Fall Safety Guide

FALL SAFETY GUIDE

PREVENTING WORKPLACE FALLS

HORIZON SOLUTIONS

Fall Safety is Critical

The Most Common Workplace Accidents

Whether employees are working at height or walking
down an office hallway, slips, trips, and falls happen in
workplaces across every industry. In the latest report-
ing available from the U.S. Bureau of Labor Statistics,
31.5% of all occupational injuries requiring missed
workdays were the result of these types of accidents.
Fatalities due to slips, trips, and falls increased 11% in
2019. And according to OSHA, 35.5% of workplace
fatalities were the result of falls.
Almost all these injuries and fatalities could have been
prevented with appropriate safety measures in place,
including proper maintenance, safeguards, training,
and personal fall arrest systems (PFAS).
This guide is designed to help you protect person-
nel and prevent slips, trips, and falls while improving
safety practices and avoiding hefty fines.

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Preventing Slips, Trips, and Falls Page 4
Stepping Up Ladder Safety Page 6
Raising Working at Height Standards Page 9
Providing Fall Protection Page 12
Training Employees to Prevent Falls Page 14
Fall Prevention Checklist Page 16

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HORIZON SOLUTIONS

Preventing Slips, Trips, and Falls

Slips, trips, and falls are commonly caused by wet, oily, or messy workplaces. Sorbents, matting, and
housekeeping can prevent such injuries. And fall arrest equipment and training are critical when working at
height, and ladder safety is also critical in providing a safe workplace.
Let’s start by breaking down each type of incident.
⏹ Slips – Loss of balance caused by a lack of traction. Slick surfaces caused by spills and weather hazards are

most often the issue. Inattention, hurrying, and inappropriate footwear can be contributing factors.
⏹ Trips – Loss of balance caused by a foot striking an object. Walkway obstructions, loose equipment, and

untethered cords are often the cause. Inattention and hurrying can be contributing factors.
⏹ Falls – Loss of balance causing bodily contact with the ground or another object. Falls can occur when

a body is moved too far off-center balance and/or when proper PFAS is unavailable or used improperly.
Inattention and hurrying can be contributing factors.
These types of workplace accidents come down to three key factors:
⏹ Friction – The resistance that one surface or object encounters when moving over another.
⏹ Momentum – The motion of an object, measured as a product of its mass and velocity.
⏹ Gravity – The force attracting an object toward the center of the Earth.
When friction is lacking and/or momentum is too great, the results can be devastating, causing debilitating
injuries and even death.
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5 Steps to Minimize Risks

When friction is lacking and/or momentum is too great, the results
can be devastating, causing debilitating injuries and even death.

#1. GENERAL HOUSEKEEPING

⏹ Ensure your workplace is kept clean and sanitary.
⏹ Keep floor areas clean and dry.
⏹ Keep walkways, stairways, and paths clear of debris and refuse.
⏹ Be sure rugs or matting is secure with edges and corners flat

on the floor.
⏹ Winter ice should be addressed immediately.
⏹ Water and spills should be cleaned up or the area marked off until cleared.

#2. AISLES AND PASSAGEWAYS

⏹ Clear the area of hazardous obstructions.
⏹ Be sure to label permanent aisles and passageways properly.
⏹ Each aisle must be wide enough for PITs (powered industrial trucks) or handling equipment.
⏹ The minimum requirement for emergency route walkways is 28 inches.

#3. COVERS AND GUARDRAILS

⏹ Provide covers, shields, and/or guardrails to protect workers from exposures to hazards of open pits, tanks,
vats, ditches, or similar structures.

⏹ Protect workers performing or exposed to “hot work,” generating welding or grinding sparks, riveting
projectiles, and light.

#4. STAIR STANDARDS

⏹ Stairs must be provided where regular access is required to move from one level to another and must be
constructed to carry five times the anticipated live load and never less than a 1,000 lb load.

⏹ Fixed stairs should have a minimum width of 22 inches. If tread is present, it should be constructed out of
reasonably non-slip material or coating.

#5. RAILING STANDARDS

⏹ Railings and toe boards must be used (regardless of height) to guard: open-sided floors, walkways,
platforms, and runways above or adjacent to dangerous equipment.

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HORIZON SOLUTIONS

Stepping Up Ladder Safety

OSHA’s walking and working surface safety regulations include working from ladders. One of the most popular
workplace tools in both construction and general industry can often pose a safety risk when used incorrectly.
Many workplace accidents involve falls from ladders. And all these falls could and should have been prevented
by following safe practices.
Even though many companies include ladder safety in their annual safety training program, people still
use ladders unsafely. Safety training is an important element in any safety culture, reinforcing policies and
procedures. It’s also important to frequently assess conditions at facilities and around work sites to ensure proper
precautions are taken to avoid injuries.

12 Tips for Improving Ladder Safety

Here are a few OSHA regulations that must be followed in the workplace and should also be followed when
working at home.

#1. SELECT THE RIGHT LADDER FOR THE JOB

Ladders should have legible labels on the side rail that indicate the total weight load allowed and ladder
classification, including the worker, tools, and materials allowed. And, that label must also indicate the safe
working height. OSHA requires that these labels be in place and visible.

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#2. DON’T OVERREACH

The most common safety error is overreaching. This can cause
a step ladder to topple or an extension ladder to slide sideways
along a surface. Injuries are often serious and sometimes fatal.
Overreaching is considered moving a shoulder past the center
line of the ladder.

#3. MAINTAIN THREE POINTS OF

CONTACT

Three points of contact must be maintained when climbing and working on a ladder. That means a combination
of hands and feet. If a task requires both hands to be free, a scaffold, scissor lift, or other elevated platform
should be implemented.

#4. FACE THE LADDER WHEN CLIMBING AND WORKING

To maintain balance, it’s critical that the body is pointed toward the ladder at all times. Twisting, bending, and
turning can disrupt that balance and cause a fall.

#5. LADDERS ARE DESIGNED FOR ONE PERSON AT A TIME

It’s never safe for more than one person to be on a ladder at one time. Not only does it disrupt the balance of
the ladder and the people on it, but it also puts multiple people in danger.

#6. USE STEP LADDERS AS INTENDED

When using a step ladder, all four feet must be on a flat, level surface. Never climb a step ladder that is leaning
against a wall or support. Do not step higher than the third step from the top. Paint/tool trays that fold down on
the back of a step ladder are not steps and not designed to support a person, nor are the rungs on the back of a
step ladder.

#7. MIND LIMITS FOR EXTENSION LADDERS

Extension ladders come in many forms and have defined limits for use. They should always extend three feet
beyond the top ledge of the building. Often, two workers are required to set the ladder up properly. Ergonomic
injuries often occur when ladders are caught by a gust of wind or snag on a tree branch. The base of the ladder
should be one foot out from the wall for every four feet of elevation. This provides the safest angle, and most
ladders have flats on the rungs that meet this angle. And again, the label should be in clear sight on the side rail.

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HORIZON SOLUTIONS

#8. BEWARE OF ELECTRICAL CONTACT

When doing electrical work, use non-conductive ladders made of wood or fiberglass. Electrical shocks can cause
or compound fall injuries and even cause death.

#9. KEEP HANDS FREE FOR CLIMBING

Tools and equipment should be brought up in a tool belt, not carried by hand. Additionally, you can use
tethering devices for the safe use of portable power and hand tools at height. Not only does keeping your hands
free prevent falls, but it will also help you avoid dropped-from-above accidents.

#10. INSPECT LADDER CONDITION REGULARLY

All ladders should be inspected for damage, missing labels, condition of non-skid pads, hardware, latches, ropes,
pulleys, and cleats. Damaged ladders must be taken out of service until repairs are made.

#11. TETHER STORED LADDERS

Stored ladders of any kind must be tethered to a wall or support. Many injuries take place when a ladder is
bumped and tips onto nearby workers.

#12. GET VERTICAL LADDERS INSPECTED

Fixed vertical ladders require complete inspection on a regular basis depending on environmental and use
conditions. OSHA regulations regarding the safety devices for these ladders have changed recently.

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Raising Working at Height Standards

The term “working at height” refers to work performed above another level, including ladder, scaffolding, roofs,
or near an edge or opening. The common denominator for working at height is the potential to fall to another
level if proper safety precautions aren’t in place.
Someone is working at height if they are working:
⏹ Above the ground or another level.
⏹ Near an edge or ledge.
⏹ Near an opening or on a fragile surface.
Falls from height result in a greater risk for serious injuries and fatalities.

Top 3 Hazards When Working at Height

Recognizing conditions that make working at height dangerous can help you prevent workplace falls. Whether
you’re developing a fall protection plan or performing a hazard assessment, identifying hazards can help you
mitigate them.

#1. LEADING EDGES AND SHARP EDGES

Understanding the difference between leading and sharp edges can mean the difference between life and
death. Each presents unique hazards and requires the right equipment to keep workers safe.
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HORIZON SOLUTIONS

⏹ Sharp Edge – An edge that is not rounded that can
cut and/or completely sever most types of lifelines. The
smaller the edge radius of the edge, the sharper it is.

⏹ Leading Edge – ANSI A10.32-2012 defines a leading
edge as the “unprotected side or edge during periods
when it is actively or continuously under construction.”
Leading edge hazards occur when a fall protection system
is anchored at foot level behind the worker. When that
worker moves away from the anchor point, there is a
potential to fall over the edge.

Sharp edges endanger workers when lifelines become frayed,
cut, or severed entirely. These equipment conditions can cause
falls to a level below, resulting in serious injuries. Leading edges
can pose additional risks, including:

⏹ Increased Fall Distances – With leading-edge work,
employees are often attached at foot level, which means
they will fall further than if they were anchored at shoulder
height or overhead. In these situations, employers need
to take fall clearance into account and provide PFAS
designed for leading-edge applications.

⏹ Lock-up Speed – Self-retracting lifelines anchored at foot
level may not react to a fall over a leading edge until the
worker’s D-ring passes over the leading edge. That means
they may have fallen five feet or more before the self-
retracting lifeline engages to arrest the fall.

⏹ Increased Fall Arrest Forces – The further a worker falls
before fall-arrest systems engage, the greater the impact
on their body. Employers should provide PFAS that are
rated for leading and sharp edge work and contain energy-
absorbing devices.

⏹ Increased Potential for Swing Fall Hazards – Even in
a harness, hanging off an edge is dangerous. The danger
increases significantly if a worker is swinging, and the lifeline
is stretched over a sharp edge. The motion can fray or cut
the line, leading to a fall.

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#2. FALL CLEARANCE

Fall clearance is the minimum distance needed between a person’s feet and the level below to prevent them
from hitting the ground or striking any other object. In the event of a fall, there must be sufficient clearance to
allow for fall arrest. Calculating fall clearance is critical for safety when working at height.
To prevent impact in working at height situations, add the appropriate factors together to determine the fall
clearance required. This calculation will provide the safe required distance below the anchorage connection
point. Here is a simple equation for determining the required distance:
Required Distance = Lanyard Length + Deceleration Distance + Work Height + Safety Factor

⏹ Lanyard Length – The length of the lanyard or retractable device connected to the harness anchorage
point.

⏹ Deceleration Distance – The distance between the start of the fall to when the fall arrest system engages.
OSHA limits this distance to 3.5 feet or less.

⏹ Work Height – The height where the work is taking place.
⏹ Safety Factor – Additional safety distance below the

worker.
The height and weight of the worker should also be
considered when determining fall clearance.

#3. DROPPED OBJECTS

While PFAS can protect workers from fall impacts and
save lives, they cannot protect people on the ground from
objects dropped when working at height. Though falls top
OSHA’s Fatal Four, “struck by an object” comes in second
with an estimated 10% of workplace deaths resulting from
falling, swinging, or misplaced objects. Employers can
mitigate these risks by investing in fall protection for tools.

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HORIZON SOLUTIONS

Providing Fall Protection

Workplace falls can cause injuries and fatalities, especially for employees working at height. All of these can be
prevented with the right fall protection.
OSHA requires employers to take measures to prevent falls from overhead platforms, elevated
work areas, and holes in the floor and walls. And employers must provide fall protection to
anyone working at elevations of four feet in general industry, five feet in shipyards, six feet
in the construction industry, and eight feet in longshoring operations. Additionally, OSHA
requires employers to provide fall protection for those working over dangerous equipment and
machinery, regardless of the fall distance.

3 Fall Protection Basics

#1. SAFETY MANAGEMENT SYSTEMS

All falls are preventable if you engineer the risk out. We can generally classify safety
management systems into passive and active.
⏹ Passive systems include guardrails, scaffolding, limiting lanyards, etc. to prevent a fall from

occurring.
⏹ Active systems include safety nets, personal fall arrest gear, harnesses, etc. to prevent an

impact should a fall occur.
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⏹ Other options include sky lifts, bucket lifts, scissor lifts, mobile ladders, and rolling ladders.
Each of these options has its subset of best practices as well as formally published guidelines.

#2. THE ABCs AND THE Rs OF FALL PROTECTION

Appropriate personal fall protection systems (PPE gear) must be
available and in use. Here’s a quick look at the ABCs of fall protection:
⏹ Anchor: How is your lanyard attached and secured to a structural

point? Who inspects that structural point? Who installs the
attachment?
⏹ Body: Does your team have harnesses readily available that fit
properly? Do they know how to properly don their gear and use
it throughout a workday? Are they wearing it all the time or just
sometimes?
⏹ Connection Device: What types of hardware connect a user to a
lanyard or self-retracting lifeline and/or to an anchor point?
⏹ Retrieval and Rescue: A person fell, but they didn’t hit the
ground. How will you rescue and retrieve them safely? Do you have
suspension trauma straps?
And don’t forget I is for Inspection. Is all your fall protection equipment
inspected annually by a competent person?

#3. JOB HAZARD ANALYSIS

A JHA is a job hazard analysis. Look at the situation, determine how to do it safely. The goal is to develop,
implement, and enforce a safety and health program that addresses
hazard recognition and avoidance of unsafe conditions.
A JHA (also known as a fall protection plan) is required whenever a
worker is working at height. Government regulations require written
plans be available to all workers. The plan must be available at the
worksite before work where there is a potential for a fall. Workers
affected by the fall protection plan must be trained in all its elements,
including the rescue plan.

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HORIZON SOLUTIONS

Training Employees to Prevent Falls

Employers must provide a training program for every employee exposed to fall hazards. The training must be
taught by a competent person and address the following:
⏹ Nature of fall hazards in the work area.
⏹ Correct procedures for erecting, maintaining, disassembling, and inspecting the fall protection systems to

be used.
⏹ Use, operation, and limitation of guardrail systems.
⏹ Personal fall arrest systems, safety net systems, warning line systems, and safety monitoring systems.
⏹ Controlled access zones and flaglines.

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HORIZON SOLUTIONS

Fall Prevention Checklist

From minor stumbles to major drops, slips, trips and falls account for tens of thousands or injuries and deaths
each year. This is a sample safety checklist to help you assess your workplace safety and identify areas for
improvement.

General

⏹ Inspection: Equipment must be regularly inspected by a competent person with the date documented.
⏹ Program: There must be a written fall protection program that is regularly reviewed.
⏹ Plan: Written rescue and retrieval plan.
⏹ Records: Fall protection training records for employees.

Ladders

⏹ Use only proper ladders or portable steps to access high shelves or cabinets.
⏹ Ladder safety training for employees.
⏹ Ladder labels and markings in place.
⏹ Ladders tethered when stored.
⏹ Fixed vertical ladder annual inspection.
⏹ Two workers to handle extension ladders.
⏹ Safety climb systems must be installed at 24 feet or higher fixed vertical ladders (FLV).
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Scaffolds

⏹ Labels for weight and height restrictions.
⏹ Qualified person to inspect assembly.
⏹ Guarding in place.
⏹ Documented training for affected workers.

Slip, Trip, and Fall Hazards

⏹ Keep walkways, stairways, and paths clear of debris and refuse.
⏹ Be sure rugs or matting is secure with edges and corners flat on the floor.
⏹ Winter ice should be addressed immediately.
⏹ Water and spills should be cleaned up or the area marked off until cleared.

Stairways

⏹ Handrails on stairways should be in place and firmly mounted.

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HORIZON SOLUTIONS

SAFETY FROM TOP TO BOTTOM

Products, services, and training to promote safety compliance.

As an employer, you must identify hazards in your workplace and take steps to eliminate or minimize them.
Workplace safety training provides your employees with the knowledge and skills they need to protect
equipment, facilities and, most importantly, each other. Safety not only ensures that all your workers return home
safe and healthy every day—it increases brand reputation, improves efficiency and worker morale, and ultimately
saves you money.

If you want to start a safety program or boost an existing one, give us a call at (800) 724-4750. We have safety
specialists, authorized OSHA Outreach Instructors on staff, and offer a range of resources to support you as
you develop a more efficient and safer workplace.

Safety Services

⏹ Plant Hazard Assessment
⏹ Annual Lockout/Tagout Audits
⏹ LOTO Consulting & Implementation
⏹ Confined Space Requirements
⏹ Fall Protection Competency & Inspection
⏹ Conformity Audits
⏹ Machine Safety
⏹ Safety Circuit Analysis
⏹ Arc Flash Studies & Remediation
⏹ Comprehensive Workplace Safety Training & Prevention Programs
⏹ And More

Safety Products and Gear

⏹ Arc Flash PPE & Clothing
⏹ Cleanroom Supplies & Equipment
⏹ Lockout/Tagout
⏹ Machine Guarding
⏹ Fall Protection

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⏹ Respiratory Protection
⏹ Eye & Face Protection
⏹ Facility Marking & Signs
⏹ Hand, Head, & Hearing Protection
⏹ Floor Mats
⏹ Sorbents
⏹ And More

Training and Prevention Programs

⏹ Arc Flash Safety Awareness
⏹ Arc Hazard Prevention & Protection
⏹ Lockout/Tagout Awareness
⏹ OSHA Electrical Hazards, 29 CFR 1910, Subchapter S
⏹ Fall Protection Awareness – anchor, body, connections, and rescue (ABC-R)
⏹ Fall Protection Inspectors
⏹ Fall Protection Competent Person
⏹ Wind Energy Fall Protection
⏹ Machine Standards
⏹ Machine Guarding
⏹ Ergonomics Awareness – avoiding repetitive motion injuries and relieve strain
⏹ Eye Protection 101 & RX Eyewear Solutions
⏹ Virtual Classroom – Machine Functional Safety and ISO 13849 System Design: Risk Assessment
⏹ Hearing Protection
⏹ Respiratory Protection
⏹ Sorbents
⏹ Spill Protection
⏹ Welding Safety
⏹ And we can create a curriculum that meets your specific needs

Contact us today to learn more about our workplace safety solutions:
Email [email protected].

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[email protected] Rexelusa.com

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