Every year thousands of workers are injured due to falls from elevated surfaces. Despite regulatory requirements for fall protection (29 CFR 1926.500 thru 503, Subpart M) injuries persist. The fall is the result of conditions or work activities that exist. To protect from the fall guard the conditions that allow the fall to occur. This involves the identification, evaluation and control of hazards present on walkways, on floor and wall openings, on stairs and stairways and on elevated surfaces.

Certain activities however, require work to be performed on elevated surfaces (above 6 feet). Generally, this type of work is associated with construction activities but is present in general industry industry as well. The requirement states:

" Each employee on a walking/working surface (horizontal and vertical surface) with an unprotected side or edge which is 6 feet (1.8 m) or more above a lower level shall be protected from falling by the use of guardrail systems, safety net systems, or personal fall arrest systems."

Guardrail Systems
FALL RESTRAINT: A fall restraint system consists of the equipment used to keep an employee from reaching a fall point, such as the edge of a roof or the edge of an elevated working surface. The most commonly utilized fall restraint system is a standard guardrail. A tie off system that "restrains" the employee from falling off an elevated working surface is another type of fall restraint.

Guardrail Systems are simply that, rails that guard against people from falling from a leading edge. They are comprised of a top rail and midrail and can be made of a number of different materials. The type of material that is used, it's strength, and the specifications that the railing is constructed to is highly regulated.

(1) For wood railings: Wood components shall be minimum 1500 lb-ft/in(2) fiber (stress grade) construction grade lumber; the posts shall be at least 2-inch by 4-inch (5 cm x 10 cm) lumber spaced not more than 8 feet (2.4 m) apart on centers; the top rail shall be at least 2-inch by 4-inch (5 cm x 10 cm) lumber, the intermediate rail shall be at least 1-inch by 6-inch (2.5 cm x 15 cm) lumber. All lumber dimensions are nominal sizes as provided by the American Softwood Lumber Standards, dated January 1970.

(2) For pipe railings: posts, top rails, and intermediate railings shall be at least one and one-half inches nominal diameter (schedule 40 pipe) with posts spaced not more than 8 feet (2.4 m) apart on centers.

(3) For structural steel railings: posts, top rails, and intermediate rails shall be at least 2-inch by 2-inch (5 cm x 10 cm) by 3/8-inch (1.1 cm) angles, with posts spaced not more than 8 feet (2.4 m) apart on centers.

"Safety nets shall be installed as close as practicable under the walking/working surface on which employees are working, but in no case more than 30 feet (9.1 m) below such level. When nets are used on bridges, the potential fall area from the walking/working surface to the net shall be unobstructed."
Safety nets shall extend outward from the outermost projection of the work surface as follows:

In addition to these requirements "drop-tests" are required in order to verify the integrity and capability of the system. There are exceptions to this rule and in those instances the regulations should be consulted 29 CFR 1926.502.

Personal Fall Arrest Systems
FALL ARREST: According to the definition in the Federal OSHA standard, a personal fall arrest system means a system used to arrest an employee in a fall from a working level. It consists of an anchor point, connectors, a body belt or body harness and may include a lanyard, deceleration device, lifeline, or suitable combinations of these. The entire system must be capable of withstanding the tremendous impact forces involved in stopping or arresting the fall. The forces increase with the fall distance due to acceleration (a person without protection will free fall 4 feet in 1/2 second and 16 feet in 1 second). One of the most important pieces of equipment in a personal fall arrest system are the belts and harnesses that will be worn by the employee. Consider the following:

Belts & Body Harnesses:
Thoroughly inspect all nylon webbing on belt/body harnesses for frayed edges, broken fibers, burn marks, deterioration or other visible signs of damage. Do the same if the belt or body harness is constructed of other materials. Stitching should be intact and not torn or loose. The belt or harness should be somewhat "soft" and flexible and not stiff from dirt or contaminants.
Check to see that buckles and "D" rings are not distorted or damaged. Look closely at all components for stress cracks, deformity, gouging, corrosion and sharp edges. Inspect connection points where the buckle or "D" ring is attached to the belt or body harness. Insure that no stitching is pulled and that the buckle or "D" ring is securely attached.
Inspect all rivets and grommets to be certain they are not deformed, and are securely fastened to the belt or body harness and cannot be pulled loose.
If you find any of these conditions during the inspection, do not use the equipment.

Lanyards:
Completely check the entire length of the lanyard. looking for cuts, fraying, deterioration, knots, kinks, burns or visible signs of damage. Stitching should be intact and not torn or loose. Spliced ends must also be carefully examined for damage or deterioration. Check to see that the lanyard is somewhat "soft" and not stiff from dirt or contaminants.
If using a "shock absorber" type of lanyard, look for the "warning tag" which indicates that the lanyard has been exposed to a fall.
Snap hooks and eyes should not be distorted or bent. Inspect them for cracks, sharp edges, gouges or corrosion. Check to be sure the locking mechanism is operating properly and that there is no binding of the mechanism.
If using a self retracting lanyard (SRL), you must inspect the body of the mechanism for flaws to assure that all nuts, screws and rivets are installed and tight. Also check crimped ends or stitching for damage. Inspect the entire length of the SRL for any visible signs of defects.
Test the locking mechanism by pulling sharply on the cable end to be sure it locks immediately and firmly.

Key requirements for fall arrest systems:

1) Body belts may not be used after 12/31/97. In the meantime, body belts can only be used if the system limits the maximum arresting force on an employee to 900 pounds. A maximum arresting force of 1800 pounds is allowed when a body harness is utilized. In some jurisdictions, such as Washington State, belts are currently not allowed for fall arrest purposes.

2) The system must be rigged so that an employee can neither free-fall more than 6 feet nor contact a lower level. After the free-fall distance, the deceleration or shock absorbing component of the system must bring an employee to a complete stop within 3.5 additional feet.

3) The anchorage point must be capable of supporting at least 5000 pounds per employee. Most standard guardrail systems are not adequate anchorage points because they are not built to withstand the impact forces generated by a fall.

4) The system's D-ring attachment point for body harnesses shall be in the center of the employee's back near the shoulder level.

5) The system components must be inspected for damage and deterioration prior to each use. All components subjected to the impact loading forces of a free-fall must be immediately removed from service.

OSHA Fall Protection Guidance