Working at heights is a routine part of many operations in the material handling industry. Crane operators, maintenance technicians, and installers are often exposed to fall hazards as part of their daily responsibilities. Over time, it can be easy to become comfortable and overlook risks, but it is mandatory to follow regulatory requirements and to take proper measures to prioritize safety in every work environment.

One key way to protect personnel is with fall protection systems. Engineered Systems requires every person working in any piece of equipment at height to use fall protection systems to ensure every worker returns home safely at the end of the day.

Why Fall Protection Matters

Falls continue to be one of the leading causes of serious workplace injuries and fatalities. According to the Bureau of Labor Statistics, falls are the second leading cause of workplace deaths and the leading cause within the construction industry.

Many of these incidents are preventable with proper planning, equipment, and training. Fall protection systems are designed to either eliminate fall hazards entirely or reduce the severity of an incident if a fall occurs.

In general, a fall hazard exists any time a worker is exposed to a height of four feet or more, which is where disabling injuries commonly occur.

Fall Prevention vs. Fall Protection

• Fall Prevention focuses on eliminating hazards entirely and engineering solutions such as guardrails or barriers that remove the risk of falling.
• Fall Protection focuses on minimizing injury if a fall occurs, typically through personal protection equipment (PPE) and fall arrest systems.

Types of Fall Protection Systems

There are several types of personal fall protection systems that are designed for specific applications:

Fall Restraint: Prevents the worker from reaching a fall hazard altogether. The worker is connected in a way that restricts movement from an exposed edge.

Fall Positioning: Allows a worker to be supported on a vertical surface with hands free to perform work. This system’s maximum allowable free fall by OSHA is 1 foot.

Fall Arrest (PFAS): Stops a fall after it occurs, preventing the worker from contacting a lower level. These systems are designed to safely decelerate the worker and reduce impact forces. The maximum allowable free fall allowed by OSHA is 6 feet or less.

The ABCs of Fall Arrest Systems

A properly designed fall arrest system includes three components:

A – Anchorage

The anchor point must be capable of supporting the required load and remain stable under stress. Proper anchor selection and placement are critical to minimizing fall distance and reducing swing hazards.

B – Body Wear (Full Body Harness)

The harness distributes fall forces across the body and keeps the worker positioned safely after a fall. Proper fitment, inspection, and condition are essential to ensure performance.

 C – Connecting Devices

These include lanyards, self-retracting lifelines, and rope grabs that connect the worker to the anchorage. Many include shock-absorbing features to reduce impact forces during a fall.

OSHA Standards: General Industry (1910) vs. Construction (1926)

Engineered Systems operates primarily under General Industry (1910) standards, which apply to environments such as manufacturing facilities, warehouses, and maintenance operations. These standards include specific requirements for walking-working surfaces, powered platforms, manlifts, ladders, and personal fall protection systems.

Construction standards (1926) are developed for more dynamic job sites and include their own set of requirements for fall protection.

Ultimately, OSHA standards are designed to ensure that fall protection is available and properly implemented, maintained, and understood by those using it.

Building a Fall Protection Program

A strong fall protection program starts with planning and awareness to reduce risk and maintain compliance with safety standards.

•     Understand the types of fall protection equipment available
•     Select the equipment most suitable for the specific workplace
•     Ensure the decision is made by a qualified or competent person
•     Provide proper training for all personnel exposed to fall hazards
•     Perform routine inspections of equipment and safety

Training Classes at Engineered Systems

A well-trained workforce is one of the most effective ways to prevent incidents before they occur. At Engineered Systems, we provide training classes on fall protection and various other operational training matters to help your team be safe to then be able to serve your customers with excellence.

Contact us today to learn more about fall protection and our training courses.