Fall Protection Procedure

1. Introduction

 Purpose: The purpose of the Fall Protection Procedure is to outline a comprehensive set of
safety guidelines designed to prevent accidents and injuries caused by falls at worksites. Falls are
one of the leading causes of workplace injuries and fatalities, particularly in industries like
construction, manufacturing, and maintenance. The goal of this procedure is to establish a
structured approach to identify fall hazards, mitigate risks, and implement measures to protect
workers who are exposed to potential fall hazards.

 Scope: This procedure applies to all workers, contractors, subcontractors, and visitors on
site who may be exposed to fall hazards. It covers all types of work environments and
operations, including but not limited to:
 Elevated work platforms
 Roofs
 Scaffolds
 Ladders
 Construction sites
 Maintenance activities
 Loading docks or areas where work is conducted near unprotected edges
 Regulatory Framework: This procedure is designed to comply with all relevant
regulations, standards, and guidelines set forth by national and international safety
bodies. In particular, it adheres to the standards set by:
 Occupational Safety and Health Administration (OSHA) in the United States
 The European Agency for Safety and Health at Work (EU-OSHA)
 ANSI (American National Standards Institute) and other local safety standards

2. Standards and Regulations

 ANSI Z359 Fall Protection Code: Detailed review of the ANSI Z359 standards,
focusing on:

o Z359.0: Definitions
o Z359.1: Fall Protection Systems
o Z359.2: Minimum Requirements for a Fall Protection Program
o Z359.3: Fall Protection for Ladders and Stairways
 OSHA Fall Protection Standards (1926.500-503): Key OSHA regulations governing
fall protection in construction and general industry.
 British Standards (BS EN 795 and BS 8437):
o BS EN 795: Personal Fall Protection Equipment - Anchor Devices
o BS 8437: Code of Practice for the Selection, Use, and Maintenance of Personal
Fall Protection Systems
 Other Relevant Standards:
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 o Comparison of ANSI and BS standards.

3. Risk Assessment (3-4 pages)

 Identifying Fall Hazards:

o Height-related risks (roofs, scaffolds, open edges).
o Slippery surfaces, unguarded ladders, and scaffolding.
 Fall Hazard Evaluation:
o Use of checklists for risk assessment.
o Inspection of work areas for potential hazards.
 Risk Control Measures:
o Implementing engineering controls (guardrails, safety nets).
o Administrative controls (work procedures, training).
o Personal Protective Equipment (PPE).

4.1 Types of Fall Protection Systems

4.1.1 Passive Systems Passive fall protection systems do not require active intervention by
workers to ensure their safety. These systems are inherently safer as they eliminate fall hazards
without the need for individual actions.

 Guardrails and Safety Barriers:

o Guardrails are the most common form of passive fall protection. They are
designed to prevent workers from falling off edges, platforms, or roofs.
o Must meet specific height and strength requirements as per ANSI Z359.1, OSHA
1926.501, and BS EN 14122.
o Guardrails should have a top rail at a minimum height of 42 inches (107 cm) and
midrails placed at 21 inches (53 cm) from the working surface to prevent a fall.
 Safety Nets:
o Safety nets are used to catch workers who fall, particularly in areas where other
forms of protection are impractical.
o They should be installed as close to the work surface as possible, typically not
exceeding 30 feet (9 meters).
o Nets must be tested to ensure they can withstand the impact of a falling worker, as
per ANSI Z359.1.
 Permanent Platforms:
o Platforms such as scaffolds or work platforms can act as passive fall protection,
providing stable work surfaces at elevated heights.
o These must be properly designed to meet stability and strength criteria and be
regularly inspected to ensure they are secure.

4.1.2 Active Systems Active systems require direct involvement from the worker to ensure their
safety. These systems can be used when passive systems are not practical or adequate.

 Personal Fall Arrest Systems (PFAS):

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 o A Personal Fall Arrest System (PFAS) is a critical component of active fall
protection. It consists of a combination of a full-body harness, lanyard, and
anchor point.
o Full-Body Harness: A full-body harness is designed to secure a worker to an
anchor point in the event of a fall. It should distribute the force of a fall across the
body and prevent injury.
o Lanyard: Lanyards connect the harness to the anchor point. They can be of
different types, including shock-absorbing lanyards, retractable lanyards, and
rope lanyards.
o Anchor Points: Anchor points are secure locations where the fall arrest system is
attached. They must be capable of supporting at least 5,000 pounds (2,268 kg) per
worker attached, according to ANSI Z359.1.
 Rescue and Retrieval Systems:
o In the event of a fall, a rescue system is required to quickly retrieve a fallen
worker. These systems include rope rescue systems, elevated work platforms,
or winches that can lift or lower a worker to safety.
o The rescue system should be designed to allow quick retrieval, ideally within 15
minutes of a fall to prevent serious injury.
 Positioning Systems:
o Positioning systems allow workers to work hands-free while being secured to an
anchor point, such as with rope access or climbing harnesses.
o These systems should prevent falls but allow workers to maintain both hands on
their work. They are ideal for workers on structures like towers, cranes, or steep
roofs.
 Travel Restraint Systems:
o A travel restraint system prevents a worker from reaching the edge of a fall
hazard. It consists of a harness, a restraint lanyard, and a secure anchor point.
o This system is ideal for workers who must move along the edge of a roof or
platform without actually entering a fall zone.

4.2 Components of Fall Protection Systems

 Harnesses: Proper selection and fit of a full-body harness are crucial for the effectiveness
of a fall protection system. A harness should be:
o Comfortable and adjustable to fit workers of varying sizes.
o Strong enough to withstand the forces experienced in the event of a fall
(typically 5,000 pounds per worker).
o Equipped with D-rings: One on the back, one on the chest, and in some cases,
additional ones for positioning.
 Lanyards and Lifelines: These connecting devices link the worker's harness to the
anchor point.
o Shock-Absorbing Lanyards: Designed to absorb the energy created by a fall,
reducing the forces transmitted to the worker.
o Retractable Lifelines: Automatically extend and retract as the worker moves,
ensuring that they are always connected to the anchor point.
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 o Rope Lifelines: Used in rope access systems and can be deployed in vertical or
horizontal configurations.
 Anchor Points: The anchor points must be secure and capable of withstanding the force
of a fall. They can be permanent (e.g., fixed roof anchors) or temporary (e.g., tie-off
points for scaffolds).
o Proper inspection and testing of anchor points are critical to ensure safety.
o Anchor points must be located above the worker’s head to reduce the impact of a
fall.
 Fall Arrest Indicators: Devices that show if the system has been used in a fall event.
These can be integrated into the harness or lanyard to ensure proper replacement of
components after a fall.

5. Fall Protection Program (4-5 pages)

A fall protection program is essential for ensuring that all workers are adequately protected from
fall hazards. It includes planning, training, equipment selection, inspection protocols, and
emergency response procedures. A comprehensive program must follow the guidelines provided
in ANSI Z359, OSHA, and BS standards.

5.1 Developing a Fall Protection Plan

 Site Assessment and Risk Evaluation:

o Before starting any work, a detailed evaluation of the work site should be
performed to identify potential fall hazards.
o Identify elevated surfaces, open edges, slippery conditions, and other fall
hazards.
o Consider the types of work being performed (e.g., construction, maintenance) and
the corresponding fall protection needs.
 Selection of Fall Protection System:
o Based on the risk assessment, choose the appropriate fall protection system
(passive or active) and implement it for specific tasks.
o Ensure that the fall protection system selected meets the regulatory requirements
of OSHA, ANSI, and BS standards.
 Worksite Conditions:
o Evaluate environmental factors such as weather conditions, working on inclined
surfaces, or areas with limited access. These conditions will influence the type of
fall protection system to be used.

5.2 Roles and Responsibilities

 Employers:
o Ensure the implementation of the fall protection program, including the
procurement of fall protection systems and training for employees.
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 o Regularly inspect the worksite and equipment to ensure that fall protection is in
place and functioning properly.
o Comply with OSHA and ANSI standards.
 Supervisors:
o Oversee the daily operations and ensure that workers are using fall protection
equipment correctly.
o Monitor workers to ensure compliance with safety procedures and best practices.
o Report and address any issues related to fall protection on-site.
 Workers:
o Wear and use fall protection equipment as required.
o Participate in training sessions and understand the risks associated with their
specific tasks.
o Report any hazards or faulty equipment immediately.

5.3 Training and Competency

 Initial Training:
o Workers must undergo training to understand the fall protection systems in use,
the proper use of equipment, and how to identify fall hazards.
o Training should be provided by a competent person, as defined by OSHA and
ANSI.
o Training topics include the proper use of fall protection equipment, safe work
practices, and emergency procedures.
 Refresher Training:
o Regular refresher training should be scheduled to maintain competency in using
fall protection systems and understanding new regulations or safety guidelines.
 Documentation of Training:
o All training should be documented, and workers should receive certification that
they have been trained in fall protection.

5.4 Inspection and Maintenance

 Routine Inspections:
o A competent person should conduct regular inspections of all fall protection
equipment, including harnesses, lanyards, and anchor points.
o Inspections should be done before each use and after any incident that may have
damaged the equipment.
o A detailed inspection checklist should be used, and any faulty equipment should
be taken out of service.
 Preventive Maintenance:
o Equipment should be serviced regularly, including cleaning, lubricating moving
parts, and checking for wear and tear.
o Recordkeeping of maintenance activities should be maintained.

5.5 Emergency Response and Rescue Plan

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  Developing a Rescue Plan:
o A written rescue plan should be in place to provide a quick and safe method of
retrieving a worker after a fall.
o The plan should specify the rescue method, equipment needed (e.g., ladders,
hoists, rope systems), and trained personnel.
o Rescue plans should be reviewed and practiced regularly to ensure that all
personnel know their roles in the event of an emergency.
 Coordination with Local Emergency Services:
o Establish contact with local emergency responders (e.g., fire departments, medical
teams) to ensure they are prepared to assist in case of a fall incident.

5.6 Recordkeeping and Documentation

 Accident and Incident Reporting:

o Any fall-related incident or near-miss should be documented and analyzed to
identify causes and prevent recurrence.
o An incident report should include the type of injury (if any), the equipment
involved, the root cause of the incident, and any corrective actions taken.
 Equipment Inspection Records:
o Maintain detailed records of inspections, maintenance, and repairs of fall
protection equipment.

6. Safe Lifeline Installation with Certification Requirements

Lifelines are crucial components in many fall protection systems, especially when workers need
to move horizontally or vertically within a designated work area at height. Installing lifelines
properly ensures that workers are protected from fall hazards while maintaining mobility and
flexibility in their work.

6.1 Types of Lifelines

Lifelines can be categorized into two main types: vertical lifelines and horizontal lifelines. The
installation requirements and usage for each type may differ, but both play a critical role in
securing workers at heights.

1. Vertical Lifelines:
o Used in scenarios where a worker needs to ascend or descend a vertical structure,
such as a building, tower, or crane.
o Typically, a vertical lifeline consists of a rope, cable, or webbing that is anchored
at the top, with the worker secured to the lifeline through a fall arrest device
(e.g., a rope grab, self-retracting lifeline (SRL), or lanyard).
2. Horizontal Lifelines:
o Used for work along horizontal surfaces such as roofs, scaffolds, or bridges.
o Horizontal lifelines are typically made of steel cable or synthetic rope and are
secured at both ends to strong anchor points.
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 o Workers are connected to the lifeline through a lanyard or self-retracting lifeline
that allows for movement along the lifeline while providing fall protection.

6.2 Safe Installation of Lifelines

The proper installation of lifelines is vital to ensuring their effectiveness and compliance with
safety regulations. Below are key considerations and installation guidelines.

1. Anchor Points for Lifelines:

o Lifeline anchor points must be secure, rigid, and able to withstand the forces of a
fall. As per ANSI Z359.1, anchor points should be capable of supporting at least
5,000 pounds per worker attached, or be designed based on the maximum
arresting force (MAF) requirements.
o For horizontal lifelines, anchors must be positioned in a way that minimizes the
fall clearance and prevents excessive swing or forces during a fall.
o Ensure that anchor points are designed and located to prevent shock loading or
the risk of swing falls.
2. Installation of Vertical Lifelines:
o The lifeline should run vertically and be secured at the top, with a self-locking
mechanism (e.g., rope grab or fall arrestor) to protect the worker from falls as
they move up or down.
o Lifelines should be free of sharp edges, rough surfaces, or other obstacles that
could cause damage to the line or pose a hazard to the worker.
o Rope lifelines should be attached to a fixed, non-moving anchor (e.g., roof
structure or mast) using knotless or mechanical connectors.
3. Installation of Horizontal Lifelines:
o Horizontal lifelines should be installed in a straight line and tensioned properly
to avoid sagging. Ensure that the span between anchors is appropriately sized,
with no more than a 20-foot (6-meter) distance between anchor points for
horizontal lifelines.
o When tensioning, ensure that the lifeline can accommodate the load of a fallen
worker without exceeding the fall arrest force limits. The lifeline should be
installed at a height that will allow the worker to safely traverse the area without
significant risk of injury from fall impact.
o Turnbuckles or mechanical tensioners should be used to maintain the
appropriate tension in the lifeline, preventing slack.
4. Clearance and Fall Arrest Requirements:
o Fall clearance must be considered when installing any type of lifeline. Ensure
that the total clearance (including the worker’s height, harness, and the length of
the fall) will not result in the worker hitting the ground or other hazards below.
o Horizontal lifelines should be positioned at a height that minimizes the risk of
swing falls. Proper clearance ensures that a worker will not swing into obstacles
or other workers.
5. Inspection and Testing:
o After installation, the lifeline system must be tested to ensure its strength and
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 person before use, ensuring it meets all safety requirements and is in full working
condition.
o A formal load test should be conducted, typically with a test weight or using fall
simulation to verify that the system will safely arrest a fall.

6.3 Certification Requirements for Lifeline Systems

The installation and use of lifelines must comply with the relevant standards set by ANSI,
OSHA, and BS. Certification is required to ensure that lifelines meet safety requirements and are
safe for use in fall protection programs.

1. Installer Certification:
o The installer of the fall protection system must be trained and certified as a
competent person. This means they must have the knowledge, training, and
experience to identify hazards and ensure that lifeline systems are installed
according to safety standards.
o Competent Person certification, as defined by OSHA 1926.503 and ANSI
Z359.2, is necessary for workers responsible for installing and inspecting fall
protection systems.
2. Equipment Certification:
o All fall protection equipment, including lifelines, connectors, and anchors, must
be certified by an accredited testing organization. Certification ensures the
equipment meets the required strength and performance standards.
o ANSI Z359.1: This standard governs the requirements for fall protection systems,
including lifelines, to ensure they are suitable for their intended use. Lifelines
must be tested for durability and impact resistance.
o OSHA 1926.502(d)(15): OSHA requires that lifelines be inspected and tested
before each use to verify compliance with safety standards.
o BS EN 795: This British Standard covers personal fall protection systems,
including lifelines, and outlines the requirements for their strength and stability.
3. Inspection and Certification of Lifelines:
o Lifelines must undergo regular inspection by a competent person to ensure they
remain in good working condition. This inspection should be documented and
include checks for any damage (e.g., fraying, cuts, kinks) or wear that could
compromise the safety of the system.
o Lifeline inspection certificates should be issued annually or after any incident
that could have compromised the lifeline’s integrity.
4. Manufacturer Certification:
o Ensure that the manufacturer’s guidelines are followed during installation and
maintenance. Lifelines and associated components should have product
certification from recognized organizations such as OSHA, ANSI, and CE
marking (for Europe).
o Test reports and user manuals from the manufacturer must be kept on file to
demonstrate compliance with the appropriate standards.
5. Documentation:
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 o All certifications, inspection records, and maintenance logs should be stored for
reference and audits. This includes:
 Lifeline installation reports
 Inspection records for each lifeline system
 Training records for employees involved in the installation and
maintenance of fall protection systems
 Manufacturer’s certification and product testing reports

6.4 Safety Considerations for Lifeline Installation

 Environmental Conditions: Always take into account weather and site conditions
when installing lifelines. For example, extreme temperatures, wind, and rain may affect
the integrity of the lifeline material (e.g., ropes can weaken when exposed to UV rays or
moisture).
 Worker Safety During Installation: Workers involved in the lifeline installation must
use their own fall protection, such as personal fall arrest systems, while setting up or
modifying the lifeline. A two-person rule is often used to ensure that no worker is left
exposed to a fall hazard during the installation process.

7. Safe Work Practices for Fall Protection Systems

Safe work practices are crucial in ensuring that workers remain safe when working at heights or
in fall-prone areas. These practices are designed to minimize the risk of falls, reduce injury
severity if a fall occurs, and ensure that workers follow a disciplined approach to using fall
protection systems. In addition to the installation and inspection of fall protection systems,
implementing safe work practices is a key part of any fall protection program.

Safe work practices should be documented, reviewed regularly, and communicated to all workers
on-site. Below is a detailed guide to Safe Work Practices for fall protection systems.

7.1 General Safe Work Practices

1. Pre-Work Risk Assessment

o Fall Hazard Identification: Prior to beginning any work at height, conduct a
thorough fall hazard assessment. Identify areas with potential fall risks, including
elevated platforms, edges, holes, unguarded openings, and unstable surfaces.
o Site Conditions: Evaluate environmental conditions such as weather, wind, and
visibility, which can impact the safety of work at height. Conditions such as rain,
snow, or ice can make surfaces slippery and increase fall risk.
o Work Area Control: Establish a work zone around fall hazards and clearly mark
boundaries to prevent unauthorized personnel from entering high-risk areas.
2. Work at Height Authorization
o Authorized Personnel: Only authorized workers who have received appropriate
fall protection training should be allowed to work at height. Ensure workers are
physically fit and properly equipped for the tasks.
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 o Permit-to-Work System: In high-risk environments, implement a permit-to-work
system that ensures all fall protection systems are in place before work begins.
This system ensures compliance with safety protocols and requires approval from
supervisors before any work at height is initiated.
3. Planning and Coordination
o Work Plan: Develop a work plan that includes specific fall protection measures,
the type of system to be used, and the required equipment for each task. Ensure
that the plan includes clear instructions on how to safely perform the task, use fall
protection equipment, and respond to emergencies.
o Supervision and Communication: Supervisors should ensure that all workers
follow safe work practices at all times. Maintain effective communication, using
radios or other devices, between workers, supervisors, and emergency responders
in case of an emergency.
o Coordinating with Other Trades: When multiple contractors or workers are
involved on-site, coordinate activities to avoid creating new fall hazards or
interfering with existing fall protection systems.

7.2 Safe Use of Fall Protection Equipment

1. Personal Protective Equipment (PPE)

o Full-Body Harness: Workers must wear an appropriate full-body harness that
fits securely. Ensure that the harness is adjusted to prevent excessive movement
or slippage. Inspect harnesses before each use for signs of wear, fraying, or
damage.
o Lanyards and Lifelines: Use shock-absorbing lanyards or self-retracting
lifelines (SRLs) to connect workers to a secure anchor point. Ensure that the
length of the lanyard or lifeline is appropriate for the work being done, and
prevent excessive slack that could lead to the worker being exposed to fall
hazards.
o Helmet: Use hard hats or helmets with chin straps to protect workers from head
injuries caused by falling objects or impacts during a fall. Helmets should be
ANSI-certified and properly secured.
o Footwear: Ensure that workers wear non-slip boots or footwear with adequate
grip to prevent slips and trips while working at height.
2. Anchorage and Attachment Points
o Anchor Point Selection: Choose secure anchor points that are capable of
supporting the forces generated by a fall (typically 5,000 lbs per worker or per
ANSI/OSHA guidelines). Ensure that the anchor point is free of sharp edges or
points that could damage the fall protection equipment.
o Independent Attachment: Ensure that each worker has an independent
attachment to an anchor point. Avoid connecting multiple workers to a single
anchor point, which could result in excessive forces during a fall.
o Vertical vs. Horizontal Systems: For vertical systems, ensure the lifeline or
lanyard is kept as vertical as possible to minimize swinging. For horizontal
systems, ensure that lifelines are properly tensioned and supported at regular
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 3. Fall Arrest Systems
o Correct Use of Fall Arrest: When using personal fall arrest systems (PFAS),
ensure that the lanyard length is sufficient to arrest a fall before the worker strikes
a lower surface or object.
o Shock Absorbers: Use shock-absorbing lanyards or SRLs with integrated
shock absorbers to reduce the forces on the worker’s body in the event of a fall.
Ensure that the fall arrest system is compatible with the worker’s environment
(e.g., horizontal vs. vertical lifelines).

7.3 Safe Work Practices During Specific Tasks

1. Roof Work
o Edge Protection: Always install guardrails, parapets, or other forms of edge
protection before workers begin work on roofs. If edge protection is not possible,
use personal fall arrest systems (PFAS) with properly secured anchor points.
o Roof Hatch and Skylights: Secure roof hatches and skylights using guardrails or
covers to prevent falls. Ensure that workers are aware of their location to avoid
walking near open holes.
o Tie-Off Requirements: Workers must be properly tied off to a secure anchor
point before working on a roof. This should be done even when moving short
distances.
2. Ladder and Scaffold Use
o Ladders: Always ensure that ladders are positioned on a stable, level surface.
Workers should maintain three points of contact (two hands and one foot, or two
feet and one hand) while climbing or descending ladders.
o Scaffolding: Ensure that scaffolding is built according to design specifications
and that all safety rails and guardrails are in place before use. Workers should use
personal fall protection while working on scaffolds more than 10 feet (3 meters)
above the ground.
3. Aerial Lifts and Platforms
o Platform Safety: Workers using aerial lifts or scissor lifts must wear a full-body
harness with a lanyard that is tied off to the platform. Ensure that the lift is stable
and that no part of the lift platform extends beyond the safe work zone.
o Electrical Hazards: Maintain a safe distance from electrical lines and other
overhead hazards while using aerial lifts. Always de-energize electrical lines or
use appropriate insulation barriers before starting work.
4. Construction of Temporary Structures
o Scaffold Erection and Dismantling: During the erection or dismantling of
scaffolding, ensure that fall protection is provided. Workers should wear personal
fall arrest systems while working at heights and should use guardrails or safety
nets when possible.
o Temporary Platforms: When installing or working on temporary platforms (e.g.,
catwalks, scaffolds), ensure that all fall protection systems are in place and that
the platforms are stable and secure.

Clas 7.4 Inspection and Maintenance of Fall Protection Equipment

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 1. Daily Inspections
o Workers should inspect their fall protection equipment before each use. This
includes checking harnesses for fraying, cuts, or damaged stitching; inspecting
lanyards for abrasions, knots, or broken connectors; and ensuring that anchor
points are secure.
o Equipment found to be damaged should be removed from service immediately
and replaced.
2. Periodic Inspections
o Competent Person Inspections: A qualified individual should inspect all fall
protection equipment on a regular basis, typically on a monthly or quarterly
schedule, or after any fall incident. This inspection should include an evaluation
of anchor points, lifelines, harnesses, and other fall protection components.
o Maintenance and Testing: Lifelines and fall protection systems should be tested
periodically for durability, impact resistance, and proper function, in accordance
with manufacturer guidelines and relevant standards.
3. Documentation
o Maintain records of all inspections, maintenance, and repairs of fall protection
equipment. This should include inspection dates, details of the inspection, and
corrective actions taken.

7.5 Emergency Response and Rescue

1. Rescue Plan
o Establish a clear and practical rescue plan before work begins. Workers should
be trained on the steps to take if a fall occurs, including how to summon help and
how to safely retrieve a fallen worker.
o Rescue Training: Train workers on how to perform a self-rescue or assist in a
rescue operation if needed. Rescue systems should be in place to retrieve fallen
workers within 15 minutes of the fall.
2. Rescue Equipment
o Ensure that appropriate rescue equipment is available on-site, such as rescue
ropes, winches, harnesses, or aerial work platforms for retrieving fallen
workers.
o Practice the rescue procedures regularly to ensure that all workers are familiar
with the process and can respond quickly in case of an emergency.

7.6 Free Fall Distance and Its Importance in Fall Protection Systems

Understanding and controlling free fall distance is a critical element in any fall protection
system, as it directly affects the severity of a fall, the potential for injury, and the effectiveness of
the fall arrest system. Free fall distance refers to the distance a worker falls before the fall arrest
system (e.g., a lifeline, lanyard, or self-retracting lifeline) engages to stop the fall.

7.6.1 What is Free Fall Distance?

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 Free fall distance is defined as the vertical distance a worker travels from the point where the
fall begins until the fall arrest system activates and begins to slow or stop the fall.

During this period, the worker is falling freely, influenced by gravity, until the fall protection
system engages. The total free fall distance is a combination of the following:

 Initial Fall Distance: The distance the worker falls before the fall protection system is
activated.
 Deceleration Distance: The distance required for the fall arrest system to safely slow
down the worker's fall.
 Arresting Distance: The distance the fall protection system will travel to fully arrest the
fall.

The free fall distance can vary based on the type of system used (e.g., shock-absorbing lanyard,
self-retracting lifeline, or rope grab) and the positioning of the worker relative to the anchor
point.

7.6.2 Free Fall Distance Guidelines

1. OSHA Guidelines for Free Fall Distance:

o According to OSHA 1926.502(d)(16), the free fall distance must be limited to 6
feet (1.8 meters) in fall arrest systems. This is the maximum allowable free fall
distance to ensure the fall arrest system can effectively prevent injury and stop the
fall within a safe distance.
o In situations where the free fall distance exceeds 6 feet, the fall arrest system must
be designed to absorb or minimize the forces experienced by the worker during
the deceleration phase. OSHA further requires that the total fall arrest force
exerted on the worker should not exceed 1,800 pounds (8 kN) to minimize the
risk of injury.
2. ANSI Z359.1 Guidelines:
o ANSI Z359.1-2016 provides more detailed requirements for personal fall arrest
systems and specifies that the free fall distance should be as short as possible to
reduce the potential for serious injury. For most systems, ANSI also recommends
that the fall distance should not exceed 6 feet (1.8 meters).
o It is important to consider the clearance required below the worker when using
fall protection systems. This includes taking into account the worker's height,
harness length, lanyard or lifeline slack, and other variables that could affect the
total fall distance.

7.6.3 Factors Affecting Free Fall Distance

Several factors can influence the free fall distance in fall protection systems:

1. Type of Fall Protection System:

o Self-Retracting Lifelines (SRLs): These systems automatically retract to
Clas maintain tension and prevent excessive slack, thereby reducing the free fall
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 distance. However, if the worker falls, the system deploys and typically arrests the
fall within 2 feet (0.6 meters).
o Shock-Absorbing Lanyards: These lanyards use shock absorbers to slow the
fall, reducing the forces experienced by the worker. Shock-absorbing lanyards can
increase the total fall distance, depending on the length of the lanyard and the
shock absorber's design.
o Rope Grabs: A rope grab attached to a vertical lifeline may allow a worker to
climb or descend, but it will stop the worker's fall once the rope grab engages.
The free fall distance with a rope grab depends on the height of the fall and the
length of the rope.
2. Anchor Point Location:
o The location of the anchor point plays a significant role in free fall distance. A
higher anchor point allows the worker to fall a greater distance before the fall
arrest system engages. Conversely, anchor points positioned lower to the worker’s
position (e.g., waist or shoulder height) help reduce free fall distance and
associated risks.
3. Positioning of the Worker:
o Personal Fall Arrest Systems (PFAS) that use lanyards or lifelines require
workers to remain in a safe position, typically vertically aligned with the anchor.
A worker positioned away from the anchor point may experience a greater free
fall distance due to swing hazards or improper tie-off.
o Workers should always be close to the anchor point to minimize swing and
reduce the risk of experiencing a longer free fall.
4. Deceleration Distance:
o In addition to the free fall distance, the deceleration distance is another factor
that can contribute to the total distance needed to stop a fall. Systems like shock-
absorbing lanyards and self-retracting lifelines include deceleration features,
which can extend the total stopping distance. It is critical that the deceleration
distance does not exceed safe limits, as this could increase the potential for
injury.
5. Clearance Requirements:
o To prevent injuries from impacting the ground or other objects during a fall,
the free fall distance must be paired with sufficient fall clearance. This clearance
is the distance between the worker’s feet and the nearest obstruction (e.g., the
ground, floor, or equipment) that could cause injury.
o As a rule, when using fall arrest systems, clearance should account for the
worker’s height, the length of the lanyard, the shock absorber deployment, and the
fall arrest system's deceleration distance. The total clearance required could range
from 12 feet (3.7 meters) to 18 feet (5.5 meters) or more, depending on the
system used and the worker's position.

7.6.4 Managing Free Fall Distance

To minimize the risk of injury, the following strategies should be adopted when designing and
using fall protection systems:
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 1. Use of Self-Retracting Lifelines (SRLs):
o SRLs limit the amount of slack in the line and reduce the potential for free fall.
These systems are designed to arrest a fall within a few inches and typically have
a built-in deceleration feature that prevents excessive fall distances.
2. Lanyard Length Control:
o Always use shock-absorbing lanyards of the appropriate length to minimize the
free fall distance. Lanyards that are too long can result in an excessive free fall
distance, while lanyards that are too short can limit the worker's movement and
access.
o Shorter lanyards (e.g., 6 feet) help limit free fall distance, but they must still
provide enough range to allow workers to perform their tasks without causing
tension on the system.
3. Anchor Point Location:
o Position the anchor point as high as possible above the worker’s head. This
helps to reduce the free fall distance by minimizing the length of the fall before
the system activates.
o Avoid using horizontal lifelines with excessive slack, as they can allow for a
longer fall distance.
4. Fall Clearance Calculation:
o Perform a fall clearance calculation before allowing workers to use fall arrest
systems. This calculation should include the free fall distance, deceleration
distance, worker height, and any potential obstructions beneath the worker.
Ensure that the total clearance is sufficient to prevent injury.
5. Training and Awareness:
o Train workers on the importance of free fall distance and the risks associated
with excessive free fall. Workers should understand how to use fall protection
equipment properly and be aware of the importance of minimizing free fall
distance by positioning themselves correctly.

7.6.5 Example Free Fall Distance Calculation

Let’s consider a typical fall arrest system with a 6-foot shock-absorbing lanyard.

1. Worker Height: 5 feet 8 inches (1.7 meters)

2. Shock Absorbing Lanyard: 6 feet (1.8 meters) with a 2-foot (0.6-meter) deceleration
distance.
3. Anchor Point Height: 8 feet (2.4 meters) above the worker’s head.

Free Fall Distance Calculation:

 Initial fall distance = 6 feet (1.8 meters) from the anchor point.
 Deceleration distance = 2 feet (0.6 meters) from the shock-absorbing lanyard.
 Total fall distance = 6 feet + 2 feet = 8 feet (2.4 meters).

In this example, the worker will fall a total distance of 8 feet before the system engages and
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 8. Case Studies and Best Practices (3-4 pages)

 Real-Life Incidents and Lessons Learned:

o Examples of fall-related accidents and their causes.
o Analyzing case studies to improve fall protection strategies.
 Industry Best Practices:
o Successful fall protection programs in various industries.
o Insights into effective training and safety culture.
 Comparative Analysis: Review of practices from different standards (ANSI vs. BS vs.
OSHA).

Appendices

 Appendix A: Fall Protection Equipment Checklist.

 Appendix B: Example Risk Assessment Forms.
 Appendix C: Sample Fall Protection Plan.
 Appendix D: Fall Protection Training Program Outline.
 Appendix E: Inspection and Maintenance Forms for Equipment.

Fall Protection Systems Inspection Checklist

This checklist is designed to ensure fall protection systems are in proper condition before use.

1. Anchorage Points

[ ] Ensure anchor points are rated for the required load capacity.

[ ] Verify that anchor points are securely attached to a strong structure.

[ ] Check for rust, corrosion, or deformation on anchor components.

[ ] Ensure anchor connectors (e.g., D-rings, bolts) are in good condition.

[ ] Confirm no unauthorized modifications have been made to anchor points.

2. Full Body Harness

[ ] Inspect webbing for cuts, fraying, burns, or other damage.

[ ] Check stitching for loose threads or unraveling.

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 [ ] Confirm the harness fits properly and is adjusted correctly.

[ ] Ensure labels and markings are legible and not worn off.

3. Lanyards & Lifelines

[ ] Inspect lanyards for wear, cuts, or chemical exposure damage.

[ ] Ensure shock absorbers are intact and not deployed.

[ ] Check snap hooks and carabiners for proper locking function.

[ ] Verify lifelines are free of knots, kinks, or excessive wear.

[ ] Ensure self-retracting lifelines extend and retract smoothly.

4. Guardrails & Safety Nets

[ ] Ensure guardrails are securely fastened and meet height requirements.

[ ] Check for missing or damaged rails, toe boards, or posts.

[ ] Inspect safety nets for holes, cuts, or broken mesh.

[ ] Confirm safety nets are properly installed and positioned correctly.

[ ] Ensure all connections and attachments are secure.

5. Rescue & Emergency Plan

[ ] Ensure a rescue plan is in place and communicated to workers.

[ ] Verify workers are trained on emergency procedures.

[ ] Confirm rescue equipment (ropes, harnesses) is available and inspected.

[ ] Ensure first aid kits are stocked and accessible.

[ ] Document inspection findings and report any issues immediately.

Lifeline Inspection Checklist

Use this checklist to ensure lifelines are in proper condition before each use.

1. Visual Inspection

[ ] Check for cuts, fraying, or abrasions along the entire length of the lifeline.

[ ] Inspect for discoloration, burns, or chemical damage.

[ ] Ensure there are no knots or twists that could weaken the lifeline.

[ ] Examine for signs of UV damage (brittleness, fading).

Clas [ ] Verify all labels and markings are legible and intact.
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 2. Functionality Checks

[ ] Test snap hooks and carabiners for proper operation and locking function.

[ ] Ensure the self-retracting lifeline (if applicable) retracts smoothly without hesitation.

[ ] Confirm that the lifeline locks when pulled sharply.

[ ] Check that any shock absorbers are intact and not deployed.

[ ] Verify the anchorage point is secure and meets load requirements.

3. Documentation & Maintenance

[ ] Record inspection details in the equipment logbook.

[ ] Remove damaged lifelines from service immediately.

[ ] Store lifelines in a clean, dry environment away from chemicals and direct sunlight.

[ ] Ensure routine maintenance and inspections are up to date.

[ ] Verify all equipment complies with relevant safety standards and regulations.

APPENDIX C

1. Introduction

This Fall Protection Plan outlines the measures and procedures necessary to prevent and
mitigate falls from heights in the workplace. It is designed to comply with the requirements of
OSHA regulations (29 CFR 1926.501) and ANSI standards (Z359.1-2016). This plan applies to
all workers engaged in tasks where the potential for falls exists, particularly those working at
heights greater than six feet or in fall-prone areas.

1.1 Purpose

The purpose of this Fall Protection Plan is to:

 Identify fall hazards.

 Specify how fall protection will be implemented.
 Ensure the safety of employees working at height.
 Outline emergency procedures in the event of a fall.

Clas 1.2 Scope

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 This Fall Protection Plan applies to all employees working on elevated surfaces such as rooftops,
scaffolds, ladders, and elevated platforms. It is intended for use on [Project Name/Jobsite] and
covers all employees who may be exposed to fall hazards.

2. Fall Hazard Assessment

2.1 Identification of Fall Hazards

The following potential fall hazards have been identified on this project/job site:

 Rooftops: Unprotected edges or openings.

 Ladders and Scaffolds: Lack of proper fall protection on elevated platforms.
 Hoist Areas: Fall risks around loading areas.
 Excavation Sites: Open trenches or holes.
 Walking/Working Surfaces: Elevated surfaces with unprotected edges.

A hazard assessment will be conducted regularly to identify new fall hazards as work
progresses.

2.2 Risk Assessment

A thorough risk assessment will be conducted to determine the likelihood of falls occurring at
each worksite. Risk assessment will include:

 Determining the height of the work area.

 Evaluating the surface conditions (e.g., slippery or uneven surfaces).
 Reviewing the tasks to be performed.
 Identifying if guardrails, personal fall arrest systems (PFAS), or other controls are
needed.

3. Fall Protection System Selection

Based on the identified hazards, the following fall protection systems will be implemented:

3.1 Personal Fall Arrest Systems (PFAS)

 Workers will be required to wear full-body harnesses when working at heights above 6
feet.
 Lanyards will be used for connection to appropriate anchor points.
 Lanyard lengths will be no more than 6 feet to minimize free fall distances.
 Self-retracting lifelines (SRLs) will be used where applicable to reduce fall distance and
arrest forces.

3.2 Guardrails and Barriers

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  Guardrails will be installed around open edges, holes, and elevated platforms where
feasible.
 Guardrails will meet the OSHA standards (42 inches in height, with a mid-rail halfway
between the top rail and working surface).

3.3 Safety Nets

 Safety nets will be installed when guardrails or other forms of fall protection are
impractical, especially in areas with heavy activity or when working near unguarded
openings.

3.4 Ladder Safety

 Fixed ladders will be equipped with ladder safety systems or fall arrest devices.
 Workers will be trained on proper use of ladders to maintain three points of contact at all
times.

3.5 Scaffolding

 Scaffolds will be erected with guardrails, mid-rails, and toe boards to prevent falls from
elevated platforms.
 Workers will wear PFAS when working above 10 feet on scaffolding.

3.6 Aerial Lifts

 Aerial lifts will be used to reach elevated surfaces. Workers must wear full-body
harnesses connected to the lift's anchor point while in use.

4. Roles and Responsibilities

4.1 Employer

 Ensure that the fall protection systems meet or exceed OSHA and ANSI standards.
 Provide fall protection training and ensure that workers are competent to use fall
protection equipment.
 Conduct regular inspections of the fall protection systems and the worksite.
 Develop and implement emergency procedures for fall incidents.

4.2 Safety Manager

 Conduct hazard assessments to identify fall hazards.

 Ensure the proper selection and installation of fall protection equipment.
 Monitor compliance with the Fall Protection Plan and ensure adherence to safe work
practices.
 Review and evaluate incidents and provide recommendations for corrective actions.
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 4.3 Supervisors

 Ensure that employees use fall protection equipment correctly.

 Conduct daily site safety meetings to review fall hazards and mitigation strategies.
 Report any equipment malfunctions or fall hazards to the safety manager.

4.4 Workers

 Use required fall protection systems at all times when working at height.
 Participate in fall protection training programs.
 Inspect fall protection equipment before use.
 Immediately report any hazards or unsafe conditions to supervisors or the safety
manager.

5. Training

All workers who are required to work at heights or near fall hazards will undergo fall protection
training, which includes the following components:

 Understanding fall hazards and how to identify them.

 Proper use of fall protection equipment such as harnesses, lanyards, and lifelines.
 Rescue procedures in the event of a fall.
 Inspection of fall protection systems to ensure they are in good condition.
 Emergency response procedures and the importance of timely response to a fall event.

5.1 Training Schedule

 Initial Training: Prior to beginning any work at height.

 Refresher Training: Annually or as needed based on changes in procedures or
equipment.

6. Fall Protection System Inspections

6.1 Daily Inspections

 Fall protection systems (harnesses, lanyards, SRLs, etc.) will be inspected before each
use by the worker.
 The worker will check for damage (e.g., fraying, cuts, and stitching issues) and report
any defective equipment immediately.

6.2 Weekly Inspections

 The Safety Manager or designated person will conduct weekly inspections of all fall
protection equipment.
 Inspection will include ensuring that all anchor points are secure, guardrails are properly
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 6.3 Monthly Inspections

 A detailed inspection of the entire fall protection system will be conducted monthly by a
competent person to ensure compliance with safety regulations and identify any areas
for improvement.

7. Emergency Response and Rescue Plan

In the event of a fall, immediate rescue is essential to prevent serious injury or death. This
emergency response and rescue plan details the steps to be followed:

7.1 Immediate Action

 Alert: Call emergency services immediately (911 or designated emergency number).

 Assess the Situation: Ensure the safety of other workers in the area and assess the
condition of the fallen worker.
 Rescue Procedures:
o If using a self-retracting lifeline (SRL), immediately retract the line to reduce
slack and limit the fall distance.
o If a worker is unconscious or immobilized, use aerial lifts or rescue ropes to
safely retrieve the worker.
o Ensure medical assistance is available on-site for immediate treatment.

7.2 Rescue Team

 A trained rescue team will be established before work begins. This team will be
equipped with the necessary tools and equipment to perform rescues effectively.
 The rescue team will conduct mock rescue drills monthly to ensure they are familiar
with the procedures.

8. Fall Protection Equipment and Materials

The following equipment will be provided and maintained to ensure worker safety:

 Full-body harnesses (ANSI/OSHA certified)

 Lanyards (shock-absorbing and adjustable)
 Self-retracting lifelines (SRLs)
 Guardrails and barriers (for perimeter protection)
 Aerial lifts (for elevated work)
 Rescue equipment (ropes, winches, and aerial work platforms)

All equipment will be inspected regularly and maintained according to manufacturer instructions.

9. Recordkeeping
Clas The following records will be maintained for compliance and review:
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  Training records for all employees working at height.
 Inspection logs for all fall protection equipment.
 Incident reports for any fall-related incidents, including near misses.
 Emergency response drills and rescue plan evaluations.

10. Conclusion

This Fall Protection Plan is designed to ensure that all employees working at height are
adequately protected from the hazards of falling. By adhering to the procedures outlined in this
plan, including the use of appropriate fall protection systems, conducting regular inspections, and
having an effective emergency response system in place, we will minimize the risk of falls and
ensure a safer work environment for all employees.

Prepared by:
Date:
Approved by:

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