Workplace Access Safety - The Safety & Numbers Blog, presented by IAS

Mining Industry Ladder Safety

The MSHA (Mining Safety & Health Administration) recently published an excellent summary of ladder safety standards for the mining industry. The MSHA was formed to ‘administer the provisions of the Federal Mine Safety and Health Act of 1977 (Mine Act). MSHA carries out the mandates of the Mine Act at all mining and mineral processing operations in the United States, regardless of size, number of employees, commodity mined, or method of extraction.’

The published document covers all topics and categories related to ladder safety training, from the basics of safe access requirements, requirements for each ladder category and special circumstances such as alternating tread and underground ladders. This blog post will summarize standards related to Fixed Ladders, Mobile Equipment Ladders, and the basics of Access Requirements, Ladder Construction and Maintenance. For complete access to this valuable MSHA resource, mining professionals are encouraged to download the Mining Ladder Safety Standards PDF.

Safe Access & Construction and Maintenance

The MSHA standards document provides a detailed summary of possible mining ladder safety citations complete with images of compliant and non-compliant ladders. In addition to common sense factors such as the condition and strength of a ladder, factors such as the height of the bottom rung, the width of the ladder uprights, ladders that require workers to climb over obstructions to mount or unmount, and other potential fall hazards are described. In some cases personal fall protection equipment such as lanyards and harnesses may also be required.

Fixed Ladders

Fixed ladders have been assigned highly detailed requirements specific to the application. In many cases, safety measures such as landings, backguards, and protection for openings at the upper level are required. To review these complex standards, we recommend reviewing the Mining Ladder Safety Standards presentation for details.

Mobile Equipment Ladders

“Fixed mobile equipment ladders must comply with applicable fixed ladder standards such as 30 CFR §§ 56/57.11005 and 30 CFR §§ 56/57.11017.”

The details provided in the MSHA ladder standards document are extended to include even standards for mobile equipment ladders. These ladders must be maintained the same as other ladders and when affixed to equipment, fall under the fixed ladder category. The uniqueness of mobile equipment fixed ladders leads to certain exemptions and standards that may also apply to walkways that provide access to operator cabs.

For information about designing custom ladder access solutions for your mining facility, contact Innovative Access Solutions, LLC.

Shipyard Work Safety

Shipyard work safety programs for private sector businesses are generally under the jurisdiction of Federal OSHA regulations. The shipyard workplace environment presents a wide range of injury hazards including confined spaces, scaffolds and ladders, rigging, and equipment associated with painting, welding, and material handling. To help reduce the risks affiliated with these environments, Personal Protective Equipment is frequently recommended. OSHA has published a complete guide to Shipyard Industry Safety Standards with recommendations for small, medium, or large businesses.

Of particular interest to this blog are the shipyard safety standards provided for Scaffolds, Ladders, and Other Working Surfaces. In this post we will take a look at the training recommendations for work safety Hazard Identification, Assessment and Control, and also provide information about access products to meet OSHA requirements at shipyards.

Hazard Identification and Controls

We have discussed the importance of work hazard assessments on this blog. The published OSHA standards cover the basic policies of inspecting the workplace, evaluating the level of risk, and working with employees and management to identify and determine solutions to work hazards. In addition, OSHA provides valuable recommendations regarding how to manage risk associated with identified hazards in the short term while longer term solutions are being developed. Placing priority on hazard abatement timeframe is important, and interim solutions should be considered.

OSHA also emphasizes the importance of systematic processes, from checking injury logs in support of hazard identification, to using checklists during inspections and breaking down jobs into tasks to determine root causes of accidents or hazards. The Shipyard Standards document additionally provides a hierarchy of hazard prevention controls, starting with engineering and work practice improvements. These involve ‘physical changes to jobs’ and are the top level priority. When engineering controls are not feasible, or in support of engineering controls, administrative controls and personal protective equipment are to be considered next in the hazard prevention hierarchy.

Custom Shipyard Access Products from IAS

OSHA provides detailed requirements for scaffolds, ladders, deck openings and edges, and access to vessels, dry docks/marine railways, and cargo spaces. Innovative Access Solutions has provided shipyard work safety access products for each of these applications. A few of the OSHA-referenced access solutions include portable metal ladders, gangways, guardrails, platforms, access to lower levels, and ladders for accessing cargo areas or confined spaces. IAS is experienced, knowledgeable and available to help meet your shipyard access needs. Contact IAS at (800) 388-6884 to inquire about shipyard access products.

The Trucker™ Series of Ladders Rated as ANSI Type IAA

The Trucker™ Series of ladders was recently tested and passed ANSI Type IAA Special Duty performance requirements. ANSI (American National Standards Institute) standard A14.7-2007 applies to portable metal ladders and provides duty ratings from 200 to 375 pound capacity. Type IAA is the maximum 375 lb. duty rating, described as an Extra Heavy Duty Industrial Ladder.

The Trucker™ Series of ladders are safety engineered to reduce fall injuries and improve efficiency when accessing truck trailer decks. The Trucker ladders provide dimpled Wide Grip Strut® plank steps, feature handrails that extend above the deck to provide 3 points of contact, and are engineered with a diagonal stairway design for ease of access. The ladders meet and exceed the general requirements provided by OSHA for ladder safety:

When there is a break in elevation of 19 inches(48 cm) or more and no ramp, runway, embankment or personnel hoist is available, employers must provide a stairway or ladder at all worker points of access.
Source: Stairways & Ladders: A Guide to OSHA Rules

ANSI A14.7-2007 Testing Procedures

The Trucker™ ladders underwent tests far exceeding the duty rating, passing test loads in excess of 1200 lbs. to meet the requirements of the 375 pound special duty rating. Tests included In-Use Inclined Load Test, Step / Rung Bending Strength Tests, Side-to-Side-Rail Shear Strength Tests, Rung Torque Tests, and Handrail Tests. With a durable design including CNC billet mounting hooks and extruded aluminum frame, The Trucker Series of Ladders offer the durability to provide mobile safety for truck fleets, stationary trailers, or individual truck drivers when accessing the trailer deck.

The Trucker™ Series of Ladders

The Trucker™ ladders are designed to mount to a variety of flatbed trailers including drop deck, roll tarp, curtain side, and more. The Trucker Series of ladders feature plank steps and a pivoting bottom step, and fold up compactly for storage and mobility. Additional ANSI rated Trucker ladders include a shorter two step ladder and longer four step ladder, originally designed for crane trucks. Mounting options include the standard CNC mounting hooks, for mounting throughout the stake rack, or steel brackets for more permanent ladder placement.

The Safety & Numbers blog is pleased to highlight The Trucker™ Series of ladders as a valuable equipment investment for businesses to improve work safety. Trucker ladders provide features designed for the mobile truck driver or service fleet. In addition to the compact design, lockable storage racks and accompanying flatbed work platforms can provide safety on and off the work site.

OSHA’s Fall Prevention Campaign: Ladders

In previous posts, we have discussed the importance of Fall Prevention and the national focus on providing training, guides, and resources in support of this fall protection safety risk management. Falls are the leading cause of death in construction and a frequent safety issue in many other industries. Even falls at minimal height can result in broken bones, lost worker time, and worker’s comp injury claims. Nearly a third of fall fatalities in construction are falls from ladders.

Recently OSHA has produced several resources to provide guidance to safety managers with respect to ladders. Specific guidelines include:

Use the right ladder for the job
When using a ladder to access another level, secure and extend the ladder at least 3 feet above the landing point
Wear proper footwear
Place the ladder on stable and level ground
Ensure that the ladder is fully extended before accessing
Prevent passersby from walking under or near ladders while in use
Do not work on the top rung of the ladder
Maintain three points of contact at all times
Do not carry tools or materials while using a ladder
Do not lean on the ladder while working and keep your weight centered
Do not use ladders near accessible doorways
Check, maintain and safely store ladders
Do not use faulty ladders: bent, missing a step, or unable to be locked open

In addition, the California Department of Industrial Relations provides additional resources for specific ladder requirements, including design and construction (complete with ANSI regulations); ladder types and proper ladder selection; care, use, and maintenance; and employee training.

ANSI: Follow the Proper Guidelines

The number of variations between ladder designs, applications, and composition is nearly as unique as the people that use them. It can be difficult to determine the applicable ANSI standard and rating that applies to each ladder at a workplace. As an example, the ANSI category for portable metal ladders (ANSI-ASC A14.2-2007) covers a wide range of ladders, and excludes others that may seem to fit the category:

Ladder styles include ladder type step stools, portable extension, step, trestle, sectional, combination, single, platform, and articulating ladders, but excluding ladders in and on mines, the fire services, mobile equipment, hoisting equipment, work platforms, antenna communications towers, transmission towers, utility poles, and chimneys. It does not cover special-purpose ladders that do not meet the general requirements of this standard, nor does it cover ladder accessories, including, but not limited to, ladder levelers, ladder stabilizers or stand-off devices, ladder jacks, or ladder straps or hooks, that may be installed on or used in conjunction with ladders.

The importance of being informed to prevent falls from ladders and conform to trending OSHA regulations is clear. For details about requirements for your workplace access equipment, visit the ANSI website or contact a safety professional.

Preventing Falls in Construction

Falls in construction are a well known cause of work injury. A common misconception is that fall injuries are primarily of concern to individuals that work at heights. This is not an accurate representation of the danger presented by slips, trips, and falls, even at minimal height. In heavy and highway construction, also known as horizontal construction, falls account for approximately 25% of workers compensation claims. These consist of falls from trucks, trailers, and construction equipment (45%); ladders, stairs, and scaffolding (20%); and walking or working surfaces (5%). Fortunately, a recent national focus on fall prevention has raised awareness of the issue and improved the quality of resources available to safety professionals. Resources are published daily at sites like OSHA’s Stop Falls Initiative, CDC’s Campaign to Prevent Falls in Construction, and StopConstructionFalls.com in support of this important work safety trend.

Source: Tennessee Road Builder Magazine

Falls from Trucks, Trailers, & Equipment

As a leading cause of injury in the workplace, the risk of falls from trucks, trailers, and equipment is an important hazard for which to mitigate risk. Communicating the need to maintain three points of contact, wear proper footwear, and clean debris from ladders and steps is a good first step. For many types of equipment, upgrading to access ladders that provide three points of contact and durable weight support can provide additional injury risk management. United Rentals is one example of a company that has provided a Safety Best Practice document recommending all employees at their 800+ locations upgrade to the Trucker portable side truck mount ladder. The Trucker ladder provides 3 points of contact, ANSI rated weight support, and slip resistant tread in a sturdy, lightweight design.

Indirect Costs from Fall Injuries

It is important to remember the indirect costs of work injuries when considering falls from minimal heights. It is easy to take for granted the risk of a fall from a 4′ flatbed trailer, particularly under the stress of work timelines. Nevertheless, while these may not always be a fatality risk, the consequences of a work injury extends far beyond broken bones and injury claims. Individuals can suffer long term complications that affect their ability to work and your company’s ability to excel. Even when injuries are minor, your company’s workers’ comp EMR (Experience Modifier Rate) is affected, causing insurance rates to go up and potentially limiting your ability to win valuable contracts. Clearly, the national focus on construction fall protection is a worthy cause for the sake of workers and the industries that employ them.

OSHA Top 10: Guarding Floor and Wall Openings and Holes

Floor openings are a broad OSHA standard covering stairwells, ladderways, hatches, skylights, pits, manholes, and other walking or working surfaces that workers can fall into. In industrial workplaces, floor openings commonly provide multi-level access or access to storage or materials, and are often found when labor or construction is underway. Consider the Top 10 citations for OSHA safety standard 1910.23 in 2012.

Manufacturing (302 Citations in 2012)
Wholesale Trade (71 Citations)
Transportation, Communications, Electric, Gas, and Sanitary Services (61 Citations)
Services (49 Citations)
Mining (38 Citations)
Retail Trade (30 Citations)
Construction (12 Citations)
Agriculture, Forestry, and Fishing (5 Citations)
Public Administration (3 Citations)
Finance, Insurance, and Real Estate (2 Citations)

Source: OSHA 2012 Statistics and Data

Safety managers and operations personnel must keep in mind OSHA guidelines including proper railings, floor opening covers, toe boards, manhole guards, and platforms. Industries with the most frequent violations include manufacturing, transportation/energy, and mining. The common thread among these industries? Material storage, operational setting variations, and multi-level access.

Wall Opening Ladder for Material Access — Storage Access

Walkway Across Floor Opening — Floor Opening Walkway

Manhole Guard with Spring Latch — Manhole Guard

If your work area provides access to multiple levels for which standard equipment will not safely facilitate, custom solutions may be necessary. Proper equipment will protect your employees, manage worker’s comp safety risk, and prevent OSHA citations.

Innovative Access Solutions, LLC

For custom access design, Innovative Access Solutions is an experienced and knowledgeable producer of OSHA safe solutions, across industries. For more information about IAS, visit IAScustom.com or call (800) 388-6884.