Fall Protection: Failure is Not an Option

Despite special emphasis programs from OSHA and increasingly sophisticated fall protection equipment, falls from heights remain a serious occupational safety challenge. In 2006, the Bureau of Labor Statistics (BLS) reported that fatal work injuries involving falls increased 5 percent after a sharp 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 in 2006, a rise of 15 percent.

Falls from ladders and roofs still account for the majority of falls. Occupational fatalities caused by falls remain a serious public health problem. The U.S. Department of Labor (DOL) lists falls as one of the leading causes of traumatic occupational death, accounting for 8 percent of all occupational fatalities 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 Bureau of Labor Statistics (BLS), there were at least 442 construction worker fatalities during 2007 as a result of falls from all causes.

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

Identifying fall hazards and deciding how best to protect workers is the first step in reducing or eliminating 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 general industry, 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 as guardrail 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 practices and training. The use of warning lines, designated areas, control zones and similar systems are permitted by OSHA in some situations and can provide protection by limiting the number of workers exposed and instituting safe work methods and procedures. These alternative systems may be more appropriate 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 focus attention on prevention efforts. If personal fall protection systems are used, particular attention should be given to identifying attachment points and to ensuring that employees know how to properly don and inspect the equipment.

COMPONENTS OF PERSONAL FALL ARREST SYSTEMS

There are three key components (anchorage/anchorage connector, body wear and connecting device) 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 properly and 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, here they are:

MISTAKE NO. 6: NOT USING FALL PROTECTION EQUIPMENT

The need for consistency in using fall protection often is ignored. It is important to have a plan and implement it, and that means wearing fall protection equipment every day. The plan should include identification 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 that employees 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 many instances, workers wear the harnesses too loose.

While misusing harnesses is a big mistake, many contractors also buy incorrect equipment for specific applications. One common example is that many contractors buy shock-absorbing lanyards and use them in areas with inadequate fall clearance. A retractable lifeline or a fall limiter should be used 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. Using equipment 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't worth 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 safety equipment no longer can be used.