Falls are one of the leading causes of accidents and fatalities across many industries. Whether it's in construction, manufacturing, or any other type of workplace, identifying and addressing fall hazards is essential to keeping workers safe. One of the most effective ways to do this is by conducting fall hazard analysis or completing a fall hazard survey.

A fall hazard survey involves a thorough and comprehensive inspection of the workplace to identify potential hazards that could result in falls. This includes examining equipment, tools, and materials, as well as evaluating the physical environment, such as the layout or configuration of the workspace and the condition of floors, stairs, walkways, and other working platforms. The survey should be conducted by someone with expertise in fall prevention, such as a safety professional, qualified person, or fall protection competent person.

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Whether it's in construction, manufacturing, or any other type of workplace, identifying and addressing fall hazards is essential to keeping workers safe.

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During the survey, the inspector should look for all potential fall hazards in and around the worksite. Inspectors should also assess the potential risk to workers, considering factors such as the height of the work area, the type of work being performed, and the likelihood of workers being exposed to the hazard. Some of the most common fall hazards may include:

• Unprotected edges: Unprotected edges, such as open-sided floors, roofs, and platforms, can be dangerous fall hazards. Workers can accidentally step off these edges or be pushed off by equipment, materials, or other workers.
• Ladders: Ladders are a common tool in many industries, but they can also pose a significant fall hazard. Falls from ladders can be caused by using the wrong type of ladder, overreaching, and unstable placement of the ladder.
• Scaffolding: Scaffolding is used in construction, painting, and other industries to provide workers with access to elevated areas. However, if scaffolding is improperly erected or not used correctly, it can collapse or cause workers to fall.
• Roofs: Workers who perform tasks on roofs, such as installing solar panels or conducting maintenance, are at risk of falling off the roof or through skylights or roof openings.
• Elevated walkways: Elevated walkways, such as catwalks, bridges, and elevated work platforms, can also be dangerous fall hazards. These walkways can be slippery, and workers may fall through openings in the walkway.
• Unguarded machinery: Workers who operate machinery at elevated heights may be at risk of falling into the machinery or off of it. Unguarded machinery can also pose a danger to workers on the ground below.

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Being proactive will not only help you prevent falls, but can significantly decrease the time that it takes to perform a rescue in the event that one is needed.

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Once the survey is complete, the inspector should document their findings in a report that includes photographs or diagrams of the workplace as well as detailed descriptions of each hazard. The report should also include recommendations for corrective action, such as implementing fall protection systems, modifying work practices, or providing additional training for workers. Another consideration to include in the report is any prior history of known accidents or incidents related to the specific work area or task.

Perhaps the most commonly overlooked component of a fall hazard survey is ensuring that a documented rescue preplan is created and reviewed before beginning work. The worst time to try to develop a rescue plan is after someone has fallen! Being proactive will not only help you prevent falls, but can significantly decrease the time that it takes to perform a rescue in the event that one is needed.

OSHA provides a free fall protection plan template that can serve as an outstanding baseline for developing or improving your current fall protection plan. Additionally, you can access our Fall Hazard Survey Template here and our Rescue from Fall Protection Preplan Template here.

Whatever route you choose to implement, conducting fall hazard surveys is an essential component of an effective fall prevention program. It enables employers to identify potential hazards and take steps to eliminate or control them before an accident occurs. And remember, there’s a safe way and a SAFER way!

 

Additional Resources

• OSHA Fall Protection Plan Template
• Roco’s Fall Hazard Survey Template 
• Roco's Rescue from Fall Protection Preplan Template
  
  

 

May 1, 2023 – The U.S. Department of Labor announced that its Occupational Safety and Health Administration (OSHA) has implemented a National Emphasis Program to prevent falls. This targeted program is based on historical data from both Bureau of Labor Statistics (BLS) and OSHA enforcement activities.

According to the most recent data from BLS, 680 deaths were associated with falls from elevation in 2021. This accounts for nearly 13 percent of the 5,190 fatal workplace injuries that occurred in that year.    

According to the Assistant Secretary for OSHA, Doug Parker, “This national emphasis program aligns all of OSHA's fall protection resources to combat one of the most preventable and significant causes of workplace fatalities...”

The scope of this National Emphasis Program (NEP) applies “OSHA-wide” where an OSHA compliance safety and health officer may open an inspection whenever they observe someone working at heights. If a compliance officer determines that an inspection is not necessary after entering a worksite and observing work activities, they will provide outreach on fall protection and leave the site.

Detailed information on this NEP may be found in Directive Number CPL 03-00-025 National Emphasis Program – Falls.

See our article for tips to help create a safer workplace for you and your co-workers.

Links:

https://www.bls.gov/iif/

https://www.osha.gov/sites/default/files/enforcement/directives/CPL_03-00-025.pdf

https://www.osha.gov/news/newsreleases/national/05012023#

 

Additional Resources

• Fall Hazard Survey (pictured here) 
• Hierarchy of Fall Protection Poster 
• Personal Fall Arrest Systems (PFAS)

 

It holds true every year – falls are one of the leading causes of fatalities and injuries in the construction industry. Falls continue to make OSHA’s “Fatal Four” list year after year. What’s more, this trend doesn’t seem to be improving. The Bureau of Labor Statistics shows 371 fatal falls out of 1,034 total fatalities in construction in 2020. This is the primary reason OSHA organizes an annual National Safety Stand-Down to Prevent Falls in Construction. This voluntary event encourages employers and workers to pause and talk about fall hazards and prevention.

As a company that specializes in training and safety services, Roco Rescue knows the importance of preventing falls and preparing for emergencies. We have been teaching technical rescue, including rescue from fall protection, and providing standby rescue teams for more than 40 years. We have seen firsthand the consequences of inadequate and improperly used fall protection.

Here are five tips on how to protect yourself and your co-workers from falls when working at height:

1) Plan ahead.

Before you start any work at height, you should identify the fall hazards and plan on how to eliminate or mitigate them. OSHA offers a free fall protection plan template that you can use if you don’t know where to start. You can use the hierarchy of fall protection when identifying your plan for working at heights. OSHA also provides a free workbook, to help you manage fall protection hazards on your worksite.

You should also have a plan in place to rescue someone suspended in a fall arrest system. Being proactive will not only help you prevent falls, but can also significantly decrease the time that it takes to perform a rescue in the event one is needed. You can access our Fall Hazard Survey template here and our Rescue from Fall Protection Preplan template here.

OSHA provides a free fall protection plan template that can serve as an outstanding baseline for you to develop or improve your current fall protection plan. For jobs entailing unique hazards, complex fall protection systems, or areas where extended emergency response times may occur, a professional on-site rescue team may be the best option. Make sure you have the right equipment, such as ladders, scaffolds, aerial lifts, harnesses, lanyards, anchors, etc., and that they are inspected and maintained regularly. OSHA provides a general harness inspection checklist.

2) Use proper fall protection equipment.

Depending on the type of work and the height involved, you may need to use different kinds of fall protection systems, such as guardrails, safety nets, personal fall arrest systems (PFAS), or positioning devices. Make sure you know how to use them correctly and that they are compatible with each other. Always wear a full-body harness that fits you correctly and is adjusted properly. Connect your harness to a suitable anchor point that can support your anticipated load and prevent you from hitting the ground or any lower level. 

3) Follow safe work practices.

When working at height, you should always follow the rules and procedures established by your employer and relevant OSHA fall protection standards. Don't take shortcuts or improvise with equipment that is not designed for fall protection. Always try to work with others; working alone, especially at heights, can be fatal if something goes wrong. Avoid working in inclement weather conditions, when possible, especially on slippery or unstable surfaces. Don't lean over edges or reach too far. Don't carry too much weight or use untethered tools that can cause you to lose your balance. 

4) Train regularly.

Fall protection training is essential for anyone who works at height. You should receive training on how to recognize and avoid fall hazards, how to properly use fall protection equipment, how to inspect and maintain your equipment, how to rescue yourself or others in case of a fall, and how to report any incidents or near misses. Click here to learn more about the importance of near-miss reporting. You should also refresh your training periodically and whenever there are changes in your work environment or equipment. Consider implementing a “fall emergency drill” to your periodic training. The worst time to see if you have an effective system in place is after someone falls!

5) Be aware and alert.

One of the most important things you can do to prevent falls is to be aware of your surroundings and alert to any potential dangers. Pay attention to where you are walking, standing, or working. Look for signs, warnings, or barriers that indicate fall hazards. Communicate with your co-workers and supervisors about any issues or concerns. Report any unsafe conditions or behaviors to your supervisors and make sure that they get addressed.

By following these tips, you can help create a safer work environment for yourself and your co-workers. Remember, falls are preventable if you take the necessary precautions.

 

Chris McGlynn is the Director of Safety/VPP Coordinator for Roco Rescue. He is a Certified Safety Professional (CSP) through the Board of Certified Safety Professionals as well as a Certified Confined Space and Rope Rescue Technician, and a Nationally Registered Paramedic. As Director of Safety, Chris oversees all corporate safety initiatives, ensuring that employees at Roco have the tools and training that they need to do their work safely and effectively. He is also responsible for managing Roco's Safety Services Division, which provides trained safety professionals for turnarounds and other special projects. Finally, Chris serves as the VPP Coordinator for Roco, continuing Roco’s long-standing commitment to excellence in safety and health. Roco has been an OSHA VPP Star Worksite since 2013.

Follow Chris 

 

Additional Resources

• Fall Hazard Survey (pictured here) 
• Hierarchy of Fall Protection Poster 
• Personal Fall Arrest Systems (PFAS)

 

 

 

This week, May 2-6, is OSHA’s National Safety Stand-Down to Prevent Falls in Construction. The reason for this emphasis is the continuing injuries and deaths resulting from workplace falls – especially in construction work. Fall protection was the #1 cited standard by Federal OSHA in 2021, and falls continue to make OSHA’s “Fatal Four” list year after year.

The statistics don’t lie. In 2019, there were 1,102 fatal injuries in the construction industry; according to the US Bureau of Labor Statistics, nearly 38 percent of these fatalities were fall-related. In 2020, employers spent over 16.5 billion dollars combined indirect costs as a result of falls according to Liberty Mutual’s Workplace Safety Index for the construction industry.

In doing our part for National Safety Stand-Down to Prevent Falls, we’ve created a list of Top 5 safety tips to consider before starting work.

1) Implement the Hierarchy of Fall Controls

The most effective method to protect workers against falls is to eliminate the hazards! All too often we see employers and workers simply accepting a hazard without fully attempting to eliminate it first. Admittedly, elimination is not always possible or feasible. In this case, we should make every attempt to use passive fall protection — such as physical barriers, guardrails, or hole covers to prevent falls.  Even this may not always be a practical application in the real world. If we are unable to implement these two methods of control, then (and only then) should it be acceptable to move on to personal protective equipment (PPE) and active measures of control.

2) Develop Effective Training

If there are remaining hazards in the workplace, you must provide workers with the knowledge and skills to be aware of the hazard and their potential effects. Workers should be able to identify when they are at risk for falls and take appropriate and effective measures to protect themselves. Be sure to incorporate hands-on skills into your training with knowledge and competency assessments before allowing workers to work at height. There is no replacement for direct, hands-on learning for this type of skill set. Some examples of this may include appropriate set-up of ladders, harness inspection, maintaining 100% tie-off, and lifeline anchor selection.

3) Provide Proper Personal Protective Equipment (PPE)

As mentioned previously, elimination and passive fall protection should always be our primary and secondary goals for reducing fall-related incidents. When we are unable to implement these methods, we must then rely on PPE to protect workers from the remaining hazard. Ensure that your workers ready have access to adequate PPE for the job; remember, PPE is not a “one size fits all” application. Consider providing different styles of PPE so that workers can choose what is most comfortable or convenient for them.  Workers are a lot more likely to use PPE that they like and are comfortable using.  Also, ensure that workers know how to inspect their PPE and how to wear, use, maintain, and store it appropriately. 

4) Select Appropriate Anchor Points

Fall protection equipment is only as good as the anchor point that it’s tied off to. The ideal anchor point will be located directly above the worker. The further away a worker is from the anchor, the greater potential a worker has to swing into objects during a fall. Additionally, anchor points must be able to withstand at least a 5,000 lb. load per worker. On occasion, workers can be found tying off to electrical conduit, small diameter pipes, or other unacceptable anchor points. Ensure that your workers know and understand how to select appropriate anchor points. As a best practice, consider discussing what anchor points will be used for the job prior to starting work.

5) Accurately Calculate Fall Distances

What good is fall protection if you hit the lower level before it engages? Accurately calculating fall distances can be the difference between life and serious injury or death. The formula used for calculating this is as follows:

Required Distance = Lanyard Length + Deceleration Distance + Height of Worker + Safety Factor

Lanyard Length is exactly that, the length of the lanyard being used. Most lanyards are around 6-ft. in length; be sure to reference the manufacturer’s specifications to determine the exact length of the lanyard.

Deceleration Distance refers to the distance from when the worker falls, to when the fall arrest device activates, and to the final stopping point. Most shock-absorbing lanyards deploy to about 3.5-ft. in length when engaged. Remember that any slack between the anchor point and the worker’s dorsal ring must be added to this distance. For instance, if a worker has a 6-ft. lanyard and connects it 3-ft. above their dorsal ring, that will create an additional 3-ft. fall before the system activates. Additionally, a full-body harness will likely stretch an additional foot during a fall – be sure to include these additional distances in your calculations.

Height of Worker is also self-explanatory, the height of the average worker is about 6-ft.

Safety Factor is an additional amount of space added into the calculation to serve as a buffer. The generally accepted safety factor is 3-ft.

 

Chris McGlynn is the Director of Safety/VPP Coordinator for Roco Rescue. He is a Certified Safety Professional (CSP) through the Board of Certified Safety Professionals as well as a Certified Confined Space and Rope Rescue Technician, and a Nationally Registered Paramedic. As Director of Safety, Chris oversees all corporate safety initiatives, ensuring that employees at Roco have the tools and training that they need to do their work safely and effectively. He is also responsible for managing Roco's Safety Services Division, which provides trained safety professionals for turnarounds and other special projects. Finally, Chris serves as the VPP Coordinator for Roco, continuing Roco’s long-standing commitment to excellence in safety and health. Roco has been an OSHA VPP Star Worksite since 2013.

Follow Chris 

 

Additional Resources

• Fall Hazard Survey (pictured here) 
• Hierarchy of Fall Protection Poster 
• Personal Fall Arrest Systems (PFAS)

 

 

 

We’ve all heard it before, “falls are one of the leading causes of death in the industry.” In fact, falls have been the leading cause of death in the construction industry, year after year, for over a decade now. Additionally, Fall Protection (29 CFR 1926.501) and other related standards continue to land on OSHA’s “Top 10 Most Frequently Cited Standards” list each year.

According to NIOSH, 401 of the 1,102 construction fatalities recorded in 2019 were due to falls. To raise awareness of this hazard, OSHA now conducts a “National Fall Protection Safety Stand-down” to prevent falls in construction and has done so each year since 2014. The 2022 Stand-Down is May 2-6, but OSHA encourages holding your own stand-down any time, year-round.

With all of the emphasis on fatal falls, why are workers continuing to fall to their deaths? More importantly, what can we do to prevent them? Well, I’m glad you asked!

There are many actions that employers can take to prevent fatal falls from occurring in the industry; however, the adage “an ounce of prevention is worth a pound of cure” definitely comes to mind here. The most effective measure that any company can take to prevent fatal falls is to implement proper planning before work begins. An effective fall protection plan is multi-faceted and contains multiple steps, all of which should be given great attention to detail.

What should a fall protection plan include?

1) General Information About the Jobsite

As with any plan, an effective fall protection plan should begin with general information about the task at hand. What type of jobsite or facility is this? Is the job taking place at a residential home, a new construction project, or an industrial manufacturing facility? What type of work is being done? Consider electrical work, roofing, hot work, confined space work, or other tasks that may be a contributing factor in falls. Are there any existing fall protection measures in place? In many cases, permanent ladders and guardrails are in place throughout the jobsite; however, on new construction, there may not be any existing fall protection measures. Are there any work surfaces that could affect the job? Take note of areas that may be slippery, areas that could be abrasive, uneven or unlevel areas or areas with trip hazards. Will the weather impact the safety of the job? Consider how rain, wind, or ice accumulation could impact the jobsite. What is the estimated duration of the job? Long-term jobs may require different solutions from short-term jobs. In some instances, scaffold erection may not be an effective use of time and mobile aerial lifts may be more feasible.

2) Assessment of All Fall Hazards on Site

Once the general information of the jobsite has been documented, a thorough assessment of all fall hazards on the jobsite should be conducted and documented. OSHA has different fall protection requirements for General Industry and Construction. While there are a nearly unlimited number of ways that fall hazards can present on a jobsite, the following are a few examples of the more common situations to look for:

• Open-sided walking/working surfaces
• Open-sided ramps, runways, and platforms
• Floor openings
• Wall openings
• Elevator Shafts
• Stairwells
• Trenches

Do not skimp out on this step of your plan. After all, if you do not identify a fall hazard, you will not be able to protect against it! Consider including workers of all levels in the hazard assessment; every worker has a different perspective and may identify things that are missed by others.

3) Outline of Fall Protection Measures to be Used

Now it’s time to decide how you are going to protect workers from the hazards identified. The hierarch of fall protection is a 5-tiered approach, and the preferred method to eliminate or reduce the risk of falls. The 5 tiers are as follows:

1. 

   Hazard Elimination (best practice)
   The most effective measure of protecting workers from a fall hazard is to eliminate it all together. If possible, relocate the work to ground level or eliminate the exposed edge or opening.
2. Passive Fall Protection
   In many cases, elimination of the hazard is not possible or feasible. The next best measure to implement is to provide passive fall protection which includes things like guardrails or hole covers. Passive fall protection provides a lower possibility of error as it does not rely on the use of personal protective equipment (PPE). 
3. Active Fall Restraint
   In some cases, passive fall protection is not warranted as the duration of exposure may not offset the cost of implementing passive protection or the task being performed may not allow for passive fall protection. Active fall restraint is a type of PPE that limits a worker’s range of movement so that they cannot physically travel to the area of the fall hazard. This method is preferred over fall arrest as it significantly reduces the likelihood of secondary injury due to falls and the need to perform a suspended worker rescue. However, there are many cases where a worker must enter the area of the hazard to perform work.  
4. Active Fall Arrest
   An important note with active fall arrest systems is that they do not prevent a worker from falling but rather prevent the worker from contacting lower levels after the fall has occurred. One important, and often overlooked, element of this is having an effective rescue plan. Be sure to have a plan in place in the event that someone does fall. You must also ensure that workers are trained and understand how to properly use their equipment as well as its limitations. More on that later.
5. Establishing Controlled Access Zones (least effective)
   As a last resort, controlled access zones may be established to limit essential personnel into the area of the fall hazard. These methods generally include safety monitoring systems, warning lines or horns, or control lines. It is important to note that these controls are the least effective as they do not provide any physical means of protection. It is strongly recommended that all efforts have been exhausted to use the previous methods in the hierarchy before settling on controlled access zones.

4) Outline of Use, Maintenance, and Inspection Procedures for Equipment Being Used

Now that the methods of fall protection and prevention for the jobsite have been established, an outline of use, maintenance, and inspection procedures for the equipment used should be documented. Be sure to include proper assembly and disassembly procedures for equipment according to the manufacturer's recommendations. Ensure that a process exists for a competent person to inspect equipment at least annually or as required by manufacturer’s recommendations as well as a process for inspection of safety equipment by the end-user before each use. Any defective equipment must be tagged and removed from service immediately.

5) Outline of the Handling, Storage, and Securing of Tools and Materials on the Jobsite

This section of the fall protection plan goes hand-in-hand with the previous section. Establish a clear outline of how the equipment will be handled and stored on the jobsite. If equipment is not stored properly, it may become contaminated or damaged and render unsafe for use. Storage and handling of equipment vary from jobsite to jobsite but remember to protect equipment against heat, moisture, and chemicals when storing your equipment.

6) Outline of Overhead Protection to be Used

While not directly related to preventing workers themselves from fall hazards, it is important to address how workers in the area of overhead work will be protected. The use of toeboards, debris nets, or other side guards can be effective in preventing tools and material from falling below. Lanyards used to tether tools to the worker are also a great way to avoid dropped objects. Ensure that workers are notified of overhead work in the area with signs and barricades when possible. Consider postponing overhead work in unfavorable weather conditions and secure loose objects whenever possible.

7) Detailed Rescue Plan

Perhaps the most often overlooked item of a fall protection plan is the rescue plan. Many workers in the construction industry know that they must tie-off when working at heights; however, few take the time to think about what happens if/when they fall. Take the time to discuss and document the plan of action to be taken when someone falls. Suspension trauma is a life-threatening condition that can develop when a worker is hanging from their fall arrest system and can be lethal in as little as five minutes. Consider the use of a specialized rescue team for complex scenarios or be sure that you have the proper equipment, training, and proficiency to perform the rescue if needed. Remember, with fall protection – your life is literally on the line!

8) Employee Training and Instructions

Without adequate training, even the most effective plan is worthless. Remember that jobsites are dynamic and that fall hazards that were not present yesterday may be present today. For this reason, ensure that workers are trained to identify fall hazards and how to take measures to reduce or eliminate the hazard. Be sure that workers know when, where, how, and what fall protection equipment is to be used for the task or hazard in question. Also, ensure that workers know how to properly inspect their equipment before use and what to do with equipment that does not pass inspection. Most importantly, ensure that workers are trained on the fall protection plan, have easy access to it, and know how to access it for reference at any time.   

Summary

Despite the increased emphasis placed on falls, they continue to be the number one killer in the construction industry. Unfortunately, the one thing that doesn’t seem to fall is the number of fatalities resulting from it. While there are many actions that employers can take to reduce the likelihood of a fall occurring, the most effective measure is to have an adequate fall protection plan in place. Establish the details of the job, identify the fall hazards, and develop a method to eliminate or reduce the risk associated with the hazard. Establish a guide for proper use, maintenance, inspection, and storage of fall protection equipment and ensure that workers have the training they need to do the job safely. Last but not least, ensure that you have an adequate rescue plan in the event that a fall does occur. Remember, with fall protection – your life is on the line!

 

Chris McGlynn is the Director of Safety/VPP Coordinator for Roco Rescue. He is a Certified Safety Professional (CSP) through the Board of Certified Safety Professionals as well as a Certified Confined Space and Rope Rescue Technician, and a Nationally Registered Paramedic. As Director of Safety, Chris oversees all corporate safety initiatives, ensuring that employees at Roco have the tools and training that they need to do their work safely and effectively. He is also responsible for managing Roco's Safety Services Division, which provides trained safety professionals for turnarounds and other special projects. Finally, Chris serves as the VPP Coordinator for Roco, continuing Roco’s long-standing commitment to excellence in safety and health. Roco has been an OSHA VPP Star Worksite since 2013.

Follow Chris 

 

Additional Resources

• Fall Hazard Survey (pictured here) 
• Hierarchy of Fall Protection Poster 
• Personal Fall Arrest Systems (PFAS)