FALL PROTECTION HAZARD SURVEY

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Table Of Contents

© Gravitec Systems Inc. 2010 -Page i-

1.0 Introduction

1

2.0 Legislation

2

3.0 Hazard Ranking System

3.1 General

3

3.2 Relative Risk Rating

4

4.0 Hazard Evaluation

4.1 Sample

4.1.1 Access Ladders

5

4.1.2 HVAC on Slanted Roof

7

4.1.3 Bucket Elevator Access

9

4.1.4 Changing Rollers

11

4.1.5 Gangplank Ladder

13

5.0 Hazard Summary

5.1 Hazard Summary sorted by Hazard ID

15

5.2 Hazard Summary sorted by Relative Rank

15

Appendix A – Sample Glossary of Terms

A-1 to A-10

1.0

Introduction:

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1.0

Introduction

This sample survey has been compiled by Gravitec Systems, Inc. to help prospective clients understand the

benefits of the survey service. This document draws from actual surveys completed by Gravitec, with details altered

to maintain client confidentiality. All material is copyrighted by Gravitec Systems, Inc.

This document does not intend to judge current safety practices. Its purpose is to report observed hazards and to

compare them to industry best practices and legislative requirements. The ultimate goal is to elevate the awareness

of current risks and to provide guidance on how to reduce or eliminate them.

Gravitec’s recommendations are drawn from many years of experience, professional affiliations and intimate

knowledge of applicable legislation and consensus standards. The primary focus is on practical solutions that

enhance the work process. The most effective protection often involves training and personal protective equipment

to empower workers to recognize and address the fall hazards by themselves. In some areas, engineered solutions

are proposed if the hazard and frequent exposures warrant more positive protection than temporary systems can

provide. Engineered solutions require less critical decisions from workers exposed to fall hazards. In all cases

where fall protection equipment is required, proper procedures for use and rescue should be written and

accompany the fall protection system for the hazard.

Gravitec follows a hierarchy of fall protection when listing recommended solutions for abating hazards. This

dictates the order of solutions based on limiting of risks to the worker. The hierarchy consists of first eliminating the

hazard, followed by passive fall protection (such as guardrails), then fall restraint, and finally fall arrest. Refer to

Section 4.1 for additional details on the hierarchy. In most cases, based upon a balance between the hierarchy,

cost effectiveness, user friendliness, and some of the Relative Risk Rating information, Gravitec recommends a

hazard abatement solution and indicates that solution with

blue text

. Where more than one solution is indicated

with

blue text,

a combination of solutions may be recommended, or, similar solutions may be recommended from

which the client can select their preferred option.

This document is divided into sections including: Legislation, Hazard Ranking System, Location, Hazard Summary,

and applicable appendices. Each review will contain a color photograph, a relative risk rating, a discussion and

recommendations for improvement. A summary and comparative table at the end of the report identifies all hazards

and ranks them from highest to lowest risks. The subsequent appendices contain illustrations and supplemental

photos referred to throughout the report.

The completed survey will act as a reference tool and prioritize fall hazards to help direct all future fall protection

issues in an efficient organized manner.

2.0

Legislation:

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2.0

Legislation

2.1

General

This section is typically 8 to 12 pages long and summarizes the applicable Federal and State fall protection

regulations related to the client’s needs.

Fall protection legislation and technology are struggling to stay in step with each other, due to a rapid evolution of

available equipment and systems. Sometimes the regulations challenge industry to develop solutions that are not

yet in existence. At other times, new systems and components provide a level of protection that exceeds current

legal requirements.

While a few States still maintain their own OSHA legislation, the majority has fully adopted the Federal

OSHA standards or has enacted supplemental legislation adopting Fed/OSHA with a few modifications or additional

requirements.

The Federal Occupational Safety and Health Administration (OSHA) standards contain a variety of approaches to

providing fall protection:

•

The General industry standard focuses on permanent “conventional” fall protection systems such as

guardrails and ladders. The only section containing well-developed fall arrest requirements is subpart F

(Movable Scaffolds and Platforms). It is important to note that the “General Industry” standard cites use

of the “Construction” standards for many activities not normally understood to be construction work,

including alteration, repair, painting and decorating.

•

OSHA “Construction” standards address a wider variety of fall protection methods/requirements

because of the temporary nature of construction work. Subpart “M” provides several fall protection

methods, many of them highly skill oriented, to address the difficult fall protection issues faced during

construction activities.

When developing fall protection policies, it is prudent to review the requirements in other jurisdictions. This does not

necessarily mean adoption of the most restrictive legislation currently in force since technological improvements are

allowing relaxation of some requirements (such as anchorage strengths and fall arresting distances). Expert advice,

based on knowledge of the legislative and technological trends, is the best way to predict where agreement will be

reached during future harmonization of standards. Corporate policies that are allowed to vary from or improve upon

current legal requirements may provide better protection for the employees and a fall protection program that will

better meet future regulations.

3.0

Hazard Ranking System:

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3.0

Hazard Ranking System

3.1

General

The key objective of a risk assessment system is to rank the hazards and aid prioritization of the

responses.

A true probabilistic rating of the risks associated with each fall hazard is difficult to accurately develop. To

be practical and useful, factors involved in the hazard ranking system must be easily measured and

quantified. Fortunately, factors that are difficult to measure quantitatively may be discounted if we can

presume they uniformly influence the risk and consequences of an accidental fall. This assumption makes

a “Relative Risk Rating” system both possible and useful.

Factors that are not measured in this “Relative Risk Ranking System” are presumed to have a uniform

influence on all the hazards observed in the survey. Unmeasured influences include:

Human Factors such as age, experience, health, training, motivation and state of mind. These cannot

be accurately determined without a detailed interview and examination of each member of the

workforce and could not account for how quickly and often abilities, health, and state of mind can

change.

Uncontrollable Environmental Factors. For example, a true assessment of weather’s influence on the

probability of an accident would require lengthy statistical examination of weather norms and extremes

in respect to the duration, frequency, and time period that outdoor work occurs. In the end, the

assumption that weather will equally affect the safety of all outdoor activities is not far wrong (i.e. snow

increases the risk of a fall in the parking lot just as much as on top of a scaffold).

Working Conditions. These are controlled by the employer, greatly influence the probability of

accidents, and change over time as maintenance, housekeeping, and safety standards improve or

degrade. Nonetheless, the overall condition of an industrial complex is usually uniform according to the

current culture and practices driven or accepted by management. Although the hazard assessment

should critique and suggest improvements to working conditions in a global sense, the relative risk

ranking system only needs to quantify notable variations from the norm to fulfill its purpose of

prioritizing the hazards.

With the assumption that Human Factors, Uncontrollable Environmental Factors, and Working Condition

factors have a uniform influence on the risks faced by workers and employers, we can develop a “relative”

ranking of risks based only on those factors that are more easily measured (directly or statistically).

3.0

Hazard Ranking System:

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3.2

Relative Risk Rating: R = S x T x P

The Relative Risk Rating

(R) of any hazard is a number that is between one (for negligible risk exposure)

and sixty (for extreme risk exposures). It is calculated as the mathematical product of the Severity Index

(S), Protection Index (T), and Probability Index (P). For the purposes of this survey the hazards have been

categorized into 5 groups relative to their ratings and can be seen as follows:

Relative Risk Rating Hazard Rating 0 – 10 Low Risk Hazards 11 – 20 Medium Risk Hazards

21 - 30 High Risk Hazards 31 - 40 Dangerous Risk Hazards 41 or more Extreme Risk Hazards

The relative grouping was designed to match the severity of each hazard. Extreme hazards were designed

to include a larger range of the relative risk rating, because beyond the Dangerous rating the hazard cannot

become more hazardous (e.g. Worker falls from 60 feet or 90 feet). Dangerous and Extreme hazards are

very uncommon and should be abated immediately. Medium and High Risk hazards are very serious and

should not be dismissed due to the Extreme and Dangerous designations.

Severity (S) quantifies the severity or consequences of an accidental fall. It varies from one (1) for minor

consequences to five (5) for extreme consequences.

Probability (P) quantifies the possibility that a fall accident could occur. It is a composite of several

measurable factors and is statistically designed to vary from one (1) for improbable accidents to ten (10)

where a high possibility that a fall accident may occur.

Note that certain (exceptional) combinations of

the sub-indices may result in P being close to zero or 10.

As value of P becomes closer to zero this

indicates proper fall protection is already in place (this would not normally be listed in a hazard survey since

attention is focused on the hazards). As the value of P gets closer to 10 this indicates that almost all of the

measured factors are simultaneously at worst-case value, which should be both a rare and highly

significant occurrence.

Protection (T) assesses what fall protection is currently in use and reduces the Risk Rating accordingly.

Many identified hazards have some level of fall protection applied. For any hazard that has excellent

protection (guardrails / fall restraint) that prevents any type of fall will be reduced considerably so the Risk

number is negligible. For example, a hazard that is high severity and high probability will be reduced to one

tenth if the existing system prevents a fall. A fall hazard that incorporates a compliant fall arrest system will

be multiplied by a factor of 0.25, as fall arrest systems (even compliant systems) have an elevated level of

risk. Hazards where the existing fall protection needs improvement (but is not life-threatening) will be

reduced to three quarters of the original number. Fall hazards that are not protected or have systems that

are life-threatening will not be reduced.

Thus, the highest ranking will occur where an extreme hazard has a frequent probability of occurring and is

unprotected. The usual lowest rankings (< 1) will occur where a fall accident is both improbable, has minor

consequences and has excellent protection. There will be equal ranking of high hazards with minor

probability and minor hazards with high probability to reflect the attention these combinations should

receive in a fall protection program.

4.0

4.1

4.1.1

Hazard Evaluation

Sample

Access Ladders

Top view of edge

Access Ladders

Relative Risk Rating = 18.0

Frequency: 3 1.2 Worker(s) at the location or task is done once or twice per year

Occurrence: 2 1.2 Hazard occurs at two locations.

Proximity: 5 1.4 Worker(s) directly exposed to an unguarded fall hazard or working from a ladder

Duration: 3 1.3 Worker(s) at the location from 1 to 8 man-hours per occurrence, on average

Interference: 1 1.1 All workers are separated or there is only one worker

Security: 4 1.3 Vertical ladder, rebar, bosun chair, hoist, rope access, temp. staging, or similar Environment: 3 1.2 Uncontrolled variables or weather may compromise worker comfort & stability Probability: 2.0 4.5 There is a medium degree of possibility that a fall accident may occur at this hazard Protection: 4 1.0 No fall protection; life threatening

Severity: 4.0 >16 to 30 ft: Likely to cause critical injury, permanent or temporary disability, or death Fall distance is approximately 25 feet from the top of ladder.

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Top view of edge

North Ladder South Ladder

S = 4.0: Critical P = 4.5: Medium X = 1.4: Immediate O = 1.2: Rare F = 1.2: Annually D = 1.3: Medium E = 1.2: Variable I = 1.1: Independent C = 1.3: Vertical T = 1.0: None

4.0

Hazard Evaluation

4.1.1

Access Ladders

Hazard Description

Relative Risk Rating = 18.0 Medium Risk Hazard

Hazard Abatement

Conceptual Solutions:

1. Ladder Climbing Device: There are cable ladder climbing systems that would be permanently attached to the ladder. Workers

would connect to the cable using a very short connection to the worker's frontal D-ring. This type of system would only ensure Task:

Workers bring an A-frame ladder to access the bottom of the fixed ladder on the poles. They climb the fixed ladders to access light boxes.

Hazard:

Workers are exposed to a fall hazard of up to 25 depending on the location of the light box. Current Approach:

There is no additional fall protection used while climbing the ladders. Special Considerations:

None

© Gravitec Systems Inc. 2010 - Page 6 -

would connect to the cable using a very short connection to the worker s frontal D ring. This type of system would only ensure workers fall only a few inches in the event of an accident, as the cam mechanism connected to the cable would lock off very quickly. 2. Work Positioning Device: Once the worker reaches the work area it is difficult to maintain three points of contact with the ladder. A work-positioning device such as a Grillion would allow the worker to work hands free while on the ladder and provides for easy adjustment. A secondary fall protection system would have to be used in conjunction with the work positioning device.

3. 100% Tie-Off Lanyard: There are existing lanyards that have double legs. This allows the climber to have a connection to the anchorage at all times while climbing the ladder. This can be considered a temporary solution as it does not provide adequate fall protection during the climb due to the high clearances required.

Rescue:

Rescue can be accomplished by using a pulley system such as a Swiss Roll or RPD. Notes:

The South ladder requires some attention. There is a great deal of corrosion on the ladder. A thorough inspection of the ladder should be performed and it should be determined if the ladder needs replacement or repair.

4.0

4.1.2

Hazard Evaluation

HVAC on Slanted Roof

HVAC on Slanted Roof

Relative Risk Rating = 8.1

Frequency: 4 1.3 Worker(s) at the location 3-5 /yr; quarterly maintenance, "as needed" work

Occurrence: 1 1.1 Hazard occurs at only one location

Proximity: 4 1.3 Worker(s) from 1 to 3 feet of an improperly guarded fall hazard

Duration: 2 1.2 Worker(s) at the location from 10 to 60 man-minutes per occurrence, on average

Interference: 1 1.1 All workers are separated or there is only one worker

Security: 2 1.1 Not designed for walk & work or outdoor / worker can still navigate relatively easily Environment: 1 1.0 Indoor, climate controlled, clean, dry; worker(s) have adequate environmental PPE Probability: 2.0 2.7 An accident is unlikely, but the possibility should be addressed

Protection: 4 1.0 No fall protection; life threatening

Severity: 3.0 >10 to 16 ft: Likely to cause severe injury or result in temporary disability Fall distance is approximately 50 feet from the edge of the structure.

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S = 1.0: Minor X = 1.3: Very Close O = 1.1: Unique F = 1.4: Monthly D = 1.2: Short E = 1.0: Ideal I = 1.1: Independent C = 1.1: Fair S = 3.0: Severe P = 2.7: Unlikely X = 1.3: Very Close O = 1.1: Unique F = 1.3: Quarterly D = 1.2: Short E = 1.0: Ideal I = 1.1: Independent C = 1.1: Fair T = 1.0: None

4.0

Hazard Evaluation

4.1.2

HVAC on Slanted Roof

Hazard Description

Relative Risk Rating = 8.1 Low Risk Hazard

Hazard Abatement

Task:

Maintenance is conducted on the HVAC unit above the exit. Workers access this area by using a portable ladder to access the roof and then stand or walk on the slope to the HVAC unit.

Hazard:

Workers are exposed to a fall hazard while accessing the roof and during maintenance on the HVAC unit. Current Approach:

Currently, there is no additional fall protection used at this hazard. Special Considerations:

None

Conceptual Solutions:

1. Aerial Lift: An articulating boom lift may be able to access the HVAC unit. While workers are in basket, they must also use a full-body harness in addition to an energy absorbing lanyard (adjustable lanyard is preferred) attached to the dorsal d-ring. Only one

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y gy g y ( j y p ) g y

filter can be reached using an aerial lift.

2. Permanent Access, Guardrail & Swing Gate: A fixed ladder can be installed next to the exit door (on the wall face). The fixed

ladder would allow permanent access and a more secure method of access compared to a portable ladder. Guardrails can be installed along the edge of the wall face, with an integral swing gate at the ladder. Guardrails would afford protection to workers performing maintenance on the HVAC unit within the confines of the barrier.

3. Guardrail & Swing Gate with Temporary Access: Guardrails can be installed along the edge of the wall face, with an integral swing gate. A temporary ladder placed along the wall face would be used to access the swing gate.

Rescue:

Personnel lifts provide the easiest rescue method. Otherwise, the fallen worker could be lowered using a block and tackle system such as the DBI Rollgliss system or the Miller Series 70.

Notes:

Permanent Platforms & Guardrails: A permanent platform can be designed and installed adjacent to the HVAC unit, to provide a level surface for workers. The platform would be supported by columns connected into the sloped roof and would be encompassed by guardrails on all sides, with an integrated swing gate.

The HVAC unit is positioned on a sloped surface. Workers may have difficulty accessing the HVAC unit on the sloped surface, but stairs or terraces could be constructed on the surface to ease the difficulty.

4.0

4.1.3

Hazard Evaluation

Bucket Elevator Access

Bucket Elevator Chain and Bucket Inside Elevator Access Hatch to Vertical Elevator

Bucket Elevator Access

Relative Risk Rating = 24.9

Frequency: 5 1.4 Worker(s) at the location 6-12 /yr; monthly maintenance, "as needed" work

Occurrence: 1 1.1 Hazard occurs at only one location

Proximity: 5 1.4 Worker(s) directly exposed to an unguarded fall hazard or working from a ladder

Duration: 4 1.4 Worker(s) at the location from 8 to 40 man-hours per occurrence, on average

Interference: 3 1.3 Multiple workers in close proximity

Security: 4 1.3 Vertical ladder, rebar, bosun chair, hoist, rope access, temp. staging, or similar Environment: 4 1.3 Continuously slippery, steep, extremely difficult or uncomfortable to navigate Probability: 0.0 6.6 There is a high degree of possibility that a fall accident may occur at this hazard Protection: 3 0.8 Fall protection needs improvement; not life threatening

Severity: 5.0 >30 ft: Extremely likely to cause permanent disability, or death Fall distance is approximately 125 feet from the edge of the structure.

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Bucket Elevator Chain and Bucket Inside Elevator Access Hatch to Vertical Elevator X = 1.4: Immediate O = 1.1: Unique F = 1.5: Weekly D = 1.4: Long E = 1.3: Extreme I = 1.3: Multiple C = 1.3: Vertical S = 5.0: Extreme P = 6.7: High X = 1.4: Immediate O = 1.1: Unique F = 1.4: Monthly D = 1.4: Long E = 1.3: Extreme I = 1.3: Multiple C = 1.3: Vertical T = 0.75: Poor

4.0

Hazard Evaluation

4.1.3

Bucket Elevator Access

Hazard Description

Relative Risk Rating = 24.9 High Risk Hazard

Hazard Abatement

Task:

Workers access the Bucket Elevator on a monthly basis to perform maintenance. There can be anywhere from 2 to 5 workers in this area at one time.

Hazard:

The Bucket Elevator is a confined space that is very cramped and difficult to maneuver in. When inside, the workers are exposed to falls up to 125' depending on where and what level they are working at.

Current Approach:

Workers use lanyards to connect to the chains that raise the buckets up the elevator. Special Considerations:

This area can also be identified as a confined space. All precautions for confined space entry should be adhered to.

Conceptual Solutions:

Engineered Anchor and Vertical Lifeline: Anchors, davit or A-frame could be installed at the top of the hatch for rope or cable

vertical lifelines (VLL) to be attached into. Workers would connect an automatic rope grab with energy absorbing lanyard onto the vertical lifeline and then into the dorsal d-ring on the workers full body harness. This system would be more user friendly than using

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g y y y g

lanyards as the worker would not have to disconnect and connect to anchors every few feet. There could be two VLL's for each worker if they need to move from one to the other.

Engineered Anchor and Energy Absorbing Landyard: Y or 100% tie-off lanyards can be used in the elevator for fall protection. Workers would have to connect to one anchor prior to disconnecting from the last. The lanyards should have large Pelican or Rebar snap hooks on them and have 3600lb gates as the compatibility of many connections inside the elevator may be of question. This system does not provide hands free movement, and can be quite physically draining.

Rope Access System: It appeared as if there was little room to move around inside the elevator and that a rappel system may not work in this confined a space. It may be prudent to attempt to use a rappel system such as an I'D descender for access to this area to make sure. The pros to using such a system, rather than climbing around on the structure inside include: 1. the ability to rescue a fall or incapacitated worker is available right away. 2 the rappel device provides a positioning system that alleviates the physical demands on the worker while trying to access areas inside the elevator.

Rescue: There should be a rescue anchor established at the top of the elevator that an RSRL or man rated hoist can be attached to. If a worker is to be extracted from the elevator he/she can either be raise to the top and lowered over the side or lowered from the position in the elevator to the ground. In the case of an accident the rescuer would lowered the RSRL line to the victim and either have the victim connect the RSRL snap hook to his/her full body harness or an attendant may be required.

Notes: Presently there is no rescue plan in effect in this area. If a worker was to fall and become trapped or incapacitated it would take a great deal of time to extract the worker. This time can be drastically reduced using an effective rescue plan an appropriate equipment that would be available on site. A written fall protection plan should be written for this area. It may be wise for the workers to use a work positioning lanyard (shown in issue 4.3.8) as well as fall arrest equipment in this area so that they can work hands free.

4.0

4.1.4

Hazard Evaluation

Changing Rollers

Changing Rollers

Relative Risk Rating = 8.3

Frequency: 5 1.4 Worker(s) at the location 6-12 /yr; monthly maintenance, "as needed" work

Occurrence: 5 1.5 Hazard occurs at more than 50 locations.

Proximity: 5 1.4 Worker(s) directly exposed to an unguarded fall hazard or working from a ladder

Duration: 3 1.3 Worker(s) at the location from 1 to 8 man-hours per occurrence, on average

Interference: 2 1.2 Two workers on the same work platform

Security: 3 1.2 Difficult structure, I-beams, bracing, structural climbing, pipe racks, trusses etc. Environment: 3 1.2 Uncontrolled variables or weather may compromise worker comfort & stability Probability: 0.0 6.6 There is a high degree of possibility that a fall accident may occur at this hazard Protection: 2 0.3 Adequate fall arrest; acceptable equipment, MAF, clearance, rescue plan, etc. Severity: 5.0 >30 ft: Extremely likely to cause permanent disability, or death

Fall distance is approximately 6 to 50 feet from the edge of the structure.

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X = 1.4: Immediate O = 1.5: Recurring F = 1.5: Weekly D = 1.3: Medium E = 1.2: Variable I = 1.2: Dependent C = 1.2: Poor S = 5.0: Extreme P = 6.7: High X = 1.4: Immediate O = 1.5: Recurring F = 1.4: Monthly D = 1.3: Medium E = 1.2: Variable I = 1.2: Dependent C = 1.2: Poor T = 0.3: Good

4.0

Hazard Evaluation

4.1.4

Changing Rollers

Hazard Description

Relative Risk Rating = 8.3 Low Risk Hazard

Hazard Abatement

Task:

Workers are required to change out rollers every month on the Overland conveyor that are not functioning properly. Workers may be here 2 to 3 hours a day for up to 10 days of the month.

Hazard:

The rollers on the catwalk side are easier to access than the rollers on the far side. In both cases workers are exposed to a fall hazard that varies depending on the location from 6 to 50'.

Current Approach:

Presently workers use anchorage straps and lanyards to access the rollers safely. Special Considerations:

N/A

Conceptual Solutions:

Fall Protection Training: Workers presently use full body harnesses, lanyards and anchor straps for fall protection in this area. It is important that all workers be trained on the use of this equipment as well as educated in the requirements of fall arrest anchors. In

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important that all workers be trained on the use of this equipment as well as educated in the requirements of fall arrest anchors. In all cases workers are determining and making judgments on what is suitable to connect to as a fall arrest anchor. Workers should have the necessary knowledge to ensure that they are making good decisions.

Horizontal Lifeline: A horizontal lifeline could be installed along the length of the conveyor. Workers could use this as the

connection point for fall protection when accessing the rollers for change out. Workers could use RSRL's connected to the horizontal lifeline for fall protection and rescue, if designed correctly this system would lower free fall distances and the possibility of contacting structure while falling, provide more movement for the worker and incorporate rescue into the fall arrest system.

Rigid Rail: A rigid rail system could be used in place of the horizontal lifeline detailed in Solution 2. The advantage of the rigid rail system is that it would eliminate sag in the system, lower vertical loads on the conveyor structure and provide a more solid base for lowering a fallen worker to the ground in the event of a fall.

Rescue: Workers can be lowered to the next level using a block and tackle system such as the DBI Rollgliss system or the Miller Series 70. These systems are easy to use and can raise or lower a victim based on the need of the rescuer. If a new system is install an RSRL (Retrieval Self Retracting Lifeline) could be incorporated into the system to facilitate rescue.

Notes: Reaching some of the rollers requires the workers to climb onto the conveyor structure. This can be difficult and cramped depending on the roller location. Fall protection and rescue plans should be written and adhered to.

4.0

4.1.5

Hazard Evaluation

Gangplank Ladder

Gangplank Ladder

Relative Risk Rating = 15.5

Frequency: 6 1.5 Worker(s) at the location 13-52 /yr; weekly maintenance, "as needed" work

Occurrence: 3 1.3 Hazard occurs at 3 - 10 locations.

Proximity: 5 1.4 Worker(s) directly exposed to an unguarded fall hazard or working from a ladder

Duration: 1 1.1 Worker(s) at the location for less than 10 man-minutes per occurrence

Interference: 1 1.1 All workers are separated or there is only one worker

Security: 4 1.3 Vertical ladder, rebar, bosun chair, hoist, rope access, temp. staging, or similar Environment: 3 1.2 Uncontrolled variables or weather may compromise worker comfort & stability Probability: 0.0 5.2 There is a high degree of possibility that a fall accident may occur at this hazard Protection: 3 0.8 Fall protection needs improvement; not life threatening

Severity: 4.0 >16 to 30 ft: Likely to cause critical injury, permanent or temporary disability, or death Fall Distance is 26 feet off of a portable ladder.

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X = 1.4: Immediate O = 1.3: Common F = 1.6: Daily D = 1.1: Brief E = 1.2: Variable I = 1.1: Independent C = 1.3: Vertical S = 4.0: Critical P = 5.2: High X = 1.4: Immediate O = 1.3: Common F = 1.5: Weekly D = 1.1: Brief E = 1.2: Variable I = 1.1: Independent C = 1.3: Vertical T = 0.75: Poor

4.0

Hazard Evaluation

4.1.5

Gangplank Ladder

Hazard Description

Relative Risk Rating = 15.5 Medium Risk Hazard

Hazard Abatement

Task: Every two weeks, workers secure supply barges to the concrete piers. Workers access the concrete piers by walking along the gangplank to the desired ladder, attaching a ladder climbing device (LCD) to the their harness, and climbing down to the pier. Hazard: Workers are exposed to a 26 foot fall onto the pier or in the water when they are on top of the ladder or transitioning from the ladder to the gangplank.

Current Approach to Fall Protection: Prior to accessing the ladder, workers don a full body harness. Once at the ladder workers connect and use a ladder climbing device. Workers may transition onto the ladder before they connect their ladder climbing device. Special Considerations: The fall hazard exists over water.

Conceptual Solutions:

1. Davit and Retrieval Self Retracting Lifeline: A davit consists of a permanent base and portable davit arm (a post with a

cantilever extension). Permanent davit bases can be positioned near the ladder access points on the gangplank. Each davit base

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cantilever extension). Permanent davit bases can be positioned near the ladder access points on the gangplank. Each davit base provides an additional location where the davit arm can be erected. The davit arm slides into the davit base and a portable self-retracting lifeline (SRL) or portable retrieval self self-retracting lifeline (RSRL) is attached to the davit. The snaphook on the device is connected onto the worker's dorsal d-ring, providing protection while the worker climbs. The lifelines operate identically, except the RSRL has a built in hoist to retrieve fallen workers.

2. Permanent Structure with Retrieval Self Retracting Lifeline: Permanent structures can be designed and installed near the ladder access to provide a connection point for a portable self-retracting lifeline (SRL) or portable retrieval self retracting lifeline (RSRL). The snaphook on the device is connected onto the worker's dorsal d-ring, providing protection while the worker climbs. Rescue: A conscience fallen worker may be able to perform self rescue on the ladder or pier. If a RSRL is being used, then workers can be brought up to the gangplank using the RSRL. Otherwise, the worker could be moved using a block and tackle system such as the DBI Rollgliss system or the Miller Series 70.

Swing Gate: Swing gates can be installed on each ladder access to protect any individual occupying the plank.

Notes:

In each of the above conceptual solutions the ladder climbing device would be removed from the ladder. Any portable device mentioned should be moved to a storage container after use, to protect the equipment from environmental wear. A hazard still exists as the workers access areas around water. The following solutions address those issues:

Relative Rank

Hazard

Rating Hazard ID General Location Location ID Hazard Description Conceptual Solution

18.00 Medium 4.1.1 Sample Access Ladders Fall distance is approximately 25 feet from the top of ladder. Ladder Climbing Device/ Work Positioning Device/ Y Landyard 8.10 Low 4.1.2 Sample HVAC on Slanted Roof Fall distance is approximately 50 feet from the edge of the structure. Lift/ Permanent Access/ Temporary Access

24.90 High 4.1.3 Sample Bucket Elevator Fall distance is approximately 125 feet from the edge of the structure. Vertical Lifeline/ Energy Absorbing Landyard/ Rope Access System 8.30 Low 4.1.4 Sample Changing Rollers Fall distance is approximately 6 to 50 feet from the edge of the Training/ Horiztontal Lifeline/ Rigid Rail

15.50 Medium 4.1.5 Sample Gangplank Ladder Fall Distance is 26 feet off of a portable ladder. Davit/ Structure and RSRL/

Hazard Summary

5.1 Summary - Sorted by Hazard ID

Relative Rank

Hazard

Rating Hazard ID General Location Location ID Hazard Description Conceptual Solution

24.90 High 4.1.3 Sample Bucket Elevator Fall distance is approximately 125 feet from the edge of the structure. Vertical Lifeline/ Energy Absorbing Landyard/ Rope Access System 18.00 Medium 4.1.1 Sample Access Ladders Fall distance is approximately 25 feet from the top of ladder. Ladder Climbing Device/ Work Positioning Device/ Y Landyard 15.50 Medium 4.1.5 Sample Gangplank Ladder Fall Distance is 26 feet off of a portable ladder. Davit/ Structure and RSRL/

8.30 Low 4.1.4 Sample Changing Rollers Fall distance is approximately 6 to 50 feet from the edge of the Training/ Horiztontal Lifeline/ Rigid Rail 8.10 Low 4.1.2 Sample HVAC on Slanted Roof Fall distance is approximately 50 feet from the edge of the structure. Lift/ Permanent Access/ Temporary Access

- Page 15-© Gravitec Systems Inc.

Appendix A

© Gravitec Systems Inc. 2010 Page A - 1 Fall Protection Definitions

Appendix A – Sample Glossary of Terms

100% Tie-Off –

A method of transferring from one a

or

to another using two sets of

or a

. The user must remain connected to at least one a

/

while advancing to connect to the

next.

100% Tie-Off Lanyard

– See

.

Access –

The act of moving towards, or the route taken to reach, a location or working point. Opposite of

.

Adjustable Lanyard –

A

with special hardware which allows the user to change its length. This ability is very important

when establishing a

and to minimize the

in a

. Adjustable Lanyards

must meet the requirements of the ANSI Z359.1 - 2007 standard.

Anchor Sling –

A short length of wire rope or webbing with eyes or loops at each end that is used to encircle a

in a

basket configuration. When connected to a

, it transfers the fall arrest impact to the underlying structure at the

Secure Point

. Anchor Slings must meet the requirements of the ANSI Z359.1 - 2007 standard.

Anchorage

– a secure connecting point capable of safely withstanding the impact forces applied by the

. A fall

arrest anchorage must be independent of any anchorage used to support or suspend platforms.

For

, the forces at the anchorage are significantly higher than those generated by vertical

Fall Arrest Systems

. The anchorage must be designed, installed and used as part of a complete fall arrest system,

under the supervision of a

, maintaining a factor of safety of at least two.

In vertical

, the anchorage must be capable of supporting 5,000 lbs. per person unless it has been

designed, installed and used as part of a complete

, under the supervision of a

,

maintaining a factor of safety of at least two.

Anti-Ratchet SRL –

A

with technology that prevents

when used with a flexible

with

significant ability to deflect elastically (dynamic bounce).

Approved –

Deemed acceptable by a qualified and responsible authority.

Articulating Boom Lift –

A

with knuckles in the boom that allow it to reach over, around, under, or through

obstructions. It provides tremendous ability to position the guarded platform or bucket at locations that could not otherwise be

reached by straight

or

.

Auto Locking –

will automatically lock when released and will not unlock without at least two deliberate motions by the user.

Automatic Descent Control Device –

A

that automatically regulates the speed of descent. Users of

Automatic Descent Control Devices are lowered to the ground at the rated speed. These devices highly suited to emergency

Egress

from an elevated location to the safe lower level.

Automatic Fall Arrester –

A

that will freely travel up and down a

, smoothly following with the

movement of the user. In the event of a fall, the device will lock onto the

. Automatic Fall Arresters must meet

the requirements of the ANSI Z359.1 - 2007 standard.

Automatic Rope Grab –

See Automatic Fall Arrester.

Ballasted Anchor –

An

that rests on, but isn’t mechanically connected to, the underlying structure. It uses its own

weight and/or the lateral friction it develops with the underlying structure to resist the imposed forces.

Beam Clamp –

A

that mechanically connects to a flanged beam. Beam Clamps may be permanently or

Appendix A

© Gravitec Systems Inc. 2010 Page A - 2 Fall Protection Definitions

Boatswain’s Chair –

A simple

used for

, typically incorporating a rigid seat and a

suspension bridle. Users sit on the seat which is suspended from a higher

. A

, separate from the

Boatswain’s Chair, must be provided in case the Boatswain’s Chair system fails or the user falls out.

Body Support Device –

A strap or assembly of straps that securely encircle a user’s body and provide hardware for the

attachment of

between the user and an

. A

and a

are the two most

common Body Supporting Devices. OSHA only permits

when connecting to a fall arrest system.

Boom Lift –

A powered mobile

that uses a hydraulic boom to raise and lower a fully guarded personnel platform

or bucket. The Boom is often mounted on a turntable to enable movement of the platform or bucket in any direction (up &

down, side-to-side and forward & back). Boom Lifts may have mobility even when the boom is raised. The booms are flexible

enough that they may bounce when travelling and in extreme cases may reject the operator from the bucket or platform. Users

of Boom lifts must wear a

and use a

(such as an

connected to a

Fall Arrest Anchorage

on the Boom or in the Bucket or Platform.

Cantilever Arm Horizontal Lifeline System –

An outdoor

that uses poles on strong foundations to

elevate the

. The poles extend cantilever arms over the area to be protected so that vehicles such as trucks,

busses, and railway cars can be positioned directly beneath the

.

Carabiner –

An oval ring with a gate on one side that, when open, allows objects to pass into and out of the interior of the

Carabiner ring. A Carabiner allows users to couple and uncouple components of a

. Carabiners can be

obtained in three basic configurations –

(illegal in

),

(not recommended for

Fall Protection Systems

) and

(recommended for

). Carabiners used in

should meet the requirements of the ANSI Z359.1 – 2007 Standard.

Catwalk System –

A fully guarded platform or series of platforms, ladders and stairs that are permanently erected adjacent to

an elevated working point. The worker does not have to follow any special work procedures or receive training to be properly

protected from falling.

Certified –

Approved, in writing, by a qualified and responsible authority as meeting applicable regulations or standards.

Clearance –

The distance from the working platform to the highest obstruction that a user might encounter during a fall. A

calculation of required clearance must account for the

,

,

and

. To

minimize the risk of injury, a fall arrest system must stop all user(s) within the available clearance.

Clearance Buffer –

A short distance (safety factor) between the user of a fall arrest system and the highest lower level or

structure at the instant of fall arrest. Gravitec recommends that the clearance buffer is at least 2 feet.

Compatible Connection –

A connection that uses hardware that eliminates the possibility of accidental

.

Hardware

must be locking or auto-locking and be sized so that gates on

and

cannot be loaded in a

manner that might cause or force

.

Compatible Hardware –

Connection Hardware that eliminates the possibility of accidental

. Compatible Hardware must

be locking or auto-locking and be sized so that gates on

and

cannot be loaded in a manner that might

cause or force

or

.

Competent Person –

In this document, a person who is capable of identifying existing and predictable fall hazards and who has

authorization to take prompt corrective measures to eliminate them.

Confined Space –

An enclosed or partially enclosed location with restricted means of

and

that is not normally

intended for human occupancy except for the purposes of performing work and which may become hazardous to human

occupants.

Connecting Means –

a device or component used in a fall protection system to couple a body supporting device (preferably a

Full Body Harness

) to an anchorage. Connecting Means include

,

,

, and

.

Appendix A

© Gravitec Systems Inc. 2010 Page A - 3 Fall Protection Definitions

Control Line –

a line that marks the perimeter of a

that may also serve as a

if it

meets the requirements for that system.

Controlled Access Zone –

An area within a worksite where access is controlled and limited to trained and authorized

personnel. When fall hazards are being protected by a

the Controlled Access Zone must be clearly marked

by a

and directly supervised by a

.

“D”- Ring –

“D”-shaped ring that meets the requirements of the ANSI Z359.1 - 2007 standard. “D”-Rings are used at the

designated connecting points on

equipment such as

,

, and

and are usually sized to

allow a

to the (smaller)

used in most

.

Davit Arm –

A vertical pole with a cantilever arm extending horizontally to provide an elevated

that is horizontally

offset from the Davit Arm’s foundation. Davit Arms are often used for a rescue, retrieval and/or

. Davit Arm’s

often anchor a

or a

on the arm and use a sheave at the end

of the arm to redirect the lifeline vertically downwards. Davit Arms may pivot on their bases to swing a raised casualty onto the

adjacent platform or ground. Davit Arms should be designed by a

.

Davit Base –

A structural foundation for a

. Davit Bases may be permanent or portable and must be designed by a

Qualified Person

.

Death Grip –

During the panic of a fall, the act of grasping a

(

) so tightly that it is held open

and prevents it from locking onto the

, overriding the ability of the system to safely arrest the fall.

Deceleration Distance –

The distance fallen between the engagement of a fall arrest system and the point of

. The

Deceleration Distance is determined by the interaction and combined response of all components of the

(including deployment of

, stretch of

and

, Sag of

, etc.)

Certain limited circumstances (such as

and when using a

) legislative bodies will accept

greater Deceleration Distances under the approval of a

, so long as available

are not exceeded.

Descent Control Device –

A device that uses friction to dissipate energy and control or stop the descent of the user. See

Automatic

and

.

Dorsal “D”- Ring –

The mandatory

connection point on a

. The Dorsal “D”-Ring is correctly

positioned between the shoulder blades on the user’s back. Note that

and

and

Work Positioning Systems

allow frontal or sternal “

to be used.

Dorsal Attachment –

Connection of the

to the

, between the shoulder blades on the back of

a

. Dorsal Attachment to a

is required in all

. Note that in a

,

or

to the Full Body Harness is permitted.

Egress –

The act of exiting, or the route to exit, from a location or working point. Opposite of

.

Energy Absorbing Lanyard –

A Lanyard that incorporates a

or other means to reduce the impact force

on by the user and the

during a fall. Energy Absorbing Lanyards reduce the impact but increase the

Arrest Distance

. They must meet the requirements of the ANSI Z359.1 - 2007 standard. Most manufacturers offer models that

keep the impact forces below 900 lbs., using

.

Engineered Anchorage

– An

that has been designed and approved by a Qualified Person, maintaining a factor of

safety of at least two.

Fall Arrest –

The action or event of stopping a fall. The instant where the downward fall has been stopped.

Fall Arrest System –

A system designed to stop one or more persons from striking a lower level or obstructions if a fall occurs.

Most Fall Arrest Systems (except

) require the use of a

, a

a suitable

Appendix B

© Gravitec Systems Inc. 2010 Page B - 1

Fall Protection Training

Advanced Training –

development of the advanced knowledge and skills needed to safely improvise Fall Protection

Systems. Topics must include understanding of the regulations, familiarization with the variety of equipment that may be

selected when developing a fall protection system, inspection care and maintenance of all equipment, proper use of Body

Holding Devices, calculation of required and available Clearances, emergency procedures and recognition of dangerous

situations. Advanced Training is needed by construction and maintenance personnel who must correctly judge when and how

to set-up a Fall Protection System in a wide variety of situations. Duration is typically 12 to 16 hours depending on the variety

of equipment and techniques that may be applied.

Basic Training –

development of the minimum knowledge and skills needed to safely use specific, fully developed Fall

Protection Systems. Topics must include familiarization with the regulations, inspection care and maintenance of all equipment

to be used, proper use of Body Holding Devices, emergency procedures and recognition of dangerous situations. Basic

training is usually adequate for personnel who are provided with complete systems and who do not need to make choices

about when and how to use fall protection. Examples include working in Personnel Lifts or using a few fully developed Fall

Protection Systems. Duration is typically 6 to 12 hours depending on the number and complexity of fully developed systems

that will be used.

Competent Person Training –

development of highly advanced knowledge and skills needed to develop and safely direct

others in the use of Fall Protection Systems. Topics must include thorough knowledge of the regulations, familiarization with a

wide variety of equipment and systems, inspection care and maintenance of all equipment, proper use of Body Holding

Devices, calculation of required and available Clearances, basic rescue/emergency procedures and recognition of dangerous

situations. Competent Person training is needed by trainers, on-site or corporate authorities and advisors who assist or make

decisions regarding the Fall Protection Systems to be used in a wide variety of situations. Duration is typically 40 hours to

cover the current range of available equipment and techniques.

Industrial Rescue Training –

development of advanced aerial rescue skills. Topics must include thorough knowledge of the

regulations, familiarization with a wide variety of equipment and systems, inspection care and maintenance of all equipment,

proper use of Body Holding Devices, calculation of required and available Clearances, aerial rescue/emergency techniques,

first aid, packaging of casualties for transport, and recognition of dangerous situations. Rescue training is needed by on-site

rescue teams or by mobile work teams who cannot wait for professional teams to respond when a fall emergency occurs.

Duration is typically 20 to 40 hours depending on prior fall protection training.

Qualified Person Training –

development of specialized skills and knowledge to meet OSHA requirements for a Qualified

Person. Topics must cover Competent Person Training plus specialized knowledge in one or more of the following areas: fall

protection plans; selection, approval or design of anchorages with less than 5,000 lb strength; dealing with free falls greater

than six feet; precise Clearance calculations; behavior/design/erection/approval of Horizontal Lifeline Systems. Qualified

Person training is recommended for persons writing, reviewing or approving Fall Protection Plans; engineers designing or

certifying Fall Protection Systems and Anchorages; safety management hiring or overseeing engineering consultants.

Duration is typically 20 to 30 hours in addition to Competent Person training, depending on the topics covered.

GRAVITEC SYSTEMS, INC. 21291 Urdahl Road NW Poulsbo, WA 98370

800 755 8455 www.gravitec.com

engineering training equipment testing

PROTECTING WORKERS AT HEIGHT