Fall Protection – Working at Heights

[Audio] This presentation is on Fall Protection and working at heights!.

[Audio] Today we will be reviewing the following information: Industry Statistics. When is Fall Protection Required? Fixed Guards/Barriers. Platforms, Loading Dock Areas. High Lift Trucks & Work Platforms. Scaffolding. Fall Restraint versus Fall Arrest. Special Fall Protection Issues – Roof Access, Rail car and Trailer Access. Portable Ladders. TE Fall Protection Requirements.

[Audio] The following are Industry Statics on falls: Global, estimated 500,000 Injuries every year from falls. 815 fatalities due to falls in U.S. (14% of total). 53 fatalities due to falls in the U.K. (13% of total). 9 fatalities due to falls in Ireland (18% of total). 89 fatalities due to falls in France (13% of total). Two leading causes; roofs and ladders..

[Audio] Fall protection is required for employees exposed to falls greater than 4 feet or 1.2 meters. A few examples include Hatchways Skylights Loading docks Floor holes Pits, manholes, trapdoors Wall openings Man lifts Powered Work Platforms High lift order picking devices Cat walks, elevated work platforms Elevated walkways Window wall openings in stairway landings Mezzanine storage areas Roof areas closer than 6 feet (1.8m) to roof edge Tanks tops Fixed ladders over 20 feet (6m) Portable ladders when using as platform for extended time periods.

[Audio] The Hierarchy of working from heights is as follows: Number 1: Avoid working at heights. If possible, find another way to complete the task. Number 2: When working at heights cannot be avoided, ensure employees are properly trained on the task or equipment being used. Also ensure supervisors are aware of the task being completed and available if needed. Number 3: Select the correct work equipment that prevents falls such as fall protection harness and lanyards or guardrails. Number 4: Ensure equipment is adequate for the task and in good condition Number 5: Ensure that the equipment being used is Regularly checked and maintained. Number 6: Provide Necessary personal protective equipment that will protect employees from falls. Number 7: Ensure the working environment is safe before starting work Number 8: Plan for Emergencies and rescues..

[Audio] The following are guidelines for guardrail systems: Top Rail must be 42 inches (1.1m) above walking level. Mid rai must be halfway between top rail and walking level. Screens and mesh can also be used and should extend from top rail to walking level. Platforms must be equipped with a 4-inch (10cm) kick board, or toe board, where there is hazard of materials falling. These must be fixed at walking level. Guardrail systems must be capable of withstanding a 200-pound test load in any outward or downward direction. Ladder cages are required when a fixed ladder is more than feet high..

[Audio] The pictures shown are just a few examples of guardrails Note that Stairways with four or more risers, or higher than 30 inches, must be equipped with at least one handrail..

[Audio] Alternative materials can be used if they satisfy load requirements (wood, pipe, cable lines). Chains can be used for guardrails, but deflection or sag must be minimized. 2 inches sag in 20 feet is allowed. Note that chains are not recommended for permanent installations..

[Audio] Special applications may require the use of Guardrail in addition to personal fall arrest systems. Risk assessments should always be performed!.

[Audio] Open-sided floors or platforms 4 feet or more above adjacent floor or ground level must be guarded by a standard railing (or equivalent) on all open sides, except where there is an entrance to a ramp, stairway, or fixed ladder A toeboard is required when, beneath the open sides: persons can pass, there is moving machinery, or there is equipment with which falling materials could create a hazard Regardless of height, a standard railing and toeboard must be used to guard open-sided floors, walkways, platforms, or runways above or adjacent to dangerous equipment, pickling or galvanizing tanks, degreasing units, and similar hazards..

[Audio] Mezzanine Storage or other side openings must either have standard guardrail system or other fall protection arrangement. "Pallet drop" zone (where heavy items are placed by lift trucks) must have some sort of fall protection arrangement..

[Audio] Additionally fall protection for a pallet drop area can include a fall restraint system. This could be a Beam wrap D Ring extension attached to short lanyard with deceleration device on the harness..

[Audio] In Loading dock areas, wherever practical all openings should be equipped with a guardrail system..

[Audio] High Lift Trucks and Work Platforms. When using a high lift truck or work platform, operators must be tied of when going above 4 feet. When using an Aerial Lifts Employees shall use a personal fall arrest or prevention system attached to the boom or basket when working from an aerial lift device where the basket or work platform may rotate, articulate, or otherwise extend beyond the perimeter of the base of the unit.

[Audio] Scaffolding requirements in OSHA Standards state that scaffolds must be capable of supporting four times the maximum intended load, Do not alter or move while in use, protect workers on scaffolds from overhead hazards If scaffolds are higher than 10 ft. (3 m), employes must use guardrails, midrails and toeboards Use wire mesh between the toeboard and guardrail if people work or pass underneath Must be equipped with access ladder or equivalent Damaged or weakened scaffolds must not be used. A safe means must be provided to gain access to the working platform level through use of a ladder, ramp, etc. Never work on scaffolds during storms, high winds, ice, or snow. Always be aware of the hazards of overhead power lines when working on scaffolds..

[Audio] Basic fall arrest systems include a Harness and lanyard, a deceleration device, connectors, and anchor points. It is also crucial to always have a rescue plan in place. Remember that fall arrest is for when a fall exposure still exists and all other alternatives have been considered..

[Audio] When putting on a harness ensure that the harness is snug yet comfortable and the sub pelvic strap is under the buttocks..

[Audio] When connecting your lanyard to your harness remember that the Back D-Ring is for fall arrest, the Front D-Ring is for climbing systems and the Hip D-Rings are for work positioning..

[Audio] Anchor Points Preplanning the anchor points is important! Anchor Points must be capable of supporting 5,000 pounds. They should be located above the employee whenever possible. When possible, engineering review should confirm capacity. Tying off of a lanyard around steel beam can reduce strength by 70% in these cases special webbing lanyard or other purpose built connector should be used..

[Audio] Horizontal and Vertical Lifeline systems allow maximum freedom of movement. These systems must be engineered due to the angled forces involved. Examples include, beam trolleys, horizonal rail car systems, and lifeline sliders..

[Audio] Always remember Horizontal and vertical lifeline systems must be designed by a qualified person..

[Audio] Connecters on lanyards Must be of double locking type design to avoid "roll out". This involves two motions; one to unlock, one to open. These connectors must be capable of supporting at least 5,000 pounds (2268 kg). The D- Rings should always be larger than snap hook..

[Audio] Connector snap hooks cannot be secured, directly to the webbing, to another snap hook, to another D ring that already has a snap hook or other connector attached or to a horizonal lifeline..

[Audio] Lanyards should be kept as short as possible to minimize free fall distances. These lanyards come in a variety or sizes and material. They all must have a deceleration device that absorb the energy after a fall. Once the deceleration device has been used during a fall, the lanyard must be removed and disposed of..

[Audio] If a fall occurs, the employee hanging from the harness must be rescued within 3-5 minutes. Hanging in a harness for longer than 10-15 minutes has been shown to result in adverse health effects. Ensure that a member of the maintenance team is contacted immediately following a fall to preform rescue..

[Audio] When setting up a fall arrest system Consider the following: Ensure you have adequate Clearance; The maximum free fall must be 6 feet. Consider swing fall or other obstructions. Anchor points should be located overhead whenever possible to avoid the pendulum effect. Ensure that preventative maintenance and inspections are taking place. Always inspect your equipment prior to use. If defects are found report this to your supervisor immediately..

[Audio] Let's look at the required distance needed when using a 6 foot lanyard with a deceleration device. With a 6-foot lanyard that includes a deceleration device, consider the following: The Free fall distance is 6 foot due to the six-foot lanyard. The deceleration distance is 3.5 feet. You will also need to account for 1 foot with the tightening of the harness upon impact. Lastly to ensure the employees safety add an additional 2 feet as a safety factor. With all of that in mind, the clearance needed for a fall would be around 12. 5 feet total..

[Audio] Here is an example of clearance and free fall. The 5-foot-tall man is standing on a platform where he is exposed to a 10-foot drop. The man is wearing a 6-foot lanyard with a deceleration distance of 3 and a half feet. If he fell from the platform, he would not hit the ground or another object if he connected to an anchor point is at shoulder height 4 foot above the platform. The employee will be about 4.5 feet above the surface until rescue arrives. In this example you would take the required clearance and subtract that by 4 feet due to the anchor point location being 4 foot above the platform..

[Audio] Here is another example of clearance and free fall. The man is standing on a platform where he is exposed to a 10 foot with his lanyard connected below him. In this example the man will hit the ground if he fell using a 6-foot lanyard if the anchor point is at foot height. This is because The employee does not have 12.5 feet of clearance needed for the fall..

[Audio] Here is an example of a swing fall. While the employee will not hit the ground after falling, he will swing into the stationary object due to the position of the anchor point..

[Audio] This next section will review preventative Maintenance. and inspection. All components must be inspected prior to use for mildew, wear, damage and other deterioration. The frequency of Formal Inspections should be based on the use but every 6 months as a minimum. Results of inspections should be documented. Equipment found defective should be withdrawn from service, and marked as unusable, or destroyed. Component manufacturer or system installer should be contacted for specific testing requirements, when they are applicable..

[Audio] We will now look at some issues with fall protection.

[Audio] There are many factors in certain environments such as construction sites that could cause hazards when working from heights. These factors include: Constant Changes due to weather, Unforeseen events, Hazards that can can evolve instantly, and a lack of constant supervision..

[Audio] Roof access: Fall Protection of some sort required when working within 6 feet (1.8 m) of roof edge (guardrail protection for work area or personal fall prevention/arrest). In Lickdale we require a roof access "Permit to work" ..

[Audio] Roof access hazards include skylights and hatchway fall through risks. TE requires the installation of skylight and hatchway guards to prevent fall thru.

[Audio] When it comes to routine access to heights the use of ladders is undesirable. Ladders should be avoided wherever possible. This can be difficult in manufacturing settings where operators use ladders to reduce ergonomic risks due to reaching tasks..

[Audio] For more information on portable ladders safety program please visit the TE EHS SharePoint or see a member of your sites EHS Team..

[Audio] Next, we will discuss Ladder safety. In this section we will review: Selecting the correct ladder for the task Ladder Setup and Use Inspection and Maintenance.

[Audio] Ladder Selection Aluminum ladders are generally not recommended for TE applications - While this type of ladder is light weight it can conduct electricity Wood ladders are heavy and tend to splinter, rot, warp and absorb moisture Steel is used more in rolling ladder stands and can also conduct electricity Fiberglass ladder are not conductors of electricity. They are also corrosion resistant, heavier than aluminum but recommended over other materials for most TE operations..

[Audio] Selection of a ladder should be based on access height required, duration of task and type of work being performed..

[Audio] Ladders should be of adequate size, so the operator doesn't use top rungs. The top 3 rungs should not be used on extension ladders, and the top two rungs should not be used on step ladders. Extension ladders must be long enough to go 3 feet (0.9 m) over edge when used for climbing to upper level areas.

[Audio] Ladder Load Capacity Some employees may require special consideration in equipment selection due to body weight When selecting duty rating make sure to consider the weights of the user, clothes, tools and material.

[Audio] Special Safety Equipment Stabilizer straps may be used for accessing poles. Employees may also use personal fall restraint systems when using a ladder to prevent accidental falls..

[Audio] Other special safety equipment could include portable scaffolding and other forms of ladder stabilizers..

[Audio] Ladder Set-up and use: When moving a ladder employees much use proper ergonomics and have a pre-planned route of travel. Always be sure that the ladder is inspected prior to use. See your sites ladder inspection checklist. When setting up a ladder ensure the type of surface the ladder will stand on is firm and flat as possible. For straight ladders use the 1 to 4 set-up angle when setting up the ladder. ( 1 foot out for every 4 feet in height.).

[Audio] See this example for the 1 : 4 rule. Beware of "Kick Out".

[Audio] Safe Work Methods should be documented and used for training, post accident review, and disciplinary action if necessary..

[Audio] All fixed and portable ladders should be assigned an identification number and the frequency of inspection determined for each. Assign responsibility and hold someone accountable for program. Do regular ladder inspections and maintain documentation to assure defective equipment is repaired or destroyed..

[Audio] Pre Use Inspection Training should be provided to each employee on inspecting the specific equipment being provided. Supervisors should ask for demonstrations on a routine basis. Formal Inspections Documented inspections should be performed by knowledgeable person on regular basis. Frequency of inspection based on use. Sample forms attached.

[Audio] Besides basic cleaning, there are very few ladder components that can be repaired. If there is any doubt regarding the condition of the ladder (if it is safe or not) the ladder should be tagged and sent back to the manufacturer or authorized equipment dealer. Or alternatively, the equipment should be destroyed and disposed of..