Fall hazards are common in almost every facility or on every job site. Unfortunately, struggling to meet minimum OSHA fall protection requirements is also common. Fall protection violations have been the leading cause of citation from OSHA since 2010, with violations regarding ladders, scaffolds, and fall protection training requirements also ranking in the top 10 citations every year. According to the U.S. Bureau of Labor Statistics, the annual number of fatal falls has been steadily increasing in recent years; with 850 in 2021, 865 in 2022, and 885 in 2023.
While the use of fall protection equipment has become commonplace among many employers across various industries, the statistics suggest that there is still considerable room for improvement. Any life lost is a tragedy, especially when all falls are preventable. This article will discuss the limitations of fall arrest equipment, why fall prevention is crucial to protect workers, and proactive methods that can reduce the risk of injury.
Fall arrest equipment: Is it effective?
Many employers supply their workers with fall arrest equipment, as it can be adapted for various scenarios and installed fairly quickly. It can provide a worker with life-saving equipment, but its effectiveness is dependent on user compliance. If a worker neglects to use the equipment or deviates from manufacturer instructions, they could still be exposed to a fall hazard without the means to prevent their injury. Supplying equipment to workers is one thing, but ensuring they use it properly is another.
The very concept of fall arrest equipment does nothing to prevent falls from occurring. Whenever a fall occurs, the risk of injury exists. Fall arrest equipment simply attempts to mitigate the injuries sustained from a fall, but this can only happen if the proper equipment is supplied and the worker dons their harness correctly. One mistake or accidentally altered variable can still expose the worker to severe injury or fatality. A person does not have to fall far to sustain lifelong debilitating injuries, or worse. In fact, the majority of workplace fall deaths occur under 20 feet.
If fall arrest equipment is the only option for workers, it is, of course, better than having no fall protection at all, but the importance of using the equipment properly cannot be understated. Workers must always verify they are using the proper connection device for their personal fall arrest system (PFAS). Self-retracting lifelines (SRL) connected to an overhead anchorage can be an effective form of fall arrest. Overhead anchorages help the SRL activate the moment a fall occurs, significantly reducing the distance a worker falls and how much force they will experience. Less fall distance and reduced fall forces will decrease the likelihood of serious injury.
If overhead anchorage is not available, foot-level anchorages can be used, provided the worker is equipped with a Class 2 SRL. Falls occurring with lowered anchorages will result in increased freefall distances, generate more force, and increase the risk of damaging the SRL cable. Class 2 SRLs are specifically designed and tested to sustain these increased forces and protect the worker. However, they will require a greater minimum fall clearance as opposed to Class 1 SRLs with overhead anchorage. Users must always work above a product’s minimum required fall clearance as specified in the manufacturer’s instructions.
Fall prevention is the best protection
The debate on why falls occur and what can be done to protect workers is ongoing, but one fact remains constant: the surest way to prevent injuries from falls is to prevent the fall from occurring in the first place. As Benjamin Franklin once stated, “An ounce of prevention is worth a pound of cure.”
Guardrail is the most effective form of fall prevention equipment available to employers for several reasons. It is often referred to as “passive fall protection” because guardrail requires no active input from the user to protect them from a fall. Unlike other fall protection equipment, guardrail requires no annual inspections, no training, no certification, and minimal maintenance to remain effective.
Additionally, there are many ways to purchase, construct, or provide OSHA-compliant guardrail for a variety of work environments. It is a common misconception that guardrail can only be used in permanent applications or its installation is intrusive and costly. However, permanent installation is not an OSHA requirement for guardrail. The top rail must be at least 42 inches tall and capable of withstanding 200 pounds of force in any direction and there must be a midrail that is capable of withstanding 150 pounds of force in any direction. As long as the guardrail can withstand those forces, the mounting application is irrelevant. In fact, many building owners opt for freestanding baseplates for their guardrail solution for maximum versatility and configurability. Portable guardrail can be extremely helpful for emergency rooftop maintenance or when work must occur before more permanent fall protection can be installed.
Get proactive
No matter which fall protection method is determined as most feasible and most effective, it is important to properly train workers on the risks of falls and how they can take part in their personal safety. In fact, employers simply reminding their workers that fall protection is required can increase user compliance. The Center for Construction Research & Training conducted a survey in 2021 that found the odds of using fall protection were 71% lower for individuals whose employer did not do any planning compared to those whose employer did. In the same study, they determined that workers were eight times more likely to use fall protection when they knew their employer required it.
Comprehensive fall protection training will be a continual effort. While OSHA is vague about when retraining must occur with employees, the industry consensus recommends annual refreshers at a minimum. In this author’s opinion, training should occur as frequently as possible to help combat the hazards of complacency. Additionally, frequent training sessions provide more opportunities for employees to provide feedback on their current fall protection equipment and help identify when changes or improvements are needed. Employees who feel empowered to take part in their personal safety will only help create more robust and more effective fall protection programs.
For more information and advice to bolster trainings, read 5 Tips to Improve Your Fall Protection Training Program.
Conclusion
Falls can happen in a split second and have tragic consequences for the worker and their family. Even if a fall hazard is identified beforehand and mitigated with some sort of equipment or control, it is almost impossible to predict what will happen during the actual fall. Without a focus on preventing the fall altogether, there is too much room for the unexpected to occur. On an annual basis, more than 800 workers fail to make it home at the end of the day due to a fatal fall. Companies like Diversified Fall Protection can help identify fall hazards and provide customized solutions to ensure that everyone makes it home safely.
Philip Jacklin is Continuing Education Program Manager for Diversified Fall Protection. He is an AIA continuing ed provider, QSSP certified, OSHA-30 trained, and has been a partner to the fall protection industry since 2018. Jacklin has a background in worker advocacy, team leadership, and fostering camaraderie among peers.