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Fall Protection Equipment: What Safety Professionals Need to Know

By Wajiha Ali
Last updated: October 27, 2024
Key Takeaways

Don’t believe the informal fall protection rules that tend to circulate around jobsites – always follow the applicable regulations.

Fall hazards are a consistent risk across a number of industries. The good news is they can often be avoided by adopting fall protection initiatives and using proper fall protection equipment. 

As safety professionals, we need to understand fall protection not merely as a compliance requirement, but to protect workers’ lives. 

Plus, the science around fall protection – and the equipment and PPE designed to protect workers – has also evolved tremendously over the years. 

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Here we’ll provide an overview of fall protection, some of the key misconceptions around it, and how to use fall protection equipment to keep workers safe.

What is fall protection and when is it needed?

The Bureau of Labor Statistics reported 865 fatal injuries related to slips, trips, and falls in 2022, highlighting the importance of fall protection measures. 

The construction industry accounts for almost half of fatal falls, slips and trips, according to the Bureau of Labor Statistics. To avoid the worst-case scenario, fall protection is a must when:

  • Working on roofs and using ladders and scaffolding
  • Doing maintenance and repair works at height, such as on telecommunication towers
  • Handling cargo near edges 
  • Working on leading edges 

Fall protection comprises measures and systems aimed at preventing falls and/or the severest consequences of falls at workplaces. 

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At what height is fall protection required?

Different industries require fall protection at varied heights as recommended by OSHA. For example, fall protection measures must be adopted at the following heights:

  • 4 ft in general industry (29 CFR 1910)
  • 4 ft in marine terminals (29 CFR 1917)
  • 5 ft in shipyards (29 CFR 1915)
  • 6 ft in the construction industry (29 CFR 1926)
  • 8 ft in cargo ships operations (29 CFR 1918)

OSHA further states that fall protection is required at ANY height when working above dangerous machinery.

Common Reasons for Workplace Falls

In 2022, falls from elevation represented 81% of all fatal falls and 20% of nonfatal slips, trips, and falls for all industry workers. 

As we’ve already learned, almost half of these falls occurred in the construction industry. Broadly, these falls occur due to:

  • Unprotected edges
  • Unsafely positioned ladders
  • Misused fall protection
  • Wet/icy floor
  • Tripping hazards
  • Irregularities in floors and wall openings
  • Open floors
  • No warning of slip/trip hazard

Preventing Falls: The Fall Protection Hierarchy

To protect workers from fall hazards, safety professionals must follow the hierarchy of hazard controls recommended by OSHA. The hierarchy of controls guides us to eliminate or reduce workplace hazards by ranking the most effective level of protection to the least effective level of protection. Let’s go through the hierarchy and take a closer look.

hierarchy of hazard controls in fall protection showing each level as a step

Hazard Elimination

This involves removing the fall risk altogether by modifying the workplace or work practices. This is the most effective way of dealing with hazards. 

If workers don’t need to access a rooftop frequently, you might relocate HVAC equipment away from the roof edge to avoid exposure to the fall hazard. A proper hazard assessment can help you determine any hazards with the potential to be eliminated entirely.

Passive Fall Prevention

Any physical barrier that lies between the worker and the fall hazard would be considered passive fall protection. For example, guardrails could be installed around walkways or rooftops to avoid falling from heights.

Fall Restraint Systems

Fall restraint systems are designed to prevent a worker from reaching an edge from which a fall could occur. These are typically full body harnesses that are connected to a lanyard through a D-ring on the back of the harness. 

While a fall restraint system may look like a personal fall arrest system, it is not the same. A fall restraint system is rigged so that the worker cannot fall any distance at all. Once the system is in place, you won’t be able to get close enough to the hazard to experience a fall in any direction. 

To learn more, read Arrest or Protect: Your Guide to Choosing the Right Fall Protection System.

Fall Arrest Systems

A fall arrest system is a safety harness designed to prevent serious injuries in case a worker falls from a height while working. These are usually used where fall restraints are not suitable options, as workers are working close to the edge. Ironworkers, bridge workers, steel mills, and new construction must use such types of protection while working. 

A personal fall arrest system includes a harness, connector, and anchorage point. For example, full-body harnesses with shock-absorbing lanyards that distribute fall forces and minimize impact are a form of personal fall arrest system.

Administrative Control

Administrative control of fall hazards include training, work permits, and clear safety protocols given to workers to manage fall risks. This is considered the most complex method in the hierarchy of controls. As such, it must be administered by a competent person or professional engineer. 

For example, workers are trained to use harnesses and follow instructions while completing tasks at heights. Similarly, installing warning lines, assigning controlled access zones, and assembling equipment on the ground are also administrative controls.

It’s important to note that while administrative controls are extremely important, they are considered part of a larger strategy to manage fall hazards. They are the least favored approach as a first-line solution.

Fall Protection Equipment

When it comes to fall protection equipment, there are a few key types to understand.

Fall Arrest Equipment

As we learned above, fall arrest systems protect workers from hitting the ground. Workers in construction and maintenance mostly use such equipment.

Positioning Systems

In case the workers need to work on vertical surfaces or tie rebar, positioning devices are best fitted for the purpose. These consist of a body belt or harness rigged to allow hands-free work while leaning back. For safety considerations, they are rigged to prevent more than a 2 ft freefall.

Suspension Systems

Suspension systems are of great use in otherwise unreachable elevated areas to lower and support workers. When combined with fall arrest systems, they ensure safe descent and rescue.

Retrieval Systems

Retrieval systems are designed to rescue a worker after a fall or emergency. They reel the worker back to safety.

Setting Up Fall Protection Systems

Before setting up any fall protection system, identify areas where fall protection is necessary, including elevated platforms, roofs, or any location where workers could be at risk of falling.

Choose fall protection equipment based on the specific task and environment. For example, guardrails, safety nets, personal fall arrest systems, positioning devices, warning lines, controlled access zones, safety monitoring systems, etc. Furthermore, the following steps must be taken while setting up fall arrest systems.

Choosing the Harness

Different harnesses are available with unique features and benefits depending on the task, such as lightweight harnesses, weight-minimizing harnesses, or harnesses that accommodate wide tool belts. Comfort, fit, and mobility are all considered while choosing harnesses, and breathable materials are preferred for use in summer to avoid heat exhaustion. 

Training Employees

Employees must be trained in using harnesses and conducting safety inspections of harnesses and other protective equipment before use. They should know how to don, doff, and store their harnesses safely.

To properly use harnesses, legs and armholes must be lined up and straps must be positioned correctly. The harness should be secure, and other workers might also double-check the harnesses for twists or loose ends.

Inspection

The harnesses, lanyards, and connectors must be checked every time before use for any wear and tear.

Choosing Lanyards

Like harnesses, lanyards are also chosen carefully based on the task and worker. For example, you might need to select the right length of the lanyard considering the height of the worker, distance from the anchor point, and space needed for deceleration. 

Note that a lanyard that has been used for a fall should not be used again. You should also check user manuals to determine the condition of the lanyard and its usability.

Anchoring the Lanyards

OSHA recommends selecting fall protection anchorage that meets standard fall protection anchor point requirements defined by OSHA. 

According to OSHA, anchorages shall be independent of any anchorage being used to support or suspend platforms and must support at least 5,000 lbs per employee attached. Moreover, an employee can neither free fall more than 6 ft nor touch ground level.

All-Around Safety

Besides using PPE, a safety culture must be introduced among businesses and prioritized to gain the trust of workers and build their morale. 

In addition to this, safety equipment like safety gates, guard rails, and warning signs must be in place, and regular training and discussion sessions should be an integral part of the company’s policy. This, after all, is a key part of the job for safety professionals!

Common Misconceptions About Fall Protection

There are some misconceptions about fall protection that can increase your risk of injury. Let’s cover some of the key misconceptions and why they’re wrong.

Misconception: Fall Protection Equipment Is a Bigger Hazard Than the Height

Putting on fall protection equipment can be a nuisance and can slow down tasks. But there’s no reason to think that it’s riskier than leaving it off.

Another concern is suspension trauma and orthostatic intolerance, both of which are injuries that can be sustained from dangling in a harness. While these are very real hazards, these risks are far lower than those associated with a significant fall (and should be considered and mitigated in a proper fall protection plan).

Misconception: Fall Protection Is Only for Serious Heights

A height of 4 to 6 feet triggers a requirement for fall protection (although some states that don’t follow federal OSHA mandate fall protection at even lower elevations).

Admittedly, 4 feet of elevation doesn’t feel like a significant hazard. But our perception of the hazard doesn’t inform the rules – the numbers do. 

Beyond the height itself, there can also be other hazards underneath the unprotected edge. In fact, OSHA accounts for this by adding the caveat that the minimum height doesn’t apply if there is potential to fall on something potentially injurious.

Misconception: The “6 Foot” or “Two Step” Rule

There is a misconception that if you are maintaining 6 feet of distance from the edge, you don’t need to use fall protection. In reality, there’s no 6-foot exemption in the regulations.

While there are differences between OSHA CFR 1910 (general industry) and 1926 (construction industry), neither of these regulations considers 6 feet a safe distance. In fact, the latter specifically states that “OSHA has determined that there is no safe distance from an unprotected side or edge that would render fall protection unnecessary.”

Misconception: Fall Protection Isn’t Needed if There Is a Parapet

The entire edge where a fall is possible needs to be protected if this strategy is to be used. 

Plus, anything acting as a guardrail has to meet the strength, height, and design requirements for a guardrail. That means the rail needs to be sturdy enough to withstand a force of 200 pounds at the top rail and it must not deflect under pressure below 39 inches. The rail also needs to be continuous (other than entries and stairways).

The only time a rope can be used as a barrier is when it is used only as a warning. Under certain conditions, a warning line that workers are prohibited to cross can be strung up 15 feet from the edge (or 6 feet for job sites that fall under the “General Industry” regulations). The warning line itself has to be made of a material with a breaking strength of at least 500 pounds, be made visible with flags placed at 6-foot intervals, and be set up in such a way that its supporting stanchions can’t be knocked over with less than 16 pounds of force.

Misconception: My Harness Is On and I’m Tied In – I Don’t Have to Worry About It

Fall protection isn’t a “set it and forget it” application.

A good fall protection plan includes a lot of elements, some of which are ongoing. For example, the worker needs to remain conscious of where the lanyard and anchor are. If it’s behind the user and out of site, it could be cut or abraded, rendering it useless. 

Workers who fall after wandering too far from their anchor point can find themselves in a pendular swing. This puts them at risk of swinging into objects or structures on the level below, which can result in serious injuries. 

This is especially important when using a self-retracting lanyard system, which allows a length of line to play out but locks under sudden, heavy tension. Such a system allows workers to move far from the overhead anchorage and create a swing. Wander far enough and you could swing directly into the ground.

Plus, even when a fall arrest system works perfectly, a fall can still be painful and cause injury.

Misconception: All Harnesses Are Equal

The idea that any harness is better than no harness just isn’t true. Any type of harness should meet the OSHA standard requirements and they must be used according to the provided instructions. 

Secondly, harnesses come in different styles and features, which are suitable for different tasks. The nature of the job needs to be considered before choosing the harness.

Misconception: Harnesses That Pass a Visual Inspection are Good to Go

Harnesses should be inspected regularly for signs of damage and wear. OSHA and ANSI both require that harnesses be inspected before each use and periodically by a competent person. 

However, while OSHA and ANSI don’t specify an expiry date, many manufacturers do. This tends to be around five years from the date of first use but it can vary.

Misconception: Fall Arrest Systems Are the Safest Choice

Although fall arrest systems are designed to safely secure the landing of workers, these systems can also fail. That’s why they are considered a last line of defense in a fall protection system. The safest option is to eliminate the potential for a fall whenever possible.

funnel diagram showing the hierarchy of fall protection choices

Misconception: It’s the Quality of the Harness That Matters

Yes, having an appropriate harness for the job and one that’s free of defects is essential. But the quality of anchors is of utmost importance as well as it holds most of the weight of the individual. Therefore, choosing the right fall protection anchorage is key.

Fall Protection Standards

OSHA sets guidelines for fall protection in various industries, including general industry and maritime industries. In maritime industries, specific standards apply under 29 CFR 1915, 1917, and 1918 while, for general industry, Standard 29 CFR 1910 apply

These standards cover fall protection requirements for workplaces such as factories, warehouses, and offices. Key sections include walking-working surfaces, powered platforms, man lifts, vehicle-mounted work platforms and personal protective equipment.

The American National Standards Institute (ANSI) collaborates with various organizations to develop standards related to fall protection. ANSI/ISEA 121-2018 focuses on reducing dropped object incidents in industrial and occupational settings. It establishes design, performance, testing, and labeling requirements for solutions that prevent dropped objects.

The International Safety Equipment Association (ISEA) Fall Protection Group provides practical guidance for fall protection users and administrators. They offer a comprehensive guide for selecting, using, maintaining, and inspecting fall protection equipment.

Fall Protection Training and Inspection

OSHA requires fall protection training for employees who might be exposed to fall hazards. A competent person qualified in specific areas must provide training on the following:

  • The nature of fall hazards
  • Fall protection system procedures
  • Types of protection
  • Role in safety monitoring systems
  • Limitations on mechanical equipment
  • Handling and storage of equipment
  • Fall protection plans
  • Knowledge of standards

Employers must verify compliance by preparing a written certification record for each trained employee.

For inspection of fall protection equipment, the competent person would pre-inspect knots in vertical lifelines or lanyards, examine stitching on harnesses, and inspect D-rings, belt ends, rivets, frames, bars, rollers, labeling, friction buckles, and webbing. Any equipment that fails inspection would be removed immediately.

Compliance against OSHA regulations would be done for thorough inspections every three to six months. Additional inspections would be done based on equipment usage and conditions.

FAQs About Fall Protection

What is fall protection PPE?

Fall protection PPE refers to the fall protection equipment worn by workers to protect them from falling. For example, harnesses, lanyards, self-retracting lifelines (SRLs), and other items used to secure workers working at heights.

What are the ways employers can protect workers from falls?

Employers can use conventional means, such as guardrail systems, safety net systems, and personal fall protection systems. This should be done in conjunction with adopting safe work practices and providing appropriate training to workers.

How can I identify fall hazards?

There are some key steps you can take to identify fall hazards:

  1. Conduct a site assessment: Look for elevated work surfaces, edges, and areas where workers might be exposed to falls.
  2. Review past incidents and reports: Look at accidents and near misses to identify recurring issues or patterns.
  3. Consult with workers: Gather input and observed hazards from people who have encountered those conditions firsthand.
  4. Evaluate work practices: Look at how work is conducted to identify risky behaviors.
  5. Inspect equipment and infrastructure: Check ladders, scaffolds, guardrails, barriers and other fall protection equipment.
  6. Evaluate fall protection systems: Verify that all fall protection is correctly installed and used.

Fall Protection Equipment and Your Fall Protection Plan

Fall protection equipment is a key part of your fall protection plan. Review potential hazards and use the hierarchy of hazard controls to keep workers safe when working at heights.

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Written by Wajiha Ali

Wajiha Ali
Wajiha Ali holds a PhD in Environmental Sciences and is adept at balancing environmental responsibility, safety compliance, and sustainability initiatives to drive organizational success. She has a proven track record in enhancing workplace safety, reducing environmental impact, and promoting sustainable practices. As a strong communicator, collaborator, and change agent, she fosters a safety and sustainability culture.

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