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Fall ProtectionPaul Mangiafico
OSHA Compliance Assistance SpecialistHartford Area Office
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Introduction
Why Fall Protection?
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Ironworker who fell had been on job only 3 weeks
Worker injured in second floor fall
Construction worker dies in fall from condo project
Worker Hurt In Fall At University Project
Bridge construction accident injures six
These headlines are all from the third and fourth quarter of 2003
Elementary school construction accident sends 2 to hospital
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Did you know?
• It takes most people about 1/3 of a second to become aware.
• It takes another 1/3 of a second for the body to react.
• A body can fall up to 7 feet in 2/3 of a second.
.33sec./2 feet
.67 sec./7 feet
1 sec./16 feet
2 sec./64 feet
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Falls
• Falls are the leading cause of fatalities in the construction industry.
• An average of 300 fatal falls occurred each year in construction.
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Fatal Falls Most Often From
Structural Steel 9%
Floors, Loading Docks, Ground
Level 4%
Non-moving Vehicles 3%
Roofs 37%
Other 12%
Scaffolds 20%Ladders 15%
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Non- Fatal Falls Most Often From
Ladders 35%
Scaffolds 15%
Roofs 12%Other 22%
Non-moving Vehicles 9%
Stairs/Steps 7%
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Citations
What is OSHA Focusing On?
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Most Frequently Cited Construction Standards
885
952
1051
1087
1180
1202
1244
1377
1415
1908
0 500 1000 1500 2000 2500
1053(b)(1)
21(b(2)
451(b)(1)
453(b)(2)(v)
652(a)(1)
451(e)(1)
501(b)(13)
100(a)
451(g)(1)
501(b)(1) Fall protection – unprotected sides and edges
Scaffolds - fall protection
PPE - hard hats
Fall Protection - residential construction
Scaffolds - access
Excavation - Protection of employees
Scaffolds - platform construction
Aerial lifts - Fall protection
Training & education
Ladders -three foot above
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Subpart L 1926.450-454Scaffolds
Access to scaffolds
Aerial lifts - Fall protection
Scaffold platform construction
Employee training for scaffold use
Scaffolds over 10 feet with no fall protection
655
1051
1087
1202
1415
0 200 400 600 800 1000 1200 1400 1600
454(a)
451(b)(1)
453(b)(2)(v)
451(e)(1)
451(g)(1)
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Subpart M 1926.500-503Fall Protection
315
606
842
1240
1907
0 500 1000 1500 2000 2500
501(b)(11)
501(b)(10)
503(a)(1)
501(b)(13)
501(b)(1)
Fall protection for low-slope roofs
Fall protection for residential construction
Fall hazards training program
Fall protection for steep roofs
Fall protection - Unprotected sides & edges
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Subpart R 1926.750-761Steel Erection
26
28
34
74
347
0 50 100 150 200 250 300 350 400
752(a)(1)
760(b)(3)
752(b)
761(b)
760(a)(1)
Fall Hazard Training
Commencement of Steel Erection
Connectors PFAS over 15 Feet
Concrete Strength Tested
Fall Protection 15 Feet
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Subpart X 1926.1050-1060Ladders
171
243
220
414
884
0 200 400 600 800 1000
1060(a)
1053(b)(4)
1051(a)
1052(c)(1)
1053(b)(1)
Stair rails & handrails
Stairways/ladders required
Appropriate use of ladders
Training program
Portable ladders not extending three feet above the landing surface
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Most Frequently Cited Construction Standards
• 50% of the top 25 OSHA Construction standards violated were Fall Related.
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Philosophies of Fall Protection
Restraint/Positioning
Guardrails
Warning Lines
Safety Monitors
Controlled Access Zones
Safety Nets
Catch Platforms
Fall Arrest
Stop/Prevent The Fall Catch The Fall
Controlled Decking Zones Do these stop/prevent the fall?
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Planning for Fall Protection
• Best practice dictates that fall prevention/protection becomes an integral part of the project planning process, from constructability, to systems installation, to use and maintenance
• A project cannot be truly safe unless fall prevention/protection is incorporated into every phase of the construction process
• Planning will keep workers safe and minimize liability for all parties involved
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• Select fall protection systems appropriate for given situations.
• Use proper construction and installation of safety systems.
• Supervise employees properly.• Use safe work procedures.• Train workers in the proper selection, use, and
maintenance of fall protection systems.• Evaluate the effectiveness of all steps
Controlling Fall Exposures
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Competent Person
• means one who is capable of identifying existing and predictable hazards in the the surroundings, or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has the authorization to take prompt corrective measures to eliminate them.
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Falls onto dangerous equipment • 0’ Allowable Fall
Distance • (You Must Be
Protected)
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Break in elevation without a step
• 19”
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First step onto a scaffold system
• 2’
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Work on forms or steel reinforcing
• 6’
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Work on surfaces such as decks, roofs, ramps, etc
• 6’
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Scaffold platforms without guardrails
• 10’
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Vertical fixed ladders without cages, etc.
• 24’
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Climbing steel reinforcing
• 24’
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Steel erection work
• 15-30’
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Falls from portable extension ladders • No Limit
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Which Standards Apply?
It’s Not Just Subpart M!
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Which Standards Apply?
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Guardrails• Primary Issues
– Complete System• Full coverage• Accessways/Ladderways• Material Handling Areas
– Proper construction• Strength• Deflection
– Maintenance– Custody & Control
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Coverage
Bad Better
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Accessways/Ladderways
Bad Better
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Material Handling
When areas have been opened, PFAS is required
Gates are preferred to removable rails
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Wood Guardrail Construction
Proper Height
Midrails
Toeboards
Adequate Strength
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Cable Guardrail Construction
• Proper Height• Cannot deflect below 39”• Marked every 6’• Terminations and Attachments•Maintenance!
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Holes
• Covers• Guardrails
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Skylights
Must be protected
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Leading Edges
• Catch Platforms• PFAS• Nets
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Scaffolds• Supported
– Fabricated Frame– Tube & Coupler– Wall Brackets– Form Brackets– Ladder Jacks– Pump Jacks
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Scaffolds
• Suspended– Swings– Multi-point– Catenary
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Scaffolds
• Access• Planking• Guardrails• Erection &
Dismantling• Training
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Scaffold AccessBad Better
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Scaffold Platform ConstructionBad Better
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Scaffold GuardrailsBad Better
Be especially aware of scaffold ends!
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Use of Braces for Guardrails
• Brace can be used as a Top Rail.
Platform38 - 48"Install Mid Rail
< 48"
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Use of Braces for Guardrails
• Brace can be used as a Mid Rail
Platform20 - 30"
Install Top Rail
< 48"
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Braces as Guardrails
• The guardrails are in compliance using a 2x4 as one rail and the brace as the other rail.
• May not be the safest way
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Scaffold Erection & Dismantling
• “Competent Person” Determines Where Fall Protection is “Feasible” and Does Not Create a Greater Hazard
• Using Scaffolds as Anchorage Points?
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Aerial Work Platforms
• Boomlifts• Scissorlifts• Boom Trucks (Cherry
Pickers)• Mast Climbers
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Stairs
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Ladders
• Extension• Step• Vertical Fixed• Job-built
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Ladders
• Extension
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Ladders
• Step
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Roofs
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Methods of Roof Fall Protection
Safety Monitors
Guardrails and warning lines
Fall Arrest
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Flat/Low Slope
• 4:1 Slope or Less• Beyond the Use of Guardrails, OSHA
Allows the Use of– Warning Lines– Safety Monitors
• Recommended:– Guardrails or PFAS where feasible– Limited use of lines and monitors on flat roofs
only
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Roof Warning Lines
• Must be 6 feet back from edges (10’ with equipment)
• NO CAUTION TAPE!
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Safety Monitor
• Oversees work outside the warning lines.
• Establishes the procedure to protect.
• Workers must receive special training.
• Use should be extremely limited
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High Slope
• Over 4:1 Slope• OSHA Mandates
– Guardrails– Catch Platforms– Nets– Restraint Devices– Personal Fall
Arrest Systems (PFAS)
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Fall Distances
• Total Fall Distance• Free Fall Distance
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Impacting Structures Below (Total Fall Distance)
• Consider:– anchorage point location in relation to D-ring
height– lanyard length, – harness elongation, – shock absorber opening length,– body below D-ring– body viscosity (soft tissue injuries!)
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Impacting Structures Below (Total Fall Distance)
6’ Lanyard Length
3.5’ Deceleration Device
5’ From D-Ring to Worker’s Feet
3’ Safety Factor (stretch, bounce, etc.)
Total 18.5’ below
anchorage point
All distances are approximate, and shown for illustration only.
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Free Fall Distance
• How far a worker falls before shock absorbing or deceleration equipment begins to take effect– Affects both impact forces and total fall distance
• Anchorage point location in relation to D-ring height– Below the D-ring allows excessive falls– Above the D-ring minimizes free fall to less than 6’
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Free Fall Distance or “Vertical Displacement”
6’ Lanyard Length
3.5’ Deceleration Device
5’ From D-Ring to Worker’s Feet
Total 11’ travel distance of d-ring before fall arrest takes effect. This potential impact force exceeds many lanyard
capacities (and OSHA standards).
When added to “total fall distance”,
anchoring at the feet can become
problematic3’ Safety Factor (stretch, bounce, etc.)
All distances are approximate, and shown for illustration only.
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Minimizing Free Fall Distance or “Vertical Displacement”
Tie to anchor above the D-ring
6’ Lanyard Length
3.5’ Deceleration Device
All distances are approximate, and shown for illustration only. This is why it is critical to maintain the safety factor distance!
Extended Lanyard LengthPlus maximum 2’ extension (usually within inches)
Or use a retractable
Using an anchorage above the D-ring and a standard lanyard may still allow an employee to fall a distance that may be difficult to rescue from. Using a retractable minimizes forces on the body, and may make rescue easier (and therefore more timely)
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Practical Implications of Total & Free Fall Distance Added Together• These workers are
tied to the beams they are standing on with choker slings.
• How far will they fall?
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Watch Swing Falls
• This worker is tied off using a retractable lifeline.
• There is a major swing fall potential if he fell to either side.
Swing Fall
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Anchorages
• Must support 5000# per employee attached,– Or as part of a complete personal fall arrest
system which maintains a safety factor of at least two
– Or 3000# when using fall restraint or a Self-Retracting Lifeline (SRL, Retractable, or “yo-yo”) which limits free fall distance to 2 feet
• Should always be at or above D-ring height
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Roof & Deck Anchors
Wood RoofAnchor
Metal RoofAnchor
PermanentAnchors
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Girder Grip Anchorage Rings
• These attachments can be mounted through bolt holes on steel members.
• They are rated at 5,000 lbs. in all directions
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Beam Clamps
TIGHT
PIN SET
BEAM CLAMP
Beam clamps can make an effective anchorage when used properly, and with the correct lanyard
Be sure pin is inserted full length and clamp is tight.
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Beware of potential for pulling off of coped ends on filler beams!
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Horizontal Life Lines
• Provide maneuverability.• Must be designed, installed
and used under the guidance of a qualified person– This could be interpreted as
requiring the use of manufactured systems, which is recommended
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Body (Harnesses)
• Need to be inspected frequently (daily before use by the worker, at least monthly by a Competent Person)
• Should never be modified• Should be taken out of service
immediately if defective or exposed to an impact
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Harness Fitting
• Harness must be sized for the worker
Chest strap tightened at mid chest
Butt strap supports the load
Proper snugness shoulder to hips
Leg straps snug but not binding
“D” ring between shoulder blades
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Proper Adjustment Is Key“Rules of Thumb”
• Be able to reach your D-ring with your thumb
• Maximum Four (flat) Fingers of Slack at the legs, straps as high as comfortably possible
• Ensure chest strap is across the chest/breastbone
• Have a buddy double check for twists, etc…
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Harness Pressure Points
Spread load across butt strap and belt strap if on the harness
Excess pressure here can cut blood flow to the legs
Some studies have indicated permanent damage to the lower extremities when the worker hangs for more than twenty (10) minutes
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Retractable Lifelines
• Very effective for vertical applications.
• Will normally lock up in 1 –2 feet, minimizing total fall distance and impact forces on the worker’s body
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Do Not Hook Lanyards to Retractables!
• This worker is hooked to a retractable lifeline with his lanyard.
• This can cause hook failures and affect the locking capability of the retractable.
• The retractable should be attached directly to the “D” ring.
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Positioning Systems
• Positioning Devices Provide Hands-free Work– Additional Fall
Protection (tie-off) may be required to move or access
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Positioning
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Restraint Devices
• Provide Access but Prevent the Fall• Limit anchorage requirement to 3000#• May be more suitable for loading areas,
scaffold erection and dismantling• Should be installed and used under the
supervision of a Competent Person
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Fall Restraint
• Fall restraint assumes the employee cannot reach the edge.• He is basically on a short leash.• If the employee could reach to the edge and fall over the
edge, he must be in fall arrest.
Restraint Line
Edge
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Use of Restraint Cables
RESTRAINT CABLE
Example of restraint cables used during deck anchoring.
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Will This Work?
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Planning For Rescue
Worst-case Scenario?
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When All Works!
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Rescue Plan Put Into Motion
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Safe
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On The Ground And Still Alive!
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Training
Define “Adequate”
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Training
• By a “qualified” or “competent” person• The nature of hazards• Appropriate systems and use• Limitations• Evaluated• Re-training• Documentation/Certification?
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Classroom
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Hands-on
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Site Specific
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Planning for Fall Protection
• Best practice dictates that fall protection becomes an integral part of the project planning process, from constructability, to systems installation, to use and maintenance
• A project cannot be truly safe unless fall protection is incorporated into every phase of the construction process
• Planning will keep workers safe and minimize liability for all parties involved
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Questions?