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Lessons Learned from Successful Falls Summary A contractor experienced two employee falls within a couple of weeks of each other. This case study represents lessons that can be learned from successful falls. A successful fall is defined as one where the fall protection used functioned adequately and the worker experienced no injuries and returned to work immediately. Employee A fell with a 4 ft. lanyard while tied off to a beam safe system. Employee B fell while tied off to a 34 ft. long intermediate line attached to a 6 ft. system with a 6 ft. lanyard with too much sag. Although the purpose of this case study is to evaluate the fall protection systems, it’s important to also understand the underlying causes of the falls. One fall was caused by wet working conditions. The employee lost footing while handling a tagline. The other happened when the tagline slipped off the top flange while it was being pulled, causing an expected slack in the tagline, resulting in the employee to lose footing. (For more info on Controlling Loads with Taglines, see Sept. 2015 Safety Flash.) Per company policy, both employees maintained 100% tie off while working from the steel when exposed to at least a 6-foot fall. In addition, rescue procedures were in place and other employees were prepared to provide prompt rescue for both falls. A comparison of both fall protection systems reveals that the falls experienced very different dynamics, yet both resulted in a safety factor after the fall of less than 2 feet. Employee A/Beam Safe System: This fall executed perfectly. The system was tight and the use of a 4 ft. lanyard reduced the fall distance when the employee was working from an 8 ft. floor. The employee was restrained at 1’7” above the impact surface. Employee B/Intermediate Line: Before the fall, the cable started with a 4 ft. sag. Ideally, the cable should have been tighter. After the fall, the system deflected another 2’7”. The employee was working from a 14’4” floor height with a 6 ft. lanyard. The fall arrested with a 1’11-1/2” safety factor. If the 4 ft. of sagging cable had been removed from the fall protection system, there would have been at least a safety factor of 5 ft. Best Practices Identify potential hazards and mitigate to reduce the chance of fall in the first place. (For more info on Preventing Falls, see Jan. 2016 Safety Flash. Analyze floor heights and fall protection systems to determine the best method to prevent contact with a lower level. When utilizing Beam Safe with low floor heights, retractable systems may be the best method to reduce fall distances. When utilizing Intermediate Lines, keep them taught. Sag and cable deflection can result in contacting lower levels after a fall. Know the potential fall distances in the work location and plan accordingly. Take cable lengths, cable sag, floor heights, fall protection system connection heights, lanyard lengths, and lower obstructions into consideration. Train workers on proper rescue techniques. Ideally, both general and site specific rescue plans should be in place. SEAA and LPR Construction offer the ACES Rescue Training Video as a resource, which covers the following topics: Assess the situation. Check for consciousness and/or serious injury. Emergency services notified. Safest and quickest way to perform the rescue. Access the ACES training video in the Members Only section of SEAA’s website. User Name and Password required. Other Resources Capital Safety Rescue Plan Simplified Safety: 5 Things You Need to Know about Fall Rescue and Retrieval OSHA Bulletin: Suspension Trauma/Orthostatic Intolerance
A contractor experienced two employee falls within a couple of weeks of each other. This case study represents lessons that can be learned from successful falls. A successful fall is defined as one where the fall protection used functioned adequately and the worker experienced no injuries and returned to work immediately.
Employee A fell with a 4 ft. lanyard while tied off to a beam safe system. Employee B fell while tied off to a 34 ft. long intermediate line attached to a 6 ft. system with a 6 ft. lanyard with too much sag. Although the purpose of this case study is to evaluate the fall protection systems, it’s important to also understand the underlying causes of the falls.
One fall was caused by wet working conditions. The employee lost footing while handling a tagline. The other happened when the tagline slipped off the top flange while it was being pulled, causing an expected slack in the tagline, resulting in the employee to lose footing. (For more info on Controlling Loads with Taglines, see Sept. 2015 Safety Flash.)
Per company policy, both employees maintained 100% tie off while working from the steel when exposed to at least a 6-foot fall. In addition, rescue procedures were in place and other employees were prepared to provide prompt rescue for both falls.
A comparison of both fall protection systems reveals that the falls experienced very different dynamics, yet both resulted in a safety factor after the fall of less than 2 feet.
Employee A/Beam Safe System: This fall executed perfectly. The system was tight and the use of a 4 ft. lanyard reduced the fall distance when the employee was working from an 8 ft. floor. The employee was restrained at 1’7” above the impact surface.
Employee B/Intermediate Line: Before the fall, the cable started with a 4 ft. sag. Ideally, the cable should have been tighter. After the fall, the system deflected another 2’7”. The employee was working from a 14’4” floor height with a 6 ft. lanyard. The fall arrested with a 1’11-1/2” safety factor. If the 4 ft. of sagging cable had been removed from the fall protection system, there would have been at least a safety factor of 5 ft.
Best Practices
Identify potential hazards and mitigate to reduce the chance of fall in the first place. (For more info on Preventing Falls, see Jan. 2016 Safety Flash.
Analyze floor heights and fall protection systems to determine the best method to prevent contact with a lower level.
When utilizing Beam Safe with low floor heights, retractable systems may be the best method to reduce fall distances.
When utilizing Intermediate Lines, keep them taught. Sag and cable deflection can result in contacting lower levels after a fall.
Know the potential fall distances in the work location and plan accordingly. Take cable lengths, cable sag, floor heights, fall protection system connection heights, lanyard lengths, and lower obstructions into consideration.
Train workers on proper rescue techniques. Ideally, both general and site specific rescue plans should be in place. SEAA and LPR Construction offer the ACES Rescue Training Video as a resource, which covers the following topics:
Access the ACES training video in the Members Only section of SEAA’s website. User Name and Password required.
Other Resources
Capital Safety Rescue Plan
Simplified Safety: 5 Things You Need to Know about Fall Rescue and Retrieval
OSHA Bulletin: Suspension Trauma/Orthostatic Intolerance