistake #4: Poor Version Control and Record-Keeping
Using outdated TMPs or failing to track revisions is a fast track to non-compliance. It creates confusion on-site and exposes your company to legal disputes when something goes wrong and no one can prove which version was used.
How to avoid it:
Use a cloud-based file management system with version control
Require crews to review and acknowledge the current plan each day
Link every setup video/photo to the specific TMP/TGS version in use
Sources:
AusQ Training, “7 Most Common TMP Design Mistakes,” 2024.
LinkedIn Article by Erin Studsor, “Most Common TMP Design Mistakes,” 2023.
5. Mistake #5: After-Hours Setup Is Forgotten
Even when the TMP includes after-hours arrangements, these are often skipped. Crews may pack up and leave signage, barriers, or equipment in unsafe configurations for the public.
How to avoid it:
Include after-hours signage and safety responsibilities in toolbox talks
Perform an end-of-day drive-through and upload a video for sign-off
Assign one crew member each shift to “lock down” the site safely
Source:
Safe Work Australia, “Traffic Management for Construction,” revised edition 2022.
A Common Theme: Verification Prevents Escalation
Each of these mistakes has one thing in common: they can be caught early — if there’s a culture of proactive verification. Video evidence, photos, geo-tags, and digital forms all contribute to catching slip-ups before they become compliance issues.
A quick drive-through recording provides objective, timestamped proof
Linking recordings to specific plans helps clarify what was intended
Having records centralised ensures you’re ready when inspectors or clients ask for evidence
The Role of Video Verification Tools
Good video verification software can embed all these best practices into your daily operations — with very little overhead for your crews.
Crews capture a short, hands-free video after setup
The system automatically tags it with GPS location and timestamp
The footage is stored securely and searchable for future audits, complaints, or training
Managers can review all setups remotely and request fixes before complaints arrive
It’s not just about avoiding fines. It’s about building a culture of visibility, accountability, and consistency across every job.
Final Thoughts
We all know the chaos that follows an audit or complaint when documentation is missing. But that scenario is 100% avoidable. If your team puts in place simple verification habits — and captures evidence early — most of the common field mistakes can be eliminated.
By doing this, your team won’t just be compliant — they’ll be trusted, respected, and ready for whatever scrutiny comes next.
References
AusQ Training, “7 Most Common TMP Design Mistakes,” accessed July 2025.
AWP Safety, “6 Most Common Construction Site Safety Violations and Prevention Tips,” 2024.
Safe Work Australia, “Traffic Management Guide for Construction Work,” 2022.
AusQ Training, “Industry Events and Webinars,” 2023.
Erin Studsor, “Most Common TMP Design Mistakes,” LinkedIn Article, 2023.
