When most people hear the words fall protection, they immediately picture someone standing high in the air wearing a harness and tied off to a cable. While that image certainly represents one aspect of fall protection, it is only a small piece of the overall picture.
Fall protection is much more than harnesses, lanyards and anchor points. At its core, fall protection is about protecting employees from hazards while working at heights. Whether someone is working on top of a building, servicing equipment or performing maintenance from an elevated platform, the goal is always the same: make sure they return home safely at the end of the day. Falls continue to be one of the leading causes of serious workplace injuries and fatalities across many industries. The good news is that most falls can be prevented when companies take the time to identify hazards, develop a plan, provide proper equipment and train employees on safe work practices.
The first step in any fall protection program is identifying where fall hazards exist. Every workplace is different. Fall hazards may be found on ladders, catwalks, roofs, bins, tanks, platforms and elevated work areas. Once these hazards are identified, the employer must determine how employees can perform their work safely. This process should involve a trained and qualified individual who understands fall hazards and the available methods for controlling them.
When evaluating fall hazards, safety professionals often follow what is called the hierarchy of fall protection controls. Think of it as a series of choices that help determine the safest way to protect workers. The goal is to start with the most effective solution and work down the list only when necessary. The first and best option is always hazard elimination.
Hazard elimination means removing the fall hazard entirely. If the hazard no longer exists, there is no need for employees to be exposed to the risk. Sometimes this can be accomplished by changing the way a task is performed. Equipment may be relocated to ground level for maintenance. Access points may be redesigned. Work that once required employees to climb may be completed from a safer location. While eliminating a hazard is not always possible, it should always be the first question asked: “Can we do this job without exposing someone to a fall?”
If the hazard cannot be eliminated, the next option is passive fall protection. Passive systems protect employees without requiring them to take additional action. In other words, the protection is already in place. Handrails, guardrails, covers over floor openings and permanent barriers are all examples of passive fall protection. These systems are highly effective because they do not rely on workers remembering to connect equipment or follow specific procedures. If a properly installed guardrail is in place, the protection is there every time someone approaches the area.
When passive protection is not practical, the next option is fall restraint. A fall restraint system prevents a worker from reaching a location where a fall could occur. Think of it as a leash that stops the employee before they can get close enough to the edge to fall. The important difference between fall restraint and fall arrest is that restraint systems are designed to prevent the fall altogether. If properly used, the worker should never reach the point where they could go over the edge.
If fall restraint is not feasible, then a fall arrest system may be necessary. Fall arrest systems are designed to stop a worker after a fall has already started. While nobody wants a fall to occur, these systems help reduce the forces placed on the body and can significantly reduce the severity of injuries. A complete fall arrest system consists of several important components working together.
The first component is the anchor point. This is the most important part of the entire system. If the anchor fails, the entire system fails. Anchor points must be capable of supporting the loads that could be generated during a fall and should be selected by someone who understands the requirements of the system.
The second component is the harness. A full-body harness is designed to distribute the forces of a fall across the strongest parts of the body. Modern harnesses are built to help protect the worker while minimizing injury. While they may not be the most comfortable piece of equipment an employee wears, they serve a critical purpose when a fall occurs.
The third component is the connecting device, often referred to as a lanyard or self-retracting lifeline. This equipment connects the harness to the anchor point. These devices are specifically designed and tested to absorb energy and reduce the impact forces generated during a fall. It is important to remember that not just any rope or strap can be used for fall protection. Equipment must be designed and rated for that purpose.
The fourth component is one that is often overlooked: the rescue plan. Many organizations spend considerable time selecting harnesses, lanyards and anchor points but spend very little time planning what happens after a fall. Unfortunately, simply stopping a fall does not mean the emergency is over. An employee who is suspended in a harness can quickly face serious medical complications if they remain hanging for an extended period. Workers and supervisors should know exactly what steps will be taken if someone falls. Who will be contacted? How will the employee be rescued? What equipment will be needed? How will emergency medical services be notified? A rescue plan should be developed before work begins, not after an incident occurs.
Like any piece of equipment, fall protection gear requires regular inspection and maintenance. Employees should inspect their equipment before each use, looking for damage to webbing, hardware, labels or stitching on components. Equipment that does not pass inspection should be removed from service immediately. In addition to employee inspections, companies should have a process for periodic documented inspections by a competent person. Equipment cannot be expected to perform properly during an emergency if it has not been maintained.
Training is another critical part of any fall protection program. Employees who work around fall hazards or use fall protection equipment must understand the hazards they face and how to properly use the equipment provided. Training should include recognizing fall hazards, inspecting equipment, proper use of harnesses and lanyards, anchor point requirements, emergency procedures and rescue planning. Training should not be viewed as a one-time event. Refresher training and ongoing discussions help keep safety at the forefront and ensure employees maintain the skills needed to work safely.
At the end of the day, fall protection is not about compliance, equipment or checking a box on a safety form. It is about protecting people. Every company has a responsibility to identify fall hazards, evaluate risks, provide proper protection, train employees and regularly review its safety programs. Employees also have a responsibility to follow procedures, inspect equipment and speak up when they see unsafe conditions.
The most successful fall protection programs are not built around harnesses alone. They are built around planning, training, communication and a commitment to keeping people safe. Because when it comes to fall protection, the goal is not simply to stop a fall. The goal is to make sure every employee goes home safe.
Dean Alling is the safety director for Ray-Carroll Coop in Richmond, MO (deana@ray-carroll.com, 817-932-1000).