Download Fall Hazard Recognition, Prevention & Control – and more Exercises Engineering in PDF only on Docsity!
Fall Hazard Recognition, Prevention
& Control –
Students’ Manual
A Program of the
Health & Safety Department
International Union, UAW
This material was revised under grant number SH- 22230 - 11 - 60 - F- 26 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
If you have suggestions or questions, contact: Education and Health & Safety Department, UAW 8000 E. Jefferson Detroit, MI 48214 Phone: 313. 926.
December - 2011
Course Goal
Course Goal – The aim of this program is to provide comprehensive on-site training to high-risk workers (i.e. skilled trades and maintenance workers) and management on Fall Hazards: Recognition, Prevention & Control and the prevention of serious fall injuries at their worksites. Participants will develop an understanding of the hazards associated with falls and how to eliminate or control them.
Section Content Objective
1
Introduction to Fall Hazards
Participants will be able to:
Identify potential factors that contribute to fall hazards. Explain the issues (statistics) associated with falls in the workplace., Describe the intent of a Fall Hazard Identification Program and list the essential elements of an effective program.
2
Identifying Potential Fall Hazards
Participants will be able to:
Process for identifying potential fall hazards List types of potential hazards to workers during non-routine maintenance work. o Trip hazards (extension cords, air hoses, tools, etc…) o Proximity to fall hazard during work. o Location of work (rafters, tops/sides of equipment, reach, etc…) o Slick surfaces (oil, dust, etc…) o Lack of proper lighting
3
Fall Hazard Solutions
Participants will be able to:
Identify training requirements for exposure to fall hazards Hierarchy of Health and Safety Controls Training Requirements for Rescue at Heights Fixed and Portable Standard Railings Fall Protection PPE
4
Identifying Fall Hazard PPE
Participants will be able to:
Discuss the pros and cons of “restraint devices” and “fall protection” Describe areas where permanent attachment points would be necessary Describe the components of fall hazard PPE Identify the inspection process of all fall PPE
5
Action Planning and Course Wrap- up
Participants will be able to:
Provide assistance to help achieve workplace goal of “Preventing” Fall Injuries and Fatalities. Develop “Action Plan” and strategies for implementing a Fall Hazard Program in their facility.
INTRODUCTION
We have all heard the expression - ‘it’s not the fall that’s hurts but the sudden stop at the end’. Think of a fall as “…a sudden, unanticipated descent in space driven by gravity”. Although this may not sound severe, the consequences are often disabling - or deadly. It takes most people about 1/3 of a second to become aware of a fall. It takes another 1/3 of a second for the body to react. A person can fall up to 7 feet in 2/3 of a second.
.33 second/2’
.67 second/7’
1 second/16’
Anatomy of a Fall
In 2006, the Bureau of Labor Statistics (BLS) reported that fatal work injuries involving falls increased 5 percent in 2006 after a sharp decrease in 2005. The 809 fatal falls in 2006 was the third highest total since 1992, when the fatality census began. Fatal falls from roofs increased from 160 fatalities in 2005 to 184 in 2006, a rise of 15 percent. Falls from ladders and roofs still account for the majority of falls. Identifying fall hazards and deciding how best to protect workers is the first step in reducing or eliminating fall hazards. The US Department of Labor (DOL) lists falls as one of the leading causes of traumatic occupational death , accounting for eight percent of all occupational fatalities from trauma. Any time a worker is at a height of four feet or more, the worker is at risk and needs to be protected.
2000 —March, 2008 UAW “Fall” Fatalities
November 16, 2000 – Michael Spears; 28 years old, Grounds Maintenance Worker, 6 years seniority, Chrysler Proving Grounds , Chelsea, Michigan; LU 1284; Region 1A; The victim fell off of the back of a truck as he was picking up traffic cones from the driving course.
March 7, 2002 – John Aue; 52 years old; Millwright (S/T); 32 years seniority; Federal Mogul ; Sparta, MI; LU, Region 1D. The victim was checking for leaking bags in an unlighted dust collector with an ultraviolet (black) light, when he fell 30 feet down an unguarded 60-inch clean air duct.
July 30, 2002 – Samuel R. Heckman: 55 years old, Refrigerator and Air Conditioning Maintenance Journeyman (S/T); 34 years seniority (24 years in classification); GM Allison Transmission , Indianapolis, IN; LU 933, Region 3. The victim was repairing a fan on the roof when he stumbled backwards and fell over a parapet wall , falling 20 feet to his death.
September 2, 2002 – Harold Moyle; 64 years old ; Electrician (S/T) 31 years seniority; General Motors ; Linden, New Jersey; LU 595, Region 9. The victim fell 8’4” through a drop ceiling panel down to a steel floor adjacent to a paint spray booth. The victim was assigned to repair lights and apparently was tracking electrical lines. Access to the space was by a fixed ladder. There was no lighting in the space and it does not contain safe working platforms. The ceiling panel the victim fell through was not secured to any structural beams.
October 30, 2003 - Douglas A. Mellom; 44 years old; Millwright (S/T); 25 years seniority; General Motors; Janesville, Wisconsin; Local 95, Region 4. The victim was on the roof of a freight elevator realigning the safety gate. After he had aligned the gate and as he was attempting to enter the access opening to return to ground level, he fell over the edge of the elevator roof 18 feet to the floor below.
November 22, 2003 – Jeff West; 44 years old; General Welder (S/T); 13 years seniority; Ford Motor Company ; Dearborn, Michigan; Local 600 , Region 1A. The victim fell approximately twenty (20) feet to a basement area during the installation of a stamping machine. He had received numerous injuries including head injuries and died on December 22, 2003.
- A worker walking on top of an elevator to return to the inside of the elevator falls off unguarded side into the elevator shaft.
- A makeshift scaffold with no rails or fall protection results in a 5 foot fall leaving one dead.
- A worker falls through a 60” open pipe 30’ to his death.
Fall hazards are foreseeable. You can identify them, eliminate exposure to them, eliminate them or control them before they result in injuries or death. Some of the factors that contribute to fall accidents and fatalities include: scaffolds; ladders; roofs; tops of equipment and other elevated work surfaces.
Ladders - BLS data show that each year falls from ladders account for approximately 100 fatalities each year. Factors that contribute to falls from ladders are ladder slip (top or bottom), overreaching, slipping on rung/steps, defective equipment, and improper ladder selection for a given task. One of the most frequently cited OSHA ladder violation includes not securing a portable ladder or having it extend 3 feet above the landing before workers use it to reach an upper level.
Falls from a Floor (One Level to the Next) – falls to a lower level is one of the major causes of fatalities. Factors such as improperly covered/protected floor holes are a common fall hazard. It is very easy to step backwards into them or step into them when carrying something that blocks one’s forward view.
Analyzing Work Areas for Fall Hazards
Analyzing the work area is another important step in fall hazard prevention. Analyzing the work area may include: reviewing blueprints before work begins; anticipating upcoming fall hazards as work progresses; reviewing current hazards on the site, and developing a pre-planning checklist.
Review Blueprints Before Work Begins One of the first steps in analyzing the work area should be the review of the blueprints before work ever begins on the site. By addressing fall hazards at this stage, the employer will be better prepared to eliminate the fall hazard or provide fall protection to the employees. The following are suggestions to assist employers in identifying those areas to address.
- At any stage of the job will there be unprotected sides/edges, floors, roof, vertical faces, and open sided floors where a fall hazard exists, if so, here are some options:
Change sequence to remove hazards or exposures Restrict employees from area Can guardrails be used? Can safety nets be used? If guardrails or nets cannot be used, will personal fall arrest or restraining systems, controlled accessed zones, monitoring systems, warning line systems, and positioning device systems be employed?
- Will employees be exposed to floor, or roof opening? If so, will protection be provided?
- Is there the possibility of employees being struck by falling objects, if so, will protection be provided?
- Are scissors or aerial lifts required? And is there a system in place to ensure proper inspection and maintenance of these systems?
- Are operations such as equipment maintenance, roofing, HVAC installation, etc., addressed ahead of time in order to provide fall protection?
- Is there a fall protection policy in place such as: Vertical life lines Other work methods such as installation from aerial lifts
- Are there structural member adequate to meet the requirements for anchor points with personal fall arrest systems?
Anticipate Upcoming Fall Hazards as Work Progresses
- Additionally, unique fall hazards should be addressed before any exposure. The safety director or site fall protection competent person never wants to be caught off guard with surprise hazards or exposures. To avoid, what is known as putting out fires, these individuals must always be prepared. One method is to review the job for the fall hazards that will be present in the future. The following should assist in addressing this issue:
- Review the blueprints for upcoming processes/hazards.
- Discuss the work process with the maintenance manager, superintendents and workers to identify where new hazards may develop.
- Ask the foreman for assistance in recognizing what hazards may develop in the future.
Review for Current Hazards on Site If the job has already progressed beyond the point where review of the blueprints will not be effective, then the site must be reviewed for current hazards. The review for current hazards will allow the fall protection competent person to address the fall exposures in order to eliminate or minimize the hazard.
Pre-Planning Checklist An important aspect of fall hazard prevention is planning. An assessment of all fall hazards, even potential fall hazards, must be done before appropriate corrective measures are considered. In addition, a fall hazard assessment can also determine training needs and fall rescue methods.
If proper planning isn’t done at the onset, time and materials will be wasted and, consequently, unexpected costs will rise. More importantly, fatalities and severe injuries have resulted from simply not making the time or effort to effectively identify and control fall hazards. The following is a checklist to assist you in your efforts to pre-plan for fall prevention/protection. It is preferable that this checklist be used before any designing or work begins to be most effective in eliminating falls and related hazards.
- Begin the process by identifying those areas where exposure to falls will or already do exist such as:
Scaffolds Ladders Roof and roof openings including skylights
- For personal fall arrest systems, are anchor points identified and capable of supporting 5,000 pounds per worker or two times the intended impact load? Additionally, have swing hazards been addressed in the anchor point location?
- Has an enforcement policy been established, and if so, is it communicated universally, accepted and enforced?
- Have fallen worker rescue methods and procedures been addressed?
- Are employees trained to work at heights safely?
- Have other work methods been proposed or implemented such as:
a. Working from aerial or scissor lifts. b. Assembling structures on the ground and lifting them into place, minimizing exposure. c. Installing safety nets under work level or self-retracting lanyards, vertical and horizontal lifelines materials to be hoisted aloft before the pieces leave the ground and workers are exposed. d. Installing clamp-on guardrails around roof edge instead of using a warning line system.
- Have free fall considerations been addressed including:
a. Total free fall clearances are adequate for system in use. b. Employees will not strike lower objects in the event of a fall. c. Employees will not be exposed to forces greater than 1,800 foot lbs. in a full body harness
Fall Hazard Prevention
The hierarchy of fall hazard control includes: elimination of fall hazards, prevention (Engineering Controls) of falls, and control (Training and PPE) of falls.
MOST
EFFECTIVE
1. Elimination or
Substitution
change process to be able to perform task at ground level
2.^ Engineering Controls^
Install platforms and guard railing Utilize boom or scissor lifts Install tie offs where work from heights are necessary.
3.^ Warnings^
signs
4.^ Training & Procedures^
Safe job procedures Safety equipment & inspections Rescue at Heights LEAST EFFECTIVE
5. Personal Protective
Equipment
safety harnesses and lanyards Portable Guard Rails
Elimination of fall hazards is the first and best line of defense against falls from heights. This requires a careful assessment of the workplace and the work process itself. The idea is to combine safety and health into the work process, and not simply try to add safety as an afterthought to an inherently unsafe work procedure. The prevention of fall hazards is the second line of defense when fall hazards cannot be entirely eliminated. This involves making changes to the workplace to preclude the need to rely on the employee’s behavior, and personal protective equipment to prevent falls. Examples include use of stairs, guardrails, and barriers to prevent the employee from direct and unprotected exposure to the fall hazard. These techniques prevent the fall before the onset.
Control of falls is the last line of defense. It should be considered only after determining that the fall hazard cannot be eliminated or prevented. Fall controls include fall protection such as safety nets or harnesses, and fall arrests. These controls reduce the risk of injury resulting from a fall.
“Step 1” Determine if walking/working surfaces are structurally sound
Does the walking/working surface have the strength and structural integrity to safely support all employees and their equipment?
Employees should not be permitted to work on building roofs and other walking/working surfaces until the employer has determined that the surfaces are structurally sound.
Fall hazards are present everywhere simply because any walking or working surface can provide them. In addition, many skilled trades workers work at various levels of elevation, increasing the severity of injury.
“Step 2” Conduct a Fall Hazard Assessment
Knowing what can immediately contribute to a fall can help in assessing the risk. Working near unguarded edges, lacking safe access, or walking on a slippery or uneven surface are some common examples. A fall hazard assessment greatly helps identify and evaluate these physical fall hazards.
- Determine which specific jobs, activities or areas expose employees to fall hazards
- Determine the type of work performed
- Determine if employees will be exposed to any of the following: Unprotected sides and edges Leading edges Floor holes Wall openings and hoisting areas Slippery surfaces Ramps, runways and other walkways Portable ladders and stairways Working above dangerous equipment Obstructions (materials) Working overhead and related work Roof work Aerial lifts Scaffolds
- Determine the frequency the work is being performed
- Determine if workers require horizontal and/or vertical movement
- Determine the number of workers exposed to a fall hazard (Skilled trades and/or operators)
- Determine the type of walking/working surface
- Determine the distance to floor level
- Determine if the edge of the building or the working surface is protected by a guardrail system or parapet wall. If yes, is it adequate?
- Determine if employees could be exposed to other types of health and/or safety hazards. Can it affect selection or use of fall protection systems?
The person conducting the assessment should have some education and/or relevant experience in order to recognize and evaluate all fall hazards. Furthermore, this person should also have practical knowledge and understanding of fall protection requirements and other related fall protection methods.
A competent person is someone who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are hazardous or dangerous to employees, and has authorization to take prompt corrective measures to eliminate them.
Various sources of information can be used when conducting the hazard assessment including:
- Survey employees exposed to the fall hazards
- Survey affected supervisors & managers
- Review previous inspections
- OSHA 300 & 301 records
- Injury and incident reports
- Safety committee minutes
Remember - involving employees and supervisors in the hazard assessment is essential. They can provide valuable information about where and when fall protection is necessary and ideas to possibly eliminate or better prevent fall hazards. Obtaining their input will also encourage employees and supervisors to take ownership. If the hazard assessment indicates the need for fall protection, the next step is to determine if the fall hazard(s) can be eliminated through engineering controls and/or alternative work methods.
- Redesign the process or job task
- Work at lower heights
- Use equipment that prevents fall hazards, boom lift, scissor lift and platforms that provide built-in fall protection
- Use tool extensions and work from ground level
- Lower equipment and tools to ground level
- Use appropriate aerial lifts
“Step 3” Eliminate the Need for Fall Protection if Possible
- Design buildings and other walking/working surfaces to eliminate/reduce exposure
Planning Comes First!
Eliminate
- Work from ground
- Walls/enclosures
- Covers Prevent
- Railings
- Aerial lifts
- Fences/barricades
- Parapets Arrest
- Personal fall arrest systems
- Personal fall restraint systems
- Nets
- Positioning devices
- Roof brackets/slide guards
components may include a lanyard, a deceleration device, and a lifeline. However, the personal fall-arrest system is effective only if you know how all of the components work together to arrest the fall. Guardrail systems are vertical barriers consisting of top rails, midrails, and intermediate vertical members. Guardrail systems can also be combined with toe-boards, which are barriers that prevent materials and equipment from dropping to lower levels. Safety net systems consist of mesh nets, panels, and connecting components. They are typically used as protection for those who work 25 feet or more above lower levels. Fall-restraint system consists of an anchor, connectors, and a body harness or a body belt. Unlike the personal fall-arrest system (designed to stop a fall), the fall-restraint systems prevent a fall. The fall-restraint system’s anchor must support at least 3,000 pounds. Otherwise, it must be designed, installed, and used under the supervision of a qualified person. Position-device system enables the worker to work with both hands free on a surface such as a wall or other vertical structure. They are typically used as protection for concrete form work and placing rebar. The difference between a positioning-device system and a personal fall-arrest system is that the positioning device system supports the worker on an elevated surface and limits a fall to two feet. Warning-line systems consist of ropes, wires or chains, and supporting stanchions that form a barrier to warn those who approach an unprotected roof side or edge. The lines mark off an area which one can do roofing work without using guardrails or safety nets. Safety-monitoring system is a set of procedures assigned to a competent person for monitoring or warning workers who may be unaware of fall hazards. Safety-monitoring systems are appropriate for roofing operations on low-slope roofs less than 50 feet wide. A safety monitoring system used in conjunction with a controlled access zone and a fall-protection plan is also appropriate in situations where conventional fall protection is not feasible. Controlled-access zones is a work area designated and clearly marked in which certain types of work may take place without the use of conventional fall protection systems – guardrail, personal arrest or safety net – to protect the employees working in the zone. When using a personal fall arrest system, employers must provide for prompt rescue in case of a fall or assure that employees are able to rescue themselves. Rescue comes down to planning and preparing. Some important points to consider:
- Train your rescuers in rescue techniques and practice rescue attempts
- Ensure available equipment is readily available
- Arrange and communicate with other personnel on site
- Arrange and communicate with outside services, if available
- Designate someone to summon them upon arrival
- Plan a route and establish lines of communication
- Avoid “Orthostatic Intolerance” – (See Appendix D)
- Signs & symptoms of orthostatic intolerance:
- Faintness Nausea
- Breathlessness Dizziness
- Sweating Unusually Low Heart Rate
- Paleness Unusually Low Blood Pressure
- "Graying" or Loss of Vision Increased Heart Rate
Step 5 Develop Rescue/Retrieval Procedures
First and foremost, when it comes to equipment inspection and maintenance - follow manufacturer’s recommendations!
All fall protection equipment , including harnesses, lanyards, and other connectors must be visually inspected before each use.
Inspect for:
- Cuts, tears, rips, snags, punctures, abrasions, mold, or stretching
- Alterations or additions which might effect the system’s efficiency
- Damage caused by acids, corrosives
- Distorted hooks or faulty hook springs
- Cracked, broken, or deformed D-Ring, carabiners, grommets, and snaphooks
- Loose, damaged or non-functioning mountings and parts
- Wearing or any internal deterioration in the ropes
- Color fading possibly indicating UV exposure Periodic inspections by a competent person for wear, damage, or corrosion should be a part of your safety inspection program. Defective equipment must be immediately taken out of service and tagged/marked as unusable, or destroyed.
Best Practice – destroy when subjected to any significant damage or loading. Basic care of the equipment will prolong the durable life and will contribute toward the performance of its vital safety function. Proper storage and maintenance after use are as important as the pre-use inspections.
Clean the equipment of dirt, corrosives, or other contaminants. Storage areas should be clean, dry, and free from exposure to fumes or corrosive elements. Synthetic materials should always be away from strong sunlight and extreme temperatures which could degrade the materials (color fading may indicate UV exposure).
“Step 6” Develop an equipment inspection, maintenance and storage
program
Each employee who may be exposed to fall hazards must be trained on how to recognize fall hazards and the procedures they need to follow to minimize these hazards. The construction standard requires the person providing the training be a “competent person” qualified in the following:
- Nature of fall hazards in work area
- Correct procedures for erecting, maintaining, disassembling, and inspecting fall protection systems
- Use and operation of controlled access zones and guardrail, personal fall arrest, safety net, warning line, and safety monitoring systems
- The limitations on the use of mechanical equipment during the performance of work
- Correct procedures for the handling and storage of equipment and materials and the erection of overhead protection
- Employees role in fall protection plans
- Collect and distribute “success stories” about injuries prevented by the use of fall protection
- Formally recognize employees, supervisors, and all involved!
Review
We have covered a lot of material in this section. Let’s review some of the concept of the eight step approach to fall protection by having participants do the case studies on fall prevention.
Activity: discuss and analyze these case studies using the guidelines in the eight step approach. Have available various types of fall protection equipment to help in the analysis and discussion.
Participants may want to try on and discuss the features of this equipment.
Fall Hazard Identification Exercise
Activity #1: Circle the fall hazard(s) in each of the following 8 picture. How many fall potentials did you circle? ______.
Picture #
Picture #
