Common Workplace Hazards and Engineered Fall Protection

Hazards are an inherent part of the industrial workplace, but they don’t have to be a source of accidents. From the slippery floors of a food processing plant to the open ledges of a high-rise construction site, the risks are diverse. While administrative controls (like signs) and PPE (like helmets) are important, they are at the bottom of the “Hierarchy of Controls.” To truly eliminate hazards, businesses must look toward engineering. Engineered fall protection provides a structural solution to human problems, effectively removing the variables that lead to workplace injuries.

By analyzing the most common hazards found in modern workplaces, we can see exactly how engineered systems provide a superior level of defense compared to traditional methods.

1. The Hazard: Unexpected Leading Edges

In many warehouses and manufacturing hubs, mezzanines and loading docks create “leading edges” where the environment is constantly changing. A dock door might be open one minute and closed the next.

The Engineered Solution: Instead of relying on a worker to remember to close a gate, engineered fall protection utilizes self-closing gates or dual-gate systems. These are designed so that one side is always closed while the other is open, ensuring a barrier between the worker and the drop at all times. These are mathematically tested to withstand the weight of a person stumbling against them, providing a much higher safety factor than a simple chain.

2. The Hazard: Low Fall Clearance Areas

Many indoor maintenance tasks happen at heights of 10 to 15 feet, over production lines or aircraft wings. In these “low headroom” scenarios, a traditional six-foot shock-absorbing lanyard is actually dangerous. By the time the lanyard expands to catch the worker, they have already hit the machinery or floor below.

The Engineered Solution: This is a classic case where engineered fall protection is essential. Engineers will specify a “Rigid Rail” system. Unlike a cable that sags when weight is applied, a rigid rail has zero deflection. When paired with a Self-Retracting Lifeline (SRL), the fall is arrested in inches rather than feet, making work in tight spaces safe.

3. The Hazard: Crane Rails and Overhead Tracks

Maintaining overhead cranes or conveyor systems often requires workers to walk along narrow beams high above the factory floor. These areas are notoriously difficult to protect because there are no walls to attach guardrails to.

The Engineered Solution: Overhead horizontal lifelines are engineered to be mounted to the existing building columns. These systems allow the worker to glide along the track while tied off from above. Because the system is engineered specifically for that building’s steel capacity, it can support multiple workers simultaneously, allowing a team to perform maintenance safely without cluttering the floor with scaffolding.

4. The Hazard: Human Error and Complacency

Perhaps the most common hazard of all is the human element. Even the best-trained employees can have a “lapse in judgment” or a moment of fatigue.

The Engineered Solution: Engineered systems prioritize “passive” protection whenever possible. If you install an engineered perimeter guardrail, the hazard is effectively eliminated. The worker doesn’t have to “do” anything to be safe, the environment itself is safe. When active systems are necessary, engineered fall protection makes them as “idiot-proof” as possible through clear markings, intuitive connection points, and smooth-gliding shuttles that don’t snag or frustrate the user.

Hazard Mitigation: A Comparison

Conclusion

The goal of any safety program should be the total elimination of risk. While we cannot always remove the need to work at heights, we can remove the danger of falling through engineered fall protection. By addressing specific hazards, like low clearance, swing falls, and fragile surfaces, with custom-designed solutions, we create a workplace where safety is a built-in feature, not an optional add-on.

Frequently Asked Questions

1. What is the “Hierarchy of Controls”?
   A: It is a system used to minimize or eliminate exposure to hazards. It ranks solutions from most effective to least: Elimination, Substitution, Engineering Controls, Administrative Controls, and PPE. Engineered fall protection falls into the “Engineering Controls” category, which is much more effective than PPE alone.
2. Can engineered systems be used in wash-down or corrosive environments?
   A: Yes. Engineers can specify materials like 316 stainless steel or galvanized coatings to ensure the system doesn’t degrade in harsh chemical or saltwater environments.
3. How do I identify a “Leading Edge” hazard?
   A: A leading edge is any walking-working surface where the edge is not protected by a wall or guardrail and changes location as work progresses (like during decking). Engineered “Leading Edge” (LE) lanyards and anchors are specifically designed to handle being pulled over a sharp corner.