Purpose of Fall Protection Systems:
Falls are among the most common causes of serious work-related injuries and death. Employers have a responsibility and legal obligation to ensure that they mitigate these risks by supplying their employees with the correct safety equipment and by ensuring that the correct procedures and systems are put in place to prevent employees from falling off overhead platforms, elevated workstations or into holes in the floor and walls.
In 2024/25 the Health and Safety Executive in Great Britain recorded 124 work-related deaths with Falls from height being the biggest contributor with 34 deaths – 2024/25 (RIDDOR) Reporting of Injuries, Diseases and Dangerous Occurrences Regulations. Source: Work-related fatal injuries in Great Britain – HSE
In South Africa the Federated Employers Mutual Assurance Company (FEM) reported that falls from height accounted for 14% of all fatalities in the construction industry between 2015 and 2024. Source: Falls from Different Levels in the South African Construction Industry – Master Builders KwaZulu-Natal
How to AVOID becoming a Statistic:
Fall Protection is the use of controls (which is a combination of equipment, procedures, and practices) that are designed to protect the worker from falling when working at height or in the event they do fall, to stop them without causing severe injury.
It encompasses various methods, including:
- Fall Prevention which involves putting in place measures to prevent falls from happening, with systems such as guard rails to prevents workers reaching and falling from dangerous edges, and
- Fall Arrest which is equipment used to limit the distance and impact of a fall, with the use of lanyards, harnesses, and anchorage points.
Major risks from falling after a fall is arrested include:
Suspension trauma
Forces on a body, the longer a fall, the more force on a body is experienced
Incorrectly fitted harnesses hazards
Objects in clothes pocket penetrating and piercing the body when under tension
The Basics of Fall Protection (ABC’s)
To utilize a fall arrest system the following components are vital
A is Anchorage – This is a secure point of attachment for connector and body harness that is capable of withstanding significant force and be unquestionably sound. Examples are roofs, scaffolds, steel beam, railing etc.
Some Examples of Anchorage Points are shown below:
B is Body Harness – A safety harness wraps around a worker’s body and connects to the rest of the fall protection system so that if the worker were to fall, the harness would hold the worker up while the rest of the system stops the fall.
C is Connections – A connecting device creates a steadfast connection between a worker’s body harness and an anchoring point. Self-retracting lifelines and fall protection lanyards are the two most common connecting devices yet are distinctly different.
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Fall Protection Lanyard |
Self-Retracting Lifelines (SRL) |
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A Fall Protection Lanyard (or safety lanyard) is a set length of rope, webbing, or wire rope. Designs often incorporate an internal or external shock absorbing feature. · Shock-absorbing lanyards are a bit more versatile and can be used for purposes such as fall arrest, work positioning, or restraint. · Non-shock absorbing lanyards can only be used for restraint. A Fall Protection or Safety lanyards is connected to a fixed anchor point, which can limit the wearer’s work radius. They tend to be less expensive than SRLs, so for smaller jobs or for the budget-conscious manager, they may be a good choice. A traditional lanyard results in a free fall for the entire length of the connecting device before the shock absorbing stitching starts to give way/deploy.
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Self-retracting lifelines (SRL) are designed using webbing, wire rope, or a cable that automatically retracts into a housing unit, never allowing for any slack in the line. SRLs are longer than lanyards and permit a larger working radius and move mobility even when using a fixed anchor point—which is typically overhead. A breaking mechanism inside the housing unit will arrest a worker’s fall, much like a car seatbelt. A self- retractable lifeline is slightly heavier than a safety lanyard and tends to be pricier. An SRL falls results in a decelerated fall and fast-acting fall arrest capability
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How a Fall Arrest System Works:
When using a fall arrest system, it is extremely important to understand and calculate correctly the total fall distance as this will help you to determine what type of fall arrest system and fall protection lanyard or self-retracting lifeline you should be using. When calculating the fall distance, the following factors all need to be considered:
- Length of the Lanyard (in the example below 2m)
- Extension of the energy absorber (in the example below 1.75m)
- Height of the person using the fall arrest system (2m)
- Safety Factor of 1m should always be built in
As a result, in this example where a fall protection lanyard is being used, given the length of the lanyard, energy absorber, height of the person and safety factor the user would need to be working at a height of 6.75m or higher for the fall arrest system to work effectively and prevent the user from landing on the ground before it had an opportunity to stop the fall.
Suspension Trauma
Suspension trauma, also known as harness hang syndrome (HHS) or suspension syndrome, is a life-threatening condition that occurs when a person is left hanging motionless in a fall arrest harness for an extended period. While safety harnesses are essential for fall protection, they can introduce secondary risks if the worker is left suspended for too long without rescue.
Suspension trauma is a form of orthostatic intolerance that occurs when the body’s circulatory system is disrupted due to prolonged upright suspension. Blood pools in the lower extremities, limiting blood flow to the brain and vital organs. If left untreated, this can cause dizziness, unconsciousness, and even death.
The Dromex® DFA-STS01, suspension intolerance leg strap is an invaluable fall arrest system accessory as it is used by a victim of fall arrest to combat the ill effects of suspension trauma, by alleviating and relocating pressure on the body while the user waits for his/her rescue, suspended in his/her harness providing the comfort of standing.
Importance of Training and Maintenance
Training and Maintenance can be the difference between life and death in any fall protection systems.
- Employers are legally required to provide their employees comprehensive training on the proper use, maintenance, and limitations of the chosen fall arrest system.
- Employers MUST also establish a system for regular inspection and maintenance of the fall protection equipment to ensure that it is in good working condition.
PLEASE always refer to the recommended inspection guidelines on each item of the DROMEX fall arrest system equipment.
Risk Assessment MUST be done before any work starts:
Before any work from heights can commence, a comprehensive risk assessment MUST be completed to identify all the risks and ensure that the correct fall protection system has been put in place. This involves identifying fall hazards, evaluating risks, and choosing control measures, often following a hierarchy of controls. This process will assist in selecting the correct system to effectively minimize fall-related injuries and fatalities.
Important Considerations when conducting a risk assessment
- Hierarchy of Controls – Fall protection should prioritize the elimination of fall hazards or the use of fall restraint whenever possible before relying on fall arrest systems. Image referenced https://safesitehq.com/fall-protection-equipment/
- Employer and Employee Responsibilities:
- Employers are responsible for providing a safe working environment, including fall protection equipment, training, and rescue plans.
- Employers are responsible for training their employees and ensuring that all the fall arrest equipment is correctly maintained.
- Employees are responsible for following safety procedures, using the fall protection equipment correctly, and reporting any hazards or concerns that they identify.
Servicing
- Pre-use inspections -Workers must inspect hardware of equipment before use to ensure there is no damage, and the system is in good working order
- Competent person inspection – Competent persons conduct detail thorough inspections regularly such as every 3-6 months or annually depending on usage of equipment, to identify potential issues that may not be visible during a pre-use check. A competent person is trained by the OEM of the equipment.
- Cleaning and proper storage are vital. Dirty equipment can be cleaned with appropriate solutions and procedures. Wet equipment should be air-dried, away from heat sources
- Equipment that has been used to arrest a fall, or is damaged, should be withdrawn from service immediately and properly disposed of to prevent accidental reuse.
- Detailed records of, product certificates, inspections, maintenance, and repairs must be kept on file for the life of the equipment, including the date, findings, and actions take.
Summary
Fall Protection systems help employers to proactively develop a strategy that helps to eliminate or manage a fall or hazard by creating a safe work environment for everyone.
- Worker Safety: The primary goal is to prevent falls and minimize the risk of injury or death to workers. Employees must prioritize worker safety first.
- Legal Compliance: Fall protection plans are often mandated by regulations like OSHA standards in the US or Construction Regulations in South Africa.
- Reduced Liability: Having a comprehensive plan can help reduce employer liability in the event of an incident.
- Increased Productivity: A safe work environment can lead to increased productivity and morale among workers.
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