Fall Protection

First Steps

Begin by assessing the work site for fall hazards (height, frequency of work, anchorages available, paths of travel, etc.). All hazards identified in this evaluation must be addressed with suitable controls planned and implemented. This information is imperative for selecting the right equipment for the work being performed i.e. harness D-rings, range of movement, forces generated in a fall, and fall clearance needs.

Then, plan the system(s) prior to starting the actual work. Consider all possible paths the user’s movement may take and all factors that could affect the user’s safety before, during, and after a fall anywhere along these paths.

Select the anchorage and anchorage connectors, type of system, and harness to match the work, workplace hazards, and environment. Consider the following points when planning the system(s):

• Regulations – Understand all federal, state or provincial, and local regulations pertaining to fall protection before selecting and using the equipment.
• Rescue Planning – A thorough rescue program should be established prior to using fall protection equipment. It is vitally important to minimize the time between a fall occurrence and the worker’s medical attention.
• Training – All workers should be trained by a Competent Person in the proper use of fall protection products.
• Inspection – All fall protection equipment must be inspected prior to each use.
• Warnings – Always read and follow all instructions and warnings contained on the product and packaging before using any fall protection equipment.
• System Components – Fall arrest systems can be made from available components, so it is important that components are compatible with each other when assembled. Only components compatible with one another should be used. Do not alter, remove, or modify any piece of the equipment.
• Product/System Preferences – If there are any doubts about which fall protection products to use, contact the manufacturer for assistance.
• Sharp Edges – If work must be performed near unavoidable sharp edges, plan to cover the sharp edge and protect the fall protection equipment by use of padding or other means.
• Equipment Removal – After a fall occurs, all components of the fall arrest system should be identified, segregated, and removed from service.

Anchorage and Anchorage Systems

Determine anchorage locations to ensure that the user will be continuously connected when exposed to fall hazards. Select anchorages that are stable and have the required strength. Select anchorage locations above the work area and higher than the harness attachment point whenever feasible. Using an anchorage location lower than the harness attachment point will increase forces on the user’s body, free fall, and total fall distances. Choose a location that will prevent swing falls and impact with objects in, or adjacent to, the fall path. Swing falls increase the fall distance. Plan the types of anchorage connectors needed.

Carefully select the locations of the anchorages to:

• Reduce possible free fall distance.
• Prevent swing fall hazards.
• Provide clear space in the potential fall paths to avoid striking an object.

Free Fall Distance, total Fall Distance, and Deceleration Distance

Personal fall arrest systems must be selected and rigged to ensure that potential free fall distances will never exceed 6 ft. (1.8 m) as required by regulations. Always refer to the manufacturer’s instructions to determine the deceleration distance and elongation that must be taken into consideration.

Most safety regulations provide exceptions for applications where free fall distances must exceed 6 ft. For example, a lack of an acceptable anchorage. A foot-level anchorage is approximately 5 ft. below the user’s D-ring assuming the average worker is 6 ft. tall. This additional 5 ft. may increase free fall. In these situations, free fall distances can exceed 6 ft. if fall arrest forces and clearances are still acceptable.

Several fall protection products exist for these scenarios. Higher capacity energy absorbers/lanyards and self-retracting lifelines designed for foot-level anchorages are the most common. These products are designed to have the capacity to handle increased free fall distances. However, users must be aware that when deceleration distances increase, more clearance is required, and contact with edges will likely occur. Always refer to the manufacturer’s instructions.

Total fall distance is the sum of free fall distance and deceleration distance. The worker’s height and the elongation of the system (stretch and deceleration distances of connecting components and equipment) must be added to total fall distance to allow for clearance. It is best practice to add an additional safety factor of 2 ft. below the worker’s feet.

Free fall distance must be estimated to assemble the worker’s equipment safely and select the appropriate type of connecting device. For example, for a 6 ft. worker using a 6 ft. lanyard, the total fall clearance required from the anchorage to the below surface would be 18 ft. (5.5 m). This is calculated by adding the original length of the lanyard (6 ft.), the deceleration distance (a 4 ft. maximum elongation of the energy absorber), harness stretch (1 ft.), distance from the worker’s feet to the D-ring (5 ft.), and safety factor (2 ft.).

In this case, if the clearance available is less than 18 ft., an alternative solution is needed to reduce the fall clearance required. A shorter lanyard length, higher anchorage location, or different connecting device such as a self-retracting lanyard may be the solution. If the fall clearance is 18 ft. or more, there is sufficient total fall distance available, and the 6 ft. lanyard is acceptable to use. Clearance requirements will change with every application since the equipment, anchorage, and worker location changes. Therefore, it is important that users, Competent Persons, and the Qualified Persons evaluate each location. Consult manufacturer’s instructions for specific details about each products’ clearance requirements.

Note: Do not ever tie a knot in a lanyard to shorten it as this reduces its strength by more than 50%. Instead, purchase an adjustable lanyard and adjust it to the proper working length.