1. Fall Protection I. Background for the Trainer:
The construction industry has detailed requirements for fall protection systems and training as outlined by OSHA. General industry is mostly concerned with fall protection for employees who use manlift types of equipment.
This training session is intended to be a general overview of fall protection for any employees required to work at heights greater than 6 feet above the ground.
Try to focus this training session on protecting employees from the specific fall hazards located at your company’s facility.
Consider developing a Fall Protection Program that would identify the fall hazards at your company, the procedures employees will use for preventing or arresting falls, etc. A written plan eliminates guesswork by employees and helps make sure everyone is working safely. If you have developed this plan, pass it out to the employees in the class.
II. Speaker’s Notes:
In this training session we will discuss a number of general concerns with fall protection that could apply to many situations. We will focus on the specific fall hazards at our company and how we will protect ourselves from those hazards.
This training session will focus on:
Hazards associated with falls
Rules for working safely from heights
Different types of fall protection systems
Copyright ã1999 Business & Legal Reports, Inc.

2. Why Fall Protection?
Do your hands get sweaty when you watch someone working from heights?
Do you know anyone who has fallen off of a deck or roof?
Falls accounted for 10% of fatal work injuries in 1994 and 1995
I. Speaker’s Notes:
Do your hands get sweaty or do you feel nervous when you watch someone, in real life or on TV, working or moving above the ground? Many of us have built-in anxiety about heights.
Do you know anyone who has been seriously injured or even killed because of a fall. It could have been a work incident. Or it could have occurred to someone at home who fell off a roof or high ladder while hanging Christmas lights or cleaning the gutter. Whether at work or at home, fall protection is needed.
According to the Bureau of Labor Statistics, falls accounted for 10% of fatal work injuries in 1994 and This is why we’re discussing fall safety today.
Copyright ã1999 Business & Legal Reports, Inc.

3. Fall Protection Goals Fall hazards, work rules, and fall prevention
Personal fall arrest system
Quiz
I. Speaker’s Notes:
We’ll start with identifying hazards when working above ground, then we will discuss some safe work practices followed by some fall prevention systems.
Next we will spend some significant time discussing personal fall arrest systems.
Finally, we’ll end the class with a quiz.
Copyright ã1999 Business & Legal Reports, Inc.

4. Fall Protection Requirements
General industry regulations
Platforms, equipment used to lift workers
Construction industry regulations
Scaffolds, cranes, steel erection, tunneling, stairways, ladders
Rule of thumb
When working 6 feet or more above a lower level, some form of fall protection is required
I. Background for the Trainer:
Discuss some of the specific areas or work situations in your facility that require fall protection. Do you have guardrails on mezzanines or walkways above equipment? Are personal fall arrest systems required for maintenance when they are in the cherry picker or manlift? Are fall protection systems required for some confined space entry situations?
II. Speaker’s Notes:
General industry standards are not as comprehensive as the standards for the construction industry. The standards for General Industry are related to powered platforms and can be found in 29 CFR Appendix C of that same section provides more detailed and recommended safety procedures.
The standards for the construction industry can be found in 29 CFR The standards include specific requirements for specific work situations including scaffolding, cranes, steel erection, tunneling, stairways, and ladders. Be sure you consult the specific standard that applies to the job you are doing.
For a general rule of thumb, remember that fall protection is required for any employee working 6 feet or more above a lower level. A lower level is considered an surface onto which an employee can fall and includes, but is not limited to, ground levels, floors, platforms, ramps, excavations, pits, tanks,water, equipment, and structures.
Copyright ã1999 Business & Legal Reports, Inc.

5. Hazard Recognition Tripping over tools, materials, etc.
Workers not aware of their location
Failure to use required fall protection
Dropping objects
Lifting people with improper equipment
I. Background for the Trainer:
In addition to the hazards listed on the slide, discuss hazards that might be specific to locations at your company where employees are required to work at heights.
II. Speaker’s Notes:
When working above ground there are many potential hazards that you need to be aware of.
Keep the work space neat and orderly. A cluttered work area could result in a worker tripping over tools or materials.
Know your location. How close to a leading edge are you? Have you stepped back too far in order to survey your work?
What’s your excuse for not using fall protection? Are you going to be up there for only a minute? Did you leave your harness at the other end of the facility? There is no excuse for not wearing fall protection.
Be extremely careful about dropping tools and materials. Not only will your tools or materials be damaged, but a worker below you could be killed.
Only lift workers with the proper equipment. Do not lift someone on a pallet with a forklift. Use manlifts, scissor lifts, cherry pickers, etc.
Copyright ã1999 Business & Legal Reports, Inc.

6. Aboveground Working Rules
Use a personnel lift only if you’re authorized
Only authorized employees should work on elevated areas
Stay away from edges, unless you are working there
Never run when working above ground
Listen for verbal warnings
I. Background for the Trainer:
Discuss additional rules that might be specific to your company.
II. Speaker’s Notes:
Never use any type of powered equipment, including forklifts and manlifts, unless you’ve been authorized and properly trained.
Do not climb up to an elevated place, on top of machinery, or onto a roof unless authorized and properly trained in the use of fall protection devices.
Stay away from leading edges unless doing work along that edge. In some cases, fall protection devices are not required for workers who do not work near leading edges, so observe all warnings and barriers.
Never run when working above ground. Tripping could easily result in a fall further than just to the same level.
Listen for verbal warnings. You may be unknowingly approaching a leading edge that another employee is monitoring and warning employees to stay away from.
Copyright ã1999 Business & Legal Reports, Inc.

7. Falling Objects When working above ground:
Don’t leave tools or materials where they might be kicked over the edge or tripped over
Don’t throw items over the edge
Wear hard hats when working under an aboveground work area
I. Background for the Trainer:
Are hard hats required in certain areas of your facility because of employees working above ground? If so, discuss these areas.
II. Speaker’s Notes:
Working on the lower level of a work space can be just as dangerous as working above the ground if the employees above you are not working carefully.
When working above ground, be careful not to kick tools, materials, etc., over the edge where they could fall on an employee below.
Never throw items over the edge, even when you think the coast is clear. If you must toss items over the edge, have a spotter on the lower level to keep the area clear of other personnel, or use barricades to keep employees away.
Wear a hard hat when working under an aboveground work area.
Copyright ã1999 Business & Legal Reports, Inc.

8. Guardrails Barrier along an open edge
42" high with middle rail halfway up
Toeboard or kickplate
Withstand force
I. Background for Trainer
Have you evaluated the guardrails in your company to make sure they are adequately designed, properly located, and sturdy enough to prevent an employee from falling to a lower level? If not, now is time to conduct a fall protection audit. This audit will help you write your fall protection program.
Note that your local building codes or your state occupational safety and health agency may have other guardrail requirements such as guardrails for any working surface three feet above a lower level.
II. Speaker’s Notes:
Guardrails act as a barrier along any open edge to protect employees and objects from falling over the open edge to a lower level.
Guardrails must be 42 inches high with at least one middle rail about halfway between the working surface and the top rail.
A toeboard, or kickplate, is used to help prevent an employee from stepping over the edge of the working surface and to prevent the same employee from kicking tools or equipment over the edge to where they could fall on an employee on the lower level.
The guardrailing must be able to withstand reasonable force. So, if it feels flimsy, it probably will not prevent an employee from falling to a lower level.
Copyright ã1999 Business & Legal Reports, Inc.

9. Safety Nets Safety devices located under elevated workers
Made of a strong rope mesh
Inspection requirements
I. Speaker’s Notes:
When people think of safety nets, they often envision trapeze artists in the circus. As the performers flip through the air and the audience is amazed, the performers are almost always protected by a safety net.
Safety nets are located under workers to catch them in case of a fall and to protect them from the impact.
Safety nets have specific requirements for their design, which includes the material type, the location under the workers, etc.
Safety nets also have important inspection requirements to make sure they have not been damaged and will still hold a worker in case of a fall.
Copyright ã1999 Business & Legal Reports, Inc.

10. Other Fall Protection Devices
Controlled access zones
Warning line systems
Safety monitoring
I. Background for the Trainer:
If your company uses any of these other fall protection devices, describe them to the employees.
II. Speaker’s Notes:
Controlled access zones are areas in which certain work may take place without the use of guardrails, fall protection, or safety net systems. Access to this work area is limited to specific workers that are doing specific construction jobs (i.e., overhand bricklaying).
Warning line systems are barriers erected to warn employees that they are approaching an unprotected edge. As long as employees do not cross the warning line, they may work without the use of a guardrail, body belt or harness, or a safety net system.
Safety monitoring is a system in which a competent person is responsible for recognizing and warning employees of fall hazards. This person keeps workers away from open edges.
Copyright ã1999 Business & Legal Reports, Inc.

11. Fall Protection Goals Fall hazards, work rules, and fall prevention
Personal fall arrest system
Quiz
I. Speaker’s Notes:
Are there any questions concerning general fall hazards, aboveground work rules, or fall prevention systems?
Let’s discuss personal fall arrest systems.
Copyright ã1999 Business & Legal Reports, Inc.

12. Personal Fall Arrest System
Worker tied to fixed object
Harness or belt worn
Lanyard, lifeline, deceleration device
Never use to hoist workers or objects
I. Background for the Trainer:
Bring samples of all the components of a personal fall arrest system to the class so that employees can get a hands-on feel for the equipment.
As you go through the slides, put on the personal fall arrest system and have the employees work with the system until they are comfortable.
II. Speaker’s Notes:
A personal fall arrest system is one in which the worker is tied, or anchored, to a fixed object.
The worker is wearing a belt or harness.
A lanyard, lifeline, or deceleration device connects the belt or harness to the fixed object.
A personal fall arrest system is never to be used as a hoist for workers or objects. This may cause damage to the integrity of the personal fall arrest system.
Copyright ã1999 Business & Legal Reports, Inc.

13. Uses for Personal Fall Arrest
Working above a lower level
Worker positioning
Worker restraint
Climbing
Worker riding or lifting
I. Background for the Trainer:
Describe the specific areas or work processes at your company where personal fall arrest systems might be used for these situations.
II. Speaker’s Notes:
Obviously, when working above a lower level, personal fall arrest systems must be used. There are also other situations in which personal fall arrest systems are used.
Work positioning is a situation in which an employee uses fall protection to tie off to a structure so that both hands can be free to do a job. An example is a worker tying to a utility pole or a wall of rebar so that both hands are free to work.
Work restraint actually prevents a worker from getting to the open or leading edge of a roof or other work surface. The worker is tied off with a short lanyard so that the open edge cannot even be reached. A worker in a manlift can be tied off with a short lanyard so that he cannot climb out of the manlift.
An employee climbing ladders or scaffolding may also need fall protection. Much like a rock climber will tie off to the rock, an employee may need to tie off to the fixed ladder or scaffolding.
“Man riding” is when an employee may actually be lowered into a space (i.e., a sewer manhole) or actually suspended when performing a job (i.e., washing windows of a high-rise building). Obviously, this person will also be using a personal fall arrest system.
Copyright ã1999 Business & Legal Reports, Inc.

14. Arresting Forces The act of falling is not painful
Striking an object or sudden stopping causes pain
Body weight x fall distance
I. Speaker’s Notes:
The actual act of falling does not hurt. Why do you think so many people love to jump out of airplanes? The fall is the thrilling or fun part.
Stopping is what hurts. Whether you strike an object, like the ground, or are suddenly stopped in midfall by a personal fall arrest system, it will hurt.
The force or impact of the resulting stop is determined by your body weight and the fall distance. The more you weigh, the more force it takes to stop your fall. Remember, the bigger you are the harder you fall. Second, the further your fall distance, the more force it takes to stop your fall.
Therefore, the best way to reduce the arresting forces applied to your body is to limit the distance of your fall and always use a deceleration device to prevent the sudden jolt.
Copyright ã1999 Business & Legal Reports, Inc.

15. Body Belts
As of January 1, 1998, use of a body belt for fall arrest is prohibited by OSHA
Damage to spine and internal organs
Average tolerable suspension time is 90 seconds
Maximum of only 900 pounds of arresting force
Work Restraint
Snug around midsection
D-ring at the center of the back
I. Background for the Trainer:
Make sure your company’s Fall Protection Program limits the use of belts to “work restraint” situations only.
Your company might be wise to destroy and discard any body belts to prevent an employee from accidentally using them in a fall arrest situation. If this is the case, this slide can be deleted.
II. Speaker’s Notes:
Body belts have been prohibited by OSHA for the use of fall arresting because:
Belts often cause damage to spine and other internal organs.
Average tolerable suspension time of 90 seconds does not allow much time for rescue.
Belts are rated only for a maximum of 900 pounds of arresting force.
Body belts may be used for work restraint, which is a situation in which workers are tied to a short “leash” that prevents them from even reaching the leading or open edge.
If used in this situation, make sure it is snug around the midsection.
Make sure the D-ring is located at the center of the worker’s back.
Copyright ã1999 Business & Legal Reports, Inc.

16. Harness Arresting forces on thighs, pelvis, waist, chest and shoulders
Harness rated for 1,800 pounds of arresting forces
Tolerable suspension time of 15 minutes
D-rings
Upper back for fall arrest
Sides for positioning
Front for rescue or suspension
I. Background for the Trainer:
Put on a harness to demonstrate how it should fit. The back D-ring should be positioned between the shoulder blades, the chest strap located between the collarbone and breasts, and the leg straps tightened so that only one or two fingers can fit between the legs and the straps.
Take the time here to have the students practice donning and doffing the harness. Have them each go through the process at least twice so that they are completely comfortable.
II. Speaker’s Notes:
The harness will provide the greatest protection for your body in a fall situation because all the arresting forces will be applied to the structural components of your skeletal system.
The harness is rated for a maximum of 1,800 pounds of arresting forces.
The harness has a tolerable suspension time of 15 minutes, which allows plenty of time for rescue in most situations.
The D-ring on your upper back is for fall arrest; make sure your anchor point is always above this location to limit the height of your fall.
Use the side D-rings for positioning.
The front D-ring is used for rescue or suspension.
Copyright ã1999 Business & Legal Reports, Inc.

17. Lanyard Connects harness to lifeline or anchor
Stretching or tearing system absorbs shock, prevents bouncing to reduce arresting forces
Steel provides no give, so large arresting forces
Nylon rope gives mild arresting forces, however it bounces, so lots of jolts
No knots or wrapping around sharp objects
I. Background for the Trainer:
Connect a lanyard to your harness for demonstration.
II. Speaker’s Notes:
A lanyard is a flexible line of rope or strap that generally has a connector at each end for connecting the body belt or harness to a deceleration device, lifeline, or anchorage.
The lanyard often has its own deceleration device that greatly reduces the arresting forces. Depending on the brand, lanyards may use technologies such as tearing or stretching.
Using just a steel cable lanyard would exert the most arresting forces on the fallen worker. The steel cable would not give or stretch to absorb any falling forces, so all the forces would be absorbed by the worker.
Nylon rope will give and stretch, so some of the arresting forces are absorbed by the rope. However, nylon rope also has a tendency to spring or bounce back, which would cause the fallen worker to undergo numerous small falls after the initial fall.
The deceleration device will reduce arresting forces by both giving and preventing bouncing. The lanyard will absorb most of the forces to protect the worker from potential jarring forces.
Lanyards must not have any knots or be wrapped around or over any sharp objects.
Copyright ã1999 Business & Legal Reports, Inc.

18. Deceleration Device
Dissipates a substantial amount of energy during a fall arrest
Rip-stitch, tearing, or stretching lanyard
Rope grab device
Retracting lifelines or lanyards
I. Background for the Trainer:
Discuss and demonstrate the different deceleration devices used by your company.
II. Speaker’s Notes:
The deceleration device is used to reduce a substantial amount of energy that is exerted during a fall arrest
Most lanyards utilize a rip-stitch, tearing, or stretching technology. The maximum allowed deceleration distance, or length of lanyard elongation or stretching, is 42 inches. Consider this additional distance when checking to be sure your fall location is clear.
A rope grab device travels on a lifeline and automatically, by friction, engages the lifeline and locks to arrest the worker’s fall. These might be used as part of a ladder-climbing fall protection system.
A self-retracting device allows the line to be slowly extracted from or retracted into a drum that is under slight tension during normal worker activity and movement. Upon the onset of a fall, the device will automatically lock.
Both the rope grab device and the retracting device can be longer than 6 feet, thus giving the worker additional flexibility. If these systems do not have a deceleration device, the worker must wear a lanyard between these systems and the harness.
Copyright ã1999 Business & Legal Reports, Inc.

19. Lifeline Rope or webbed material
Means to connect personal fall arrest system to an anchor
Hangs vertically from one anchor point
Stretches horizontally between two anchors
I. Background for the Trainer:
Demonstrate the vertical and horizontal uses and connections to a lifeline.
II. Speaker’s Notes:
The lifeline is used to connect a personal fall arrest system (consisting of a harness and deceleration lanyard) to an anchor point that cannot be reached by the short lanyard. The lanyard/lifeline connection point in a sense becomes the anchor point. The lifeline is not intended to stretch to add to the length of a fall.
The lifeline can be made of a flexible line such as a rope or cable, or it can be made of a strap or webbing material.
The lifeline can hang vertically from one anchor point to which the lanyard must be connected at the end of the vertical lifeline.
The lifeline can also hang horizontally between two anchor points to which the lanyard can be connected at any point along the horizontal line.
Copyright ã1999 Business & Legal Reports, Inc.

20. Anchorage Located directly above you
Avoid swinging
Clear drop zone
Can withstand 5,000 pounds of force
Don’t use guardrail or other item that may break
Ask a supervisor if unsure about proper anchor points
I. Background for the Trainer:
Your Fall Protection Program should also provide specific tie off or anchor points for each situation in which personal fall protection might be needed.
II. Speaker’s Notes:
The location of your anchor, or tie-off point, is critical. In case of a fall, you do not want to swing and potentially crash into something—so you tie off directly above you. You also do not want to fall very far, so you tie off at shoulder height or above. You also want to make sure the fall space, or drop zone, is clear, so do not tie off to an anchor that will result in your falling onto something such as machinery.
The maximum free-fall distance is 6 feet. Remember, the farther the fall, the larger the arresting forces.
The anchor point must be able to withstand 5,000 pounds of force. The construction industry will use special anchors or create horizontal tie-off lines that are safe to tie onto.
General industry must be careful not to tie to electrical conduit, water lines, guardrails, etc. Remember, there is no point in tying off at all if you plan to tie off to an anchor that will not withstand your fall arresting forces.
Ask a supervisor if you are unsure about proper anchor points.
Copyright ã1999 Business & Legal Reports, Inc.

21. Connectors Connectors are vital Includes self-locking snaphooks
Nonlocking snaphooks cannot be part of personal fall arrest systems
Do not link similar connectors together
Never tie a knot for a connection
I. Background for the Trainer:
Has your company discontinued the use of nonlocking snaphooks for fall arrest systems?
Consider discontinuing the use of nonlocking snaphooks altogether so that they are not accidentally used in a personal fall arrest system.
II. Speaker’s Notes:
Connectors include snaphooks and rings that are used to attach the lifeline, lanyard, etc., to the anchor and the harness.
Self-locking snaphooks will automatically lock shut after they have been hooked. They require the worker to manually unlock the snap hook in order to release it.
Nonlocking snaphooks, which may disconnect themselves, cannot be used as part of a personal fall arrest system. Rings have been known to roll out of nonlocking snaphooks.
Do not attach similar connectors together. For example, do not attach a self-locking snaphook to another self-locking snaphook. Attach a snaphook to a ring connector.
Never use a knot to tie a lifeline, lanyard, etc., to a harness or anchor.
Copyright ã1999 Business & Legal Reports, Inc.

22. Equipment Inspection Inspect before every use
Cuts, tears, abrasions, stitches coming out
Cracks or burrs
Parts move freely
No alterations
Appropriate labels
Record inspection in a log
I. Background for the Trainer:
Does your Fall Protection Program require documented inspections of the fall arrest equipment? If so, pass out the inspection form and review it with the class.
II. Speaker’s Notes:
Inspect the equipment before every use. Inspecting your fall arrest equipment should be a common occurrence because your life is relying on the integrity of the equipment. If it fails when you most need it, you could die.
Check the ropes and straps for cuts, tears, abrasions, loose stitches, etc.
Do the metal components (i.e., snaphooks and rings) have any cracks or burrs?
Do all the parts move freely as designed? Do the snaphooks work easily and then lock correctly? Check the rope grab device or the retracting lifelines to make sure they work correctly.
Inspect the equipment for alterations.
Does the harness and associated equipment contain the appropriate labels?
Any deficiencies noted on the equipment should result in that equipment being tagged as out of service. The equipment should then be sent to the manufacturer for repair or recertification.
Record the inspection on the appropriate inspection log.
Copyright ã1999 Business & Legal Reports, Inc.

23. Rescue Plan Each worksite or facility must have a rescue plan
Employees must be trained on the plan
Limit hanging/ suspension time
I. Background for the Trainer:
Does you Fall Protection Program provide specific rescue plans for each hazardous work area in which personal fall protection devices are utilized? Are employees trained to conduct this rescue? Do you have designated rescuers?
Go over your company’s specific rescue plan details.
II. Speaker’s Notes:
We have rescue plans in place for each work area in which personal fall protection devices are used.
Designated rescuers are aware of the rescue plan.
The goal of any rescue is to limit the hanging/suspension time of the fallen employee.
Copyright ã1999 Business & Legal Reports, Inc.

24. Fall Protection Goals Fall hazards, work rules, and fall prevention
Personal fall arrest system
Quiz
I. Speaker’s Notes:
Do you have any questions concerning fall protection?
Let’s wrap up this training session and have a quiz.
Copyright ã1999 Business & Legal Reports, Inc.

25. Summary Understand and recognize potential hazards
Keep tools and materials organized and away from edges
Reduce arresting forces by limiting fall distance
Decelerate devices to reduce arresting forces
Inspect your equipment prior to each use
I. Speaker’s Notes:
These are the main points you should take away from this session.
Copyright ã1999 Business & Legal Reports, Inc.

26. Quiz
1. Fall protection is required when working 10 feet or more above a lower level. True or False
2. Describe the only work situation in which the use of a body belt is acceptable. ________________________
3. Besides a personal fall arrest system, name two other fall protection systems: ___________and__________.
4. Because of its strength, a lanyard made only out of steel cable is the safest. True or False
5. The arresting force equals your body weight multiplied by _________________________________________.
I. Background for the Trainer:
Remind employees that the quiz is to encourage further discussion and to help you ensure that everyone understands what was discussed in the training session.
Copyright ã1999 Business & Legal Reports, Inc.

27. Quiz (cont.)
6. Your personal fall arrest system should be inspected once per month. True or False
7. Name the piece of equipment that absorbs most of the fall arresting energy: _____________________.
8. Tying a knot for a connector may be done only in few specific circumstances. True or False
9. For fall arrest, connect the lanyard to the D-ring on the front of the harness. True or False
10. What work habit will help prevent injury to both the above ground worker and those below him?
Copyright ã1999 Business & Legal Reports, Inc.

28. Quiz Answers
1. False. Fall protection is required when working six feet or more above a lower level.
2. Body belts may be used only for work restraint.
3. Guardrails, safety nets, controlled access zones, warning line systems, safety monitoring.
4. False. A steel cable provides no give, so all the arresting forces are exerted on the body.
5. Fall distance. To reduce fall distance, always connect to an anchor that is above your shoulders.
Copyright ã1999 Business & Legal Reports, Inc.

29. Quiz Answers (cont.)
6. False. Your personal fall arrest system should be inspected prior to each use.
7. Deceleration device such as shock absorbing lanyard, rope grab device, or a retracting lifeline.
8. False. A knot shall never be used as a connection in a personal fall arrest system.
9. False. The lanyard must be attached to the D-ring on your upper back for fall arrest.
10. Keep tools organized and away from edges to prevent tripping and kicking them over the edge.
Copyright ã1999 Business & Legal Reports, Inc.