Fall Protection System Epic Disasters to Never Permit

When working at height, be it on roofs, scaffolding, or ladders, failure to utilize the correct fall protection systems may result in extreme danger. In various sectors such as construction, manufacturing, oil and gas, and telecommunications among others, falls are among the reasons for injuries and death. It is important to have the right tools for fall arrest such as safety harnesses, lanyards, anchors, or horizontal lifelines to avert a fall and create a safe work environment.

Despite all these though, accidents can still occur if this equipment is not worn correctly or adequately serviced. This article will discuss some epic failures of fall protection systems and highlight what we should learn from them so that we would never let such tragedies reoccur.

Not Making Good Use of Safety Gear

Many professionals connect the increase in falls to wrong choices and use of safety gears. Just having personal fall protection equipment (PFPE) is not enough, you need proper training on how to use it correctly for your specific work situation. Additionally, it is important to follow manufacturer guidelines on inspection, maintenance and replacement of the gear. If you fail to do this then your PFPE might not be up to standard.

For example, using a worn or frayed lanyard or anchoring to a point that cannot hold arrest forces can result in catastrophic failure when a fall occurs. This should consist of suitable instruction and observance of usage/maintenance processes laid down regarding the correct protective devices.

Up High Safely Is More than Just Gear

Relying solely on fall protection equipment gives a false sense of security. More important is cultivating a culture of safety and respect for working at heights. This starts with comprehensive training on hazard identification, proper use of PFPE and safe work practices. The training should ingrain an attitude of caution, not overconfidence, when working at elevations.

Too often inadequate training leads to improper use of gear, and workers taking unnecessary risks because they feel protected. However, the gear is only effective when used correctly with safety top of mind. Proper training, supervision and planning are essential for its effectiveness.

Double-check Your Fall Protection Gear

Given the life-or-death nature of fall protection equipment, checking it before use is critically important. This includes inspecting for defects, wear/tear, confirming anchorage strength and ensuring compatibility of equipment. Damaged or incompatible components can cause failure.

For example, a faulty carabiner led to a disastrous fall where the gate unexpectedly opened under load. Likewise, anchoring to a corroded roof beam unable to hold arrest forces can pull out the anchor. Such accidents highlight why thoroughly inspecting all gear before use is a must. Never take chances with damaged or inadequate equipment.

Myths About Horizontal Lifelines

Horizontal lifelines (HLLs) allow mobility by connecting two fixed anchors, but come with common misconceptions:

• Overestimating anchor strength – While the lifeline may be rated for thousands of pounds, this strength is meaningless if the anchors fail under arrest forces. Anchors must be engineered to withstand a fall.
• Inadequate clearance – Improper sag/deflection calculations can result in the lifeline sagging below safe levels. Consult an engineer and follow manufacturer guidelines.
• Lack of training – HLLs require specialized know-how for proper installation, use and inspection. Untrained workers lead to improper rigging and use.

These myths have resulted in HLL failures. Proper anchorage design, clearance engineering and training is a must to prevent disaster. Never make assumptions with HLLs.

Roof Hatches Need Guardrails

Roof hatches are a common fall hazard, especially when left open and unprotected. Falls through roof hatches are far too common, often with grave consequences. Proper railings must guard open hatches.

All it takes is a worker backing up unaware of an open hatch behind them. Or loose materials accidentally kicked into an unguarded opening. Preventing these all-too-common scenarios requires installing hatch guardrails and closing hatches when not in use. Don’t rely on just marking or “be aware of opening” warnings. Installing physical fall protection is a must.

Avoid Absence of Expert Fall Protection

Attempting to cobble together makeshift fall protection without proper engineering and equipment is incredibly dangerous, yet persists on many job sites. Work at heights requires expert fall protection systems tailored specifically to the site.

But too often inadequate anchorage points, improper clearances, and poor equipment choices are made by non-experts. The results are entirely predictable – falls and deaths from failed systems. Every elevated jobsite needs fall protection designed and approved by qualified engineers using equipment that meets regulatory standards. No improvising or shortcuts.

Incorporate Fall Protection in Design

Rather than retrofitting fall protection after construction, building anchor points into the initial structural design is far safer and economical. Countries like those in Europe increasingly require fall prevention be considered in architectural planning.

Designing anchor points into roofs, walls and floors during construction eliminates the risk of drilling weakening structural integrity. It also reduces costs of adding anchors later. Considering fall protection proactively in design instead of reactively after construction prevents hazards.

Training

With advancing fall protection technologies, it’s essential workers are trained on proper use and inspection. Lack of training is a major factor in many gear failures and accidents. Too often workers are unsure how to correctly use new fall arrest systems.

Regular hands-on training ensures familiarity with equipment and builds key safety skills. It empowers workers to identify deficiencies and determine when gear needs replacement. Ongoing training as new equipment is introduced is vital for keeping workers safe. There is no such thing as too much practice when working at dangerous heights.

Conclusion

Hundreds of deaths each year in the workplace are caused by falls from heights, which remains a major hazard. The first line of defense is to have fall protection systems in place. However, even when used wrongly, poorly maintained or inadequately anchored best equipment fails.

To avoid epic catastrophic falls in protection training, expert installation and inspection are vital for developing safety culture. Complacency is what leads to the most devastating accidents. By being alert and respecting the dangers inherent in work at height, we can stop the next tragic fall from happening.