Fall Arrest Systems & Equipment
Keep workers safe, secure, and productive with the proper fall protection equipment and systems. Comply with OSHA standards using the right gear for your worksite.
Body belts are only for positioning or restraint, not fall arrest. All full-body harnesses have a connection point for fall arrest in the back, between the shoulder blades. Harnesses can feature additional connection points. Placement examples include at chest level in the front for repelling or connecting to ladder safety systems, on the hips for positioning or restraint, and on the shoulders for retrieval (typically from confined spaces). Extra features may be added based on worker comfort, preference, and the task being performed. These include belts, back pads, shoulder pads, seat slings, etc.
Different buckle styles are available on harnesses. For a harness worn by multiple workers, such as for a day shift and night shift, the friction style may be preferable as it adjusts quickly over the full length of the strap. When a harness goes to one worker, the quick-connect style may be preferable (as it will retain its adjustment between each use). Finally, the tongue buckle style may be preferable in either application, as it can be readily adjusted for multiple workers, and an individual worker may return the buckles to the same grommets each time they wear the harness.
Lanyards and Lifelines
Lanyards and lifelines connect a worker to an anchor point. Systems should be selected to ensure that workers are never impacted with more than 1800 pounds of arresting force. For this reason, rope and web lanyards without energy absorbers should only be for positioning or fall restraint systems. Workers close to their anchor point may require a single-energy (shock) absorbing lanyard, while workers moving from one anchor point to another may require a twin-leg energy (shock) absorbing lanyard to maintain 100% tie-off.
If additional mobility is required, choose between self-retracting lifelines and rope or cable lifelines with grabs for an ideal solution. Take care to assess the available clearance below a worker, and select equipment to prevent the employee from striking an obstruction or lower level.
Anchorage Connectors
Anchor connectors link lanyards, lifelines, or self-retracting lifelines to a suitable point. Anchor points must conform to applicable fall prevention standards, namely, 5000 lbs. strength or twice the expected load. Possible anchor points include I-beams, H-beams, concrete walls, pillars, forms, and other stable structures.
Anchorage connectors may be quite basic, such as snap hooks or carabiners. They come in different sizes to accommodate the connection point. For example, a gate opening of 1 inch or less may be sufficient for connecting a D-ring, while a bigger opening will be needed to connect to a larger support (such as bracing or angle iron).
Anchor D-rings are ideal for connecting to I-beams and H-beams with holes. When holes are not available, fixed or sliding beam anchors may be appropriate. Anchor straps are suitable for applications where there is a structure to wrap around and can be provided in any length. Rope and cable grabs connect a lanyard to a rope or cable lifeline.
Horizontal Lifelines
Horizontal lifelines allow increased mobility while protecting workers from falls. Some systems are for permanent installation, while others are removed from one work area and installed in another as needed. Prior to selecting a system, determine the following:
Distance the system must cover (length of system)
Available clearance below the worker
The number of workers who will use the system at the same time
Strength requirements for anchor points
The Occupational Safety & Health Administration (OSHA) requires that each employee on a walking/working surface 4 feet or more above lower levels (6 feet for construction) shall be protected from falling by a guard rail system, safety net system, or fall arrest system. A personal fall arrest system (PFAS) consists of an anchor point, connectors, and a full-body harness. It may include a lanyard, deceleration device, lifeline, or suitable combination of these.
When stopping a fall, these systems shall limit the maximum arresting force on an employee to 1800 lbs. Fall prevention devices shall be rigged so employees can neither free-fall more than 6 feet nor contact any lower level. The system shall bring a worker to a complete stop and limit the deceleration distance traveled to 3.5 feet. It shall have sufficient strength to withstand twice the potential impact energy of an employee falling the distance permitted by the system.
In addition to the OSHA fall protection standards, voluntary standards published by the American National Standards Institute (ANSI) establish performance criteria for systems. ANSI provides guidelines and recommendations for their use and inspection with teams working at height. In some cases, these standards may exceed OSHA requirements. For example, ANSI A10.32 recommends that the maximum arresting force imposed on the user's body shall not exceed 1,000 lbs. (versus 1800 lbs. in the OSHA standard). It is crucial to consult regulations from agencies governing your industry, as well as any general standards. Many of these can be found at websites such as www.osha.gov and www.ansi.org.
There are several factors to consider when selecting from various types of fall protection equipment:
Identify fall hazard locations, the number of workers exposed, and the type of work being performed.
Consider the presence of any hazards in addition to falls, which may impact equipment selection. This includes but is not limited to salt air or spray, chemicals, electrical hazards, flammable or toxic gases, high heat or open flames, welding sparks, and extreme cold.
Establish a suitable anchor point for connecting a fall arrester. Even if the proper equipment is selected, workers will be at risk if not tied off correctly. Some examples of unsuitable fall protection anchor points include electrical conduits, most water pipes, many wooden supports (such as 2 x 4s), most wooden or metal railings, and any open-ended connection point from which a connecting device can slide off or become dislodged. (See the section below on Anchorage Connectors for suitable anchor points.)
Maintain a written fall protection plan that addresses the hazards at each site covered by the plan and training for all workers exposed to those hazards. The plan should include provisions for rescue, including training requirements for rescuers. It’s common practice to keep training logs for personnel and inspection logs for equipment.