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Fall Protection: Failure is Not an OptionMar. 1, 2009Ed Bickrest

Despite special emphasis programs from OSHA and increasingly sophisticated fall protectionequipment, falls from heights remain a serious occupational safety challenge. In 2006, the Bureau ofLabor Statistics (BLS) reported that fatal work injuries involving falls increased 5 percent after asharp decrease in 2005. The 809 fatal falls in 2006 represent the third highest total since 1992,when the fatality census began. Fatal falls from roofs increased from 160 fatalities in 2005 to 184 in2006, a rise of 15 percent.

Falls from ladders and roofs still account for the majority of falls. Occupational fatalities caused byfalls remain a serious public health problem. The U.S. Department of Labor (DOL) lists falls as oneof the leading causes of traumatic occupational death, accounting for 8 percent of all occupationalfatalities from trauma.

Falls are the most frequent cause of fatalities at construction sites and annually account for one of

every three construction-related deaths. According to preliminary 2007 fatality data from the Bureauof Labor Statistics (BLS), there were at least 442 construction worker fatalities during 2007 as aresult of falls from all causes.

Of this total, falls from roofs are one specific concern at construction sites and the most frequentcause for fatal falls in construction in 2007. In fact, BLS reports that from 2003 to 2007, constructionworker falls from roofs resulted in 686 fatalities.

Identifying fall hazards and deciding how best to protect workers is the first step in reducing oreliminating fall hazards. OSHA mandates that at any time a worker is at a height of 4 feet or more,the worker is at risk and needs to be protected. Fall protection must be provided at 4 feet in generalindustry, 5 feet in maritime and 6 feet in construction.

PROTECTING WORKERS

There are a number of ways to protect workers from falls, including conventional systems such asguardrail systems, safety net systems and personal fall arrest systems (PFAS) (fall arrest systems,positioning systems and travel restraint systems) as well as through the use of safe work practicesand training. The use of warning lines, designated areas, control zones and similar systems arepermitted by OSHA in some situations and can provide protection by limiting the number of workersexposed and instituting safe work methods and procedures. These alternative systems may be moreappropriate than conventional fall protection systems when performing certain activities.

Whether conducting a hazard assessment or developing a comprehensive fall protection plan,thinking about fall hazards before the work begins will help to manage fall hazards and focusattention on prevention efforts. If personal fall protection systems are used, particular attentionshould be given to identifying attachment points and to ensuring that employees know how toproperly don and inspect the equipment.

COMPONENTS OF PERSONAL FALL ARREST SYSTEMS

There are three key components (anchorage/anchorage connector, body wear and connectingdevice) of a PFAS that must be in place and properly used to provide maximum worker protection.

Individually, these components will not provide protection from a fall. However, when used properlyand in conjunction with each other, they form a PFAS that becomes vitally important for safety on the

job site.

Six major recurring errors in fall protection have been identified. From the bottom to the top, herethey are:

MISTAKE NO. 6: NOT USING FALL PROTECTION EQUIPMENT

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The need for consistency in using fall protection often is ignored. It is important to have a plan andimplement it, and that means wearing fall protection equipment every day. The plan should includeidentification and evaluation of fall hazards and their elimination, if possible; the use of appropriate

fall-protection systems to prevent or control falls when hazards can't be eliminated; ensuring thatemployees receive fall-protection training; and inspecting and maintaining equipment.

MISTAKE NO. 5: WHICH WAY DOES THIS GO?

Although more workers today are using fall protection gear, it's not always used correctly. In manyinstances, workers wear the harnesses too loose.

While misusing harnesses is a big mistake, many contractors also buy incorrect equipment forspecific applications. One common example is that many contractors buy shock-absorbing lanyardsand use them in areas with inadequate fall clearance. A retractable lifeline or a fall limiter should beused in certain circumstances.

MISTAKE NO. 4: KNOW WHEN TO SAY WHEN

Knowing when a product should be removed from service is key to safe working conditions.Equipment must be inspected regularly and taken out of service if it shows wear and tear. Usingequipment past its useful life, especially a lanyard, is a potentially deadly mistake.

Adopt a Smart Policy: If in doubt, throw it out. The benefit of an extra week or month of service isn'tworth the risk.

A few of the things to be on the lookout for include fraying, cuts and deformed metal hardware. Also,exposure to heat and chemicals can cause additional damage. Signs of deployment mean safetyequipment no longer can be used.

MISTAKE NO. 3: LACK OF COMMUNICATION/TRAINING

Lack of instructions in the appropriate language is a key reason equipment is misused or notused at all. Safety directors need to check the instructions provided with equipment, and assure

proper training is provided.

As an employer, you can determine the training format. What's important is that, through training,your employees can recognize fall hazards and know procedures to minimize the hazards.

It's important that the trainer knows the hazards at the work site, knows how to eliminate or controlthe hazards and knows how to teach workers to protect themselves. That's why the trainer must be acompetent person. (A competent person is one who can identify work-site hazards and who hasmanagement authority to control them.) The trainer must know and be able to explain the following:

The nature of fall hazards at the work site. Procedures for erecting, maintaining and disassembling fall protection systems and personal fall

arrest systems.

How to use and operate fall- protection systems and personal fall arrest systems. The role of each employee who may be affected by a safety- monitoring system. The restrictions that apply to mechanical equipment used during roofing work. The procedure for handling and storing materials and for erecting protection from falling objects. OSHA's fall protection standards.

MISTAKE NO. 2: ANCHORAGES THAT MISS THE MARK

Selecting inadequate anchorages is a major problem. The best harness with the best lanyard orlifeline cannot arrest a fall if unsuitable anchorages are selected.

An anchorage must support 5,000 pounds for a single tie-off point for one individual. In all cases, thefree fall should be limited to 6 feet or less.

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An anchorage should be positioned directly overhead whenever possible to avoid a swing fall injuryand anchorages should be selected based on how a rescue would be performed.

MISTAKE NO. 1: WAITING FOR THE FREE FALL.

Don't wait for a fall to occur before taking action to update your fall protection plan. When identifyinga fall hazard, analyze the likelihood of fatal or serious injury, as well as the amount of timeemployees will be exposed to the hazard. Basically, you want to eliminate the fall by changing thework process or environment.

If you remember these three steps for proper fall protection eliminate a fall hazard entirely,prevent a fall from happening and provide personal fall arrest equipment you will save lives andprevent serious injuries.

Edward J. Bickrest is the marketing communications manager for Miller brand fall protection,Sperian Fall Protection Inc. He can be contacted at 401-233-0333 orebickrest@sperianprotection.com .

Fall Protection Tips From OSHA

Identify all potential tripping and fall hazards before work starts. Look for fall hazards such as unprotected floor openings/ edges, shafts, skylights, stairwells and roof

openings/ edges. Inspect fall protection equipment for defects before use. Select, wear and use fall protection equipment appropriate for the task. Secure and stabilize all ladders before climbing them. Never stand on the top rung/ step of a ladder. Use handrails when you go up or down stairs. Practice good housekeeping. Keep cords, welding leads and air hoses out of walkways or adjacent

work areas.

Make fall protection part of your workplace safety and health program.

Be committed to preventing and controlling fall hazards. Identify and evaluate fall hazards. Eliminate fall hazards, if possible.

Use appropriate fall-protection systems to prevent or control falls when hazards can't be eliminated. Report fall hazards and suggest how to control them. Ensure that employees receive fall-protection training. Inspect and maintain equipment. Know how to respond promptly to emergencies. Understand regulations related to fall-protection requirements. Enforce safe work procedures and practices.

Investigate all falls and near-miss incidents. Evaluate fall-protection procedures regularly.

Source: Oregon OSHA