A Guide to Fall Protection Systems

Falls are the leading cause of construction industry fatalities, accounting for 38% of 2021 construction fatalities according to the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA).

Falls are such an important issue for OSHA that they are the biggest component of what OSHA calls the “Focus Four” accidents. These are the top four workplace accidents in construction: falls, electric shock, caught-in or -between, and struck-by accidents. Moreover, each year OSHA holds a “National Safety Stand Down” to increase awareness of fall accidents and how to prevent them.

OSHA is hyper-focused on this issue because fall accidents are entirely preventable. We all owe the brave, hardworking men and women building our world sincere appreciation — and that begins with doing all we can to ensure their well-being and safety.

Fall protection systems are a critical component for your safety program to prevent workers from falling when working at heights greater than 6 feet — or when working near dangerous equipment. There are many different types, depending on the situation, so you’ll have to know which equipment is right for a given job. Plus, you’ll need to ensure these systems follow OSHA’s rules, which can get very complex.

OSHA Requirements

OSHA has specific regulations related to fall protection for construction workers, which require employers to provide workers with fall protection equipment, training, and appropriate safety measures to prevent falls.

First, OSHA requires any surfaces on which workers are walking or working must be structurally sound. This sounds obvious, but many people do not stop to think of the area they are standing on as a fall hazard. For example, a residential roofer might not expect the actual roof he is walking on to collapse — but that is always a possibility.

Second, OSHA requires construction employers to provide fall protection for workers in two general settings:

1. Anyone working at heights of 6 feet or more above a lower level.

2. Anyone working near dangerous equipment. (Note, the distance does not matter here!)

This fall protection can be provided through a variety of means, including guardrails, safety nets, personal fall arrest systems, or other appropriate systems.

Third, OSHA has specific standards for each type of fall protection system. For example, guardrails must be able to withstand a certain amount of force, be at least 42 inches high, and have a mid-rail at a height between the top rail and the walking surface. Safety nets must be installed within 30 feet of the work area and be able to catch a falling worker. Personal fall arrest systems must include a full-body harness, a lanyard, and an anchor point that can support at least 5,000 pounds per worker.

Fourth, and probably most importantly, employers must also ensure that workers are trained in the proper use of fall protection equipment and systems. Having equipment that employees don’t know how to use properly can sometimes increase the risk. OSHA requires that workers who may be exposed to fall hazards receive training before they start working and that they receive additional training if there are changes in the workplace or in the fall protection systems. The training must cover topics such as the nature of fall hazards, the correct use of fall protection equipment, and rescue procedures in case of a fall.

Four Different Types of Fall Protection Systems

Fall protection systems are designed to stop a falling worker before they reach the ground. There are several types of fall restraint systems that can be used to protect workers from falls. The advantages and drawbacks of each system type vary, and the choice of system is influenced by several variables, including the type of work being done, the height of the work area, and the type of work surface.

1. Personal fall arrest systems (PFAS): Personal fall arrest systems consist of an anchor point, a lanyard, and a full-body harness that are used together to prevent a worker from fully falling to the next lower level. The lanyard is attached to the anchor point and to the worker’s harness and is designed to absorb the force of a fall. PFAS are versatile and can be used in a wide range of work environments. Proper training and careful inspection are required to ensure PFAs systems are used correctly.

2. Safety nets: Safety nets are designed to catch falling workers and prevent them from hitting the ground. They can be installed underneath elevated work areas and provide a cushioned landing surface. Safety nets are relatively easy to install, maintain, and can protect multiple workers at once. However, they require a significant amount of space and may not be suitable for all work environments.

3. Guardrails: Guardrails are physical barriers that prevent workers from falling off the edge of elevated work areas. They are typically made of metal or wood and are installed along the perimeter of the work area. While guardrails provide a permanent fall protection solution and do not require additional equipment or training, they may not be suitable for all work environments and can be difficult to install in some cases.

4. Rope grabs: Rope grabs are used with vertical lifelines to protect workers who are working at height on a fixed ladder or scaffold. The rope grab is attached to the vertical lifeline and the worker’s harness and moves along the line as the worker moves up or down. Rope grabs are relatively easy to use and require minimal training, but they may not be suitable for all work environments and require proper maintenance.

Benefits of Using OSHA-Approved Fall Arrest Systems

Using OSHA-approved fall protection systems can provide numerous benefits for both employers and employees. OSHA-approved systems are designed to meet strict safety standards and provide maximum protection against falls.

Here are some of the benefits of using OSHA-approved fall protection systems:

• Enhanced worker safety:OSHA-approved fall protection systems provide enhanced worker safety by providing reliable protection against falls. This protection can help prevent injuries and fatalities, as well as reduce workers’ compensation costs for employers.

• Compliance with OSHA regulations: Properly using OSHA-approved fall protection systems ensures compliance with OSHA regulations related to fall protection. This protects workers from the risk of falls and can help employers avoid fines and penalties.

• Cost savings: Using OSHA-approved fall protection systems can also result in cost savings for employers. By preventing injuries and reducing workers’ compensation costs, employers can save money on medical expenses, insurance premiums, and lost productivity.

• Versatility:OSHA-approved fall protection systems are versatile and can be used in a wide range of work environments. They can be customized to fit the specific needs of each workplace and provide reliable protection against falls.

• Increased employee confidence and productivity: Using OSHA-approved fall protection systems can also help boost employee confidence in their workplace safety. When workers feel safe and valued, they are more likely to be productive and engaged in their work.

Fall Protection Training and Best Practices

Proper training and implementation of fall protection systems are critical to ensuring workplace safety and complying with OSHA regulations. Employers must provide workers with the necessary training and education to use fall protection systems correctly and safely.

Here are some best practices for training and implementing fall protection systems:

• Conduct a fall hazard assessment: Before implementing fall protection systems, employers should conduct a fall hazard assessment to identify potential hazards and determine the appropriate protection system. The assessment should consider the type of work being performed, the height of the work area, proximity to dangerous equipment, the type of work surface, and other relevant factors.

• Choose the right system: Based on the fall hazard assessment, employers should choose the appropriate fall protection system that will provide the necessary protection for workers. This may include personal fall arrest systems, safety nets, guardrails, rope grabs, or fall restraint systems.

• Provide proper training: Employers must provide proper training to workers on the correct use of fall protection equipment and systems. The training should cover the nature of fall hazards, how to inspect and maintain fall protection systems, how to properly don and doff personal fall arrest systems, and the rescue procedures in case of a fall. Workers must be trained for the exact fall protection systems they are using.

• Regularly inspect and maintain equipment: Fall protection systems should be regularly inspected and maintained to ensure they are in good working condition. Employers should establish a regular inspection schedule and ensure that workers are trained to identify and report any defects or issues with fall protection equipment.

• Implement a rescue plan: Employers must also have a rescue plan in place in case a worker falls and is suspended in the air. The rescue plan should identify the procedures for rescuing a worker and provide workers with the necessary training and equipment to perform the rescue safely.

• Write and follow your fall protection program:  Everything mentioned above should be documented and included in your written fall protection program. Your program should be thorough and specific to your working conditions (not some template downloaded off the internet). Update and maintain your program at least once a year or when your working conditions change.

About the author: Jeff Musa is the marketing manager for Lancaster Safety Consulting, Inc. He has been involved in the workplace safety industry since 2008. He helps business owners, team managers, foreman, and other proactive leaders understand the complexities of OSHA compliance and solutions. He can be reached by email at [email protected] or by calling (888) 403-6026, ext. 128.