Fall Protection PPE Equipment

Personal Protective Equipment (PPE) covers a wide range of industries and safety objectives, from law enforcement to sports, industrial settings, contractors and even casual retail environments.  The various functions of PPE are designed to protect hazards in support of work safety policies and controls.  These can range from bodily injury, exposure to environmental threats, breathing mechanisms, and much more.

With OSHA having a renewed focus on Fall Protection and having imposed new rules for Fall Protection PPE, businesses in a range of industries are investing heavily in fall protection equipment.  Consider the following review of Fall Protection PPE equipment and how it can help to reduce injuries at your workplace.

Personal Protective Equipment Options for Workplace Fall Protection Safety

Personal Protective Equipment is required by OSHA when positive fall protection such as guardrails, access platforms, gangways, catwalks, and stairways are unavailable.

When guardrails and other positive fall protection are not available to protect from falls, workers must use personal fall protection systems (such as harnesses, lanyards, lifelines). [29 CFR 1910.6729 CFR 1915.7129 CFR 1915.73, and 29 CFR 1915.77]

Harnesses & Lanyards

Harnesses and lanyards are considered personal protective equipment since each individual worker must be fitted with the equipment for fall protection safety, as opposed to an all encompassing solution.  A lanyard is the rope or other length of connection between a single point anchor source and a safety harness, worn by an employee.  Snap hooks, D-rings and caribiners are utilized to ensure a safe connection.  Anchors must be secured and can be affixed to a variety of stable structures.  The complete fall protection system must be able to adequately support the weight of the employee.  Fall protection PPE systems are typically categorized as a fall restraint system, which prevents falls similar to a car seat belt, and a fall arrest system, which catches a falling worker prior to contact with the ground or other solid structure.

Fall Restraint Systems

The advantage of fall restraint systems is the prevention of the need to absorb the shock and otherwise prevent further injury in the event of a fall.  Further, in cases where the environment requires rescue efforts in the case of a fall, a fall arrest system is preferred.  Generally speaking, fall arrest systems are more safe and less expensive, while more limiting and often less efficient in a workplace.

Fall Arrest Systems

Fall arrest systems often require shock absorbing lanyards and must be carefully considered to avoid further injuring the employee when a fall occurs.  These systems are often used in work environments such as roofing, construction, and shipyards.  In these work environments, a fall is more permissible compared to a mining operation or manufacturing plant with heavy machinery.

Horizontal and Vertical Lifelines

Lifelines are a broad range of fall protection equipment that can be applied for horizontal applications such as roofs or ship decks, as well as vertical applications such as enclosed spaces or ladder systems.  As opposed to a single point anchor, lifelines provide more freedom of movement as they are typically connected to a cable, pipe, or other continuous structure.  Horizontal systems can be designed to provide ultimate movement flexibility via pass through systems, overhead connections, and other similarly unobtrusive mechanisms.  Vertical lifelines can be track based or climb assist systems on ladders at heights, or pulley operated systems for confined spaces and similar applications.  In each case, lifelines generally differ from harness and lanyard systems in so much that they are less mobile and more of a direct method for cases where fall protection risk is consistent and eminent.

Integrate Ergonomics into Shipyard Health & Safety

The shipyard environment is complex and unique.  Workers often perform awkwardly positioned tasks in unique and varying environments and have a history of forming musculoskeletal disorders (MSDs). Nonadjustable work stations, enclosed or confined spaces, and diverse repair activities can be job requirements which contribute to health and safety risk.

Ergonomics is the study of efficiency in work environments.  Shipyards that have systematically addressed ergonomics in the work environment have been effective at reducing injury and reducing MSDs.  As a result, many companies have recognized the value of integrating ergonomics into existing safety and health programs.  Companies invested in safety policy should take general steps for initiating ergonomical improvements in the work environment, and always remember that each work environment will have different needs and limitations to consider.

Shipyard Work Environments and MSD Injuries

Shipyard Work EnvironmentA shipyard is composed of three main work environments.  Shop work, with conditions similar to manufacturing and maintenance; and Yard and Vessel work, where tasks include assembly, welding, and repair. Shoulder stress, lower back strains, and symptoms including numbness, pain and swelling can indicate a work environment for which ergonomic improvements can reduce work injuries.

In addition to reduced worker’s comp and lost worker time, ergonomic risk management initiatives can improve morale, reduce absenteeism, and increase production efficiency.

General Steps for Systematic Improvement

Integrating ergonomics into a health and safety plan can follow the following process.

OSHA Shipyards Ergonomics Report
OSHA 2008 PDF Report
  • Providing Management Support
  • Involving Employees
  • Providing Training
  • Identifying Problems
  • Implementing Solutions
  • Addressing Injury Reports
  • Evaluating Progress

These general initiatives can lead to programs and activities across departments to accomplish injury prevention goals.

Equipment Solutions and Guidelines

Ergonomics solutions can be implemented site-wide and evaluated on a task basis for unique work hazards.  Consider three equipment options and related ergonomic guidelines.

  •  Standing Platforms: Provide stability and reduce shoulder and neck fatigue, particularly for overhead work.  Ideally workers should operate with hands between waist and shoulder height.  Lightweight platforms can be utilized site-wide.  
  • Racks and Shelves: For staging, moving, storing materials, tools, equipment.  Wheeled racks simplify maneuverability.  Position between knee and shoulder.
  • Tractor Trailers: Reduce trips between work areas for transport handling and time savings.  Avoid load shifting or tipping by considering stability and balance.

For details about Systematic Improvement Measures, additional Equipment Solutions and Guidelines, and a complete summary of Shipyard Ergonomics and MSDs, view the Ergonomics for the Prevention of Musculoskeletal Disorders report online at OSHA.gov.

Ergonomic Assessment at your Shipyard

OSHA recommends setting up a plan for achieving the cost, efficiency, and morale advantages associated with ergonomics process improvement.  In unique and varying shipyard environments, operational or safety teams may need assistance to develop a plan and engineer custom equipment.

Ergonomic improvements have resulted in an 80% accident rate reduction on some shipyards, and are accompanied by operational and morale benefits that can be of great value.  OSHA provides free consultation services, and workplace access specialists also assist with recommendations and equipment design.  Contact Innovative Access Solutions to get started designing custom access equipment to meet your ergonomic safety program equipment needs.