Procedures Manual

SECTION 7
FALL PROTECTION PROGRAM
 Health & Safety Policy and
Procedures Manual
1. FALL PROTECTION
A. OSHA References: 29 CFR 1926 Subpart M (500- 503)
B. General: The purpose of this program is to prevent work-related injuries
resulting from falls. The prevention of these incidents will accomplished by
the use of fall prevention and fall arrest methods, the training of effected
employees and aggressive enforcement by all levels of management. In
addition
C. Application: This policy applies to all company employees who may be
exposed to fall hazards in the course of their daily activities. This program
also applies to non-site personnel, visitors or any individual on site exposed
to a fall hazard. Unless otherwise specified, fall protection is required at
elevations of 6 ft. or greater for the following work activities.
Examples of areas were employees may have to be protected include but
are not limited to the following:
1. Leading edges
2. Hoist areas
3. Holes in walk surface
4. Framework and reinforcing steel
5. Ramps, runways, and other walkways
6. Excavations
7. Working over Dangerous equipment
8. Roofing work on low or steep sloped roofs
9. Precast concrete construction
10. Wall openings
11. Scaffolds
12. Aerial lifts
13. Overhand brick laying
D. Subcontractor’s Plans: Subcontractor plans will meet or exceed the
requirements of this program. Plans must be submitted to the company
project manager before beginning work. Plans must identify the person or
persons responsible for monitoring the safety of the employees. (Competent
Person). Site-specific plans must be submitted for any specialized fall
protection. In an example:
1. Controlled access zones
2. Warning line system
3. Safety Monitoring System
E. Responsibilities: In addition to responsibilities previously outlined in the
Site Safety Program, the site safety coordinator or designated competent
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person for fall protection will be responsible for the training of all effected
company employees and enforcement of the company policy). Competent
persons must be able to recognize, warn and communicate with employees
that may be exposed to a fall. Also, the competent person must be
designated and assigned the task and be able to accomplish the following
while workers are exposed:
1. Recognize fall hazards
2. Warn employees if they are unaware of a fall hazard or is acting in
an unsafe manner
3. Be on same working surface and in visual sight
4. Stay close enough for verbal communication
5. Not have another assignment that would take monitors attention
from monitoring the function.
F. Training: The instructor shall be adequately trained in the fall protection
system in use and shall be responsible for training all potentially exposed
employees during the new employee orientation. In the event a new system
is employed, additional training on this system will commence immediately
for all effected employees.
1. Training will include, at a minimum:
a) The company fall program requirements.
b) Identification and elimination of fall hazards on the job site.
c) Safe work in hazardous areas.
d) Hazards associated with working near fall hazards.
e) Selection, use, care and inspection of fall protection
equipment.
2. All training must be documented in the following manner:
a) The date of training.
b) The employees printed name and signature.
c) The printed name and signature of trainer.
d) The specific subjects covered in the training session.
e) Testing results (if any).
G. Retraining: When the employer has reason to believe that any effected
employee who has already been trained does not have the understanding
and skill required under employee training, the employer shall retrain each
such employee. Circumstances where retraining is required include:
1. Changes in the work place were previous training is obsolete.
2. Changes in the type of fall protection systems or equipment were
previous training is obsolete.
3. Inadequacies in an employee knowledge or use of fall protection
system or equipment indicate that the employee has not retained the
training provided.
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H. Accountability And Enforcement: All field personnel will be held
accountable for the enforcement and compliance with this program.
Documented safety inspections, repeat discrepancies, accident
investigation and implementation of accident investigation
recommendations will provide the criteria for effectiveness of enforcement.
Failure to comply with this policy will result in the following:
1. First offense: A written warning notice will be issued to the
employee or employing subcontractor.
2. Second offense: The employee will be dismissed from the work
site.
3. Subcontractors: Subcontractor’s who fail to effectively enforce fall
protection requirements or whose employees consistently violate fall
protection requirements will be requested to leave the work site for
failure to comply with contract requirements.
I. Hazard Identification And Elimination:
1. Compliance with fall protection requirements will be a mandatory
item for all documented safety inspections. Fall protection
inspections will focus on the following hazards:
a) Scaffolds
b) Ladders
c) Steel Erection
d) Roofing
e) Floor holes
f) Open sided floors
g) Aerial lifts
2. The hazard identification process shall begin in the pre-bid phase
with review of the scope of work, blue prints and drawings. Where
feasible, pre-planning will be accomplished to prevent employees
from being exposed to fall hazards. The following pre-planning steps
must be considered:
a) Order and install stairways with the guardrails already
attached.
b) Request the designer/architect specify proper anchor points
for fall arrest systems.
c) Do not cut opening in the floors or ceilings until the material
is being installed, eliminating the need for hole covers. Attach
all guardrails on open sided floors before employees are
allowed to work on that level.
d) Install stairs, guardrails, and other fall protection equipment
early in the construction phase.
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e) Require subcontractors to install fall protection systems on
horizontal industrial steel prior to installation.
f) Maximize on ground assembly of structure or equipment.
g) Plan for the utilization of aerial lifts for all steel erection and
concrete pre-cast erection.
h) Controlled access zones are not allowed for leading edge
operation at company locations. The work method employed
will include a horizontal lifeline behind the leading edge,
designed for multiple employees, with retractable lanyards
attached for employees working on the leading edge.
Equipment used will not allow employee to travel into the fall
zone of a leading edge.
3. When no other above-mentioned methods have been implemented
a safety monitoring system shall be put in place.
J. Conventional Fall Protection:
1. Guardrails: Guardrail systems incorporate a top rail at 42 inches,
plus or minus 3 inches above the working platform, mid-rail and toe
board. On all company projects, guardrails will be constructed of 2”
X 4” construction grade lumber with posts no more than 8 feet on
center; ¼” or greater wire cable, flagged every 6 feet with high
visibility material; or 1.5 inch nominal diameter schedule 40 pipe with
posts spaced no more than 8 foot on center. All guardrails shall be
capable of supporting a 200-pound force in any direction with a
maximum deflection of 3 inches. These guardrails will be placed in
the following areas:
a) All stair systems.
b) All open sided floors.
c) Around all holes which are too large for hole covers.
d) On all elevator shaft openings.
e) On all excavations over six feet in elevation.
f) All scaffolding with working platforms over 6 feet.
2. Safety Nets: Safety nets will be used only during steel erection
activities, when working over water and on unique projects when
other conventional systems (such as guardrails, hole covers, etc.)
are not feasible. In the vent safety nets are employed, the following
guidelines will be used:
a) Nets will be installed as close as possible under
walking/working surface, but in no case will an employee be
exposed to a fall of greater than 30 feet.
b) Safety Nets will extend outward from the outer most edge of
the work surface in the following manner:
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Fall Distance Extension
Up to 5’ fall 8 foot extension
More than 5’ to 10’ fall 10 foot extension
More than 10’ (do not exceed 30’) 13 foot extension
c) Nets shall be installed in a manner that will prevent an
individual from striking any object below the net.
3. Nets will be installed, tested and inspected by a competent person.
All nets will be initially drop tested with a 400 pound bag of sand as
specified in the OSHA standard and tested each week thereafter.
Results of the tests will be documented. Where tests are not
feasible, a competent person must certify the compliance of the net.
4. Site safety personnel will inspect nets each day. Results of
inspections shall be documented.
5. Nets will be inspected after any occurrence, which could affect its
integrity, such as a steel member falling into the net or shock loading
due to a fall.
6. Any materials, tools, scrap or equipment that falls into the net must
be removed as soon as possible, but no later than the end of the
work shift.
7. Safety net design and connections shall comply with OSHA
standards and manufacturers recommendations.
8. Nets that are found to be out of compliance will be immediately
identified and no work will be performed until the compliance issues
are resolved.
K. Hole Covers: A hole is defined as a gap or void 2 inches or more in its least
dimension in a floor, roof or other walking /working surface. Employees
must be protected from falling into or through holes, including skylights that
are 6 feet or more above lower levels. Where holes exist, they must be
equipped with guardrail systems as described above or covered with a hole
cover as described below:
1. Hole covers will be capable of supporting two times the maximum
intended load. (For roadways and vehicles, two times the maximum
axle load of the largest vehicle expected to pass). For plywood hole
covers, the minimum requirement is ¾ CDX plywood.
2. All covers must be secured when installed so that wind, equipment
or employees will not displace them.
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3. All covers must have the words “DANGER – HOLE COVER” written
on them in high impact, durable color.
4. All covers must be installed to eliminate any tripping hazard.
L. PERSONAL FALL ARREST SYSTEMS/EQUIPMENT:
1. Harness and Lanyard: Only 4 point suspension harness and shock
absorbing lanyards shall be used. Lanyards shall be equipped with locking
snap hooks.
a) The designated competent person shall inspect equipment at
time of issue and periodically throughout the project. The
using employee shall inspect for defect and condition prior to
use and on return after use. Damaged or defective
equipment shall be tagged and removed from the work site
or destroyed and disposed. Shock absorbing lanyards and
harness that have experienced a shock load; pitting, chaffing,
burn holes or chemical exposure shall be immediately
destroyed and disposed to prevent accidental use.
b) All harnesses shall be properly fitted and worn. Equipment
users shall be trained and instructed in the proper selection,
care, use and inspection of fall protection equipment.
c) Caution shall be used in selection of all fall protection
equipment to ensure the proper length and application.
Swing distance shall be considered when selecting
connection points and lanyard or tether length.
d) Fall protection anchor points shall be capable of sustaining
5000 lbs.
e) Specifically engineered slings and or chokers used to provide
anchor points for lanyards shall not extend the fall distance
beyond 6 foot.
Note: All PFAS materials used shall meet or exceed all
applicable ANSI and ASTM standards
2. Self Retracting Lifelines:
a) Self-retracting lifelines are part of a complete fall protection
system, which automatically limits the free fall distance to 2
feet or less, consists of:
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(1) An anchorage point capable of supporting 5000 lbs.
(2) A locking type connector to mount the device to the
anchorage point.
(3) The self re-tracting lifeline with locking snap hook.
(4) A 4 point suspension harness
c) The installation of this device shall be directly over the work
area.
(1) Attached to an anchor point that is capable of
sustaining 5000lbs.
(2) Attached by locking snap hook to the harness “D”
ring in the center of the wearers back.
(3) Only one individual may be attached per unit.
d) Before use, the unit shall be inspected for any indication of
damage, wear or malfunction including worn cable or
damaged locking snap hook.
(1) Pull approx. four feet of cable out of the housing and
allow to retract. Maintain a slight tension on the
cable. The cable shall retract smoothly and
completely. DO NOT ALLOW THE CABLE TO
RETRACT FREELY.
(2) Repairs and adjustments may not be accomplished
in the field. Malfunctioning units will be tagged “do
not use” and removed from the site immediately.
Equipment subjected to a shock load will be tagged
and removed from the site immediately.
Note: All PFAS materials used shall meet or exceed all
applicable ANSI and ASTM standards.
M. Selection And Installation Of Anchorage Points:
1. The selection of the proper anchorage point is critical to the
effectiveness of fall protection. Anchorage points shall be:
a) Capable of sustaining a load of 5000 lbs.
b) Located equal to or above the point of operation.
c) Located above the work area to minimize or eliminate
“swing” in the event of fall.
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2. Anchorage points should be identified and installed prior to lifting
and setting equipment in place.
3. Anchorage points selected should be positioned to allow employees
to immediately connect fall protection equipment without unprotected
travel from anchorage point to anchorage point.
N. Personal Fall Restraint System: A fall restraint system physically
restricts or stops the fall before it occurs. For example, a harness with a cable
attached, which is short enough to halt the employee before they step over an
open-sided floor is considered a fall restraint system. Fall restraint systems
will meet the same requirements of the positioning system and personal fall
arrest system. The anchorage point, however, must be capable of supporting
200 pounds.
O. Positioning System: Positioning systems shall conform to the following
provisions:
1. Positioning devices shall be rigged to prevent a free fall more than 2
feet.
2. Shall be secured to an anchorage capable of supporting at least twice
the potential impact load of an employee’s fall or 3000 lbs, which
ever is greater.
3. Connectors shall be equipped with locking snap hooks and sized to
be compatible with the member to which they are connected.
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2. FLOOR AND WALL OPENINGS: Slips, trips and falls are well known causes of
workplace injuries. These injuries occur when employees fall through floor
opening/sand wall openings. This section provides general guidelines for guarding
off floor and wall openings. It is not possible, however, to cover all potential areas
of concern. The OSHA Standard, other sections of barricading, housekeeping, etc.,
in this manual and our client procedures are additional resources and should be
consulted.
A. General:
1. All workplaces, passageways, storerooms and service rooms must
be kept clean and orderly and in a sanitary condition.
2. Floors must be maintained and drainage, platforms or mats must be
provided for wet surfaces.
3. Floors must be free from protruding nails, splinter, holes, loose
boards, etc.
4. Aisles and passageways must allow sufficient safe clearances for
handling equipment, i.e. forklifts, hand trucks, pallet jacks, etc. They
must be kept clear and in good condition.
5. Permanent aisles and passageways must be marked.
6. Cover and guardrails must be provided for open pits, tanks, vats,
ditches, etc.
7. A load placed on any floor, roof, or other structure greater than that
approved by the building official or indicated on the load approval
plates installed on the facility.
B. Guarding Floor Openings And Holes:
1. All floor openings large enough for an employee’s foot to enter must
be covered.
2. Stairway floor openings must be guarded with standard railings.
3. Ladder way openings or platforms must be guarded by a standard
railing and toe board on all exposed sides.
4. Entrances to ladders from platforms or ladders from platforms must
be guarded by a swinging gate or offset to prevent walking into the
opening.
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5. Hatchways and chute openings must be guarded by hinged floor
coverings or removable railing with toe boards.
6. Hatchways equipped with hinged covers must be guarded when
open.
7. Skylight floor openings and holes must be guarded by standard
screens or railings.
8. Pits and trap door openings must be guarded by covers. When the
cover is open, a person must constantly guard the hazard.
9. Manhole openings must be guarded by covers. When the cover is
open, a person must constantly guard the hazard.
10. Temporary opening guarded must be guarded by a person in
attendance.
11. Floor holes with fixed machinery must be protected so that there is
no opening greater than 1 inch.
12. Platform doors or gates that open directly on stairways must not
reduce the effective platform width to less than 20 inches.
C. Wall Openings (30 Inches High And 18 Inches Wide): These guidelines
apply to wall openings with a drop of four (4) feet or more.
1. Openings must be guarded by rail, fence, barrier, and a removable
toe board.
2. A grab handle will be provided on each side of the opening
approximately four (4) feet above the floor.
3. Guards must be provided for extension platforms.
4. Chute wall openings must be guarded.
5. Window openings with a drop of over four (4) feet and less than
three (3) feet above the platform, must be guarded with standard
grills or slats.
6. Temporary wall openings must be guarded.
7. If materials can fall through wall holes, toe boards or screens must
be provided.
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D. Open-Sided Floors, Platforms And Runways: These guidelines apply
when the open sided floor, platform or runway is four (4) feet or above
ground.
1. Standard railing must be provided.
2. Toe boards must be provided if persons can pass beneath the
opening, moving machinery is beneath the opening, or equipment is
in a position that would create a hazard if contacted by falling
materials.
3. Special purpose runways used for oiling, etc., over 18 inches wide,
may by guarded on one side only when all other hazards are
guarded against.
4. Standard railings must be provided above dangerous equipment i.e.,
tanks, vats, etc.
E. Stairways, Railings And Guards: Stairs with four or more risers must be
provided with protection.
1. Stairs with a width of less than 44 inches must be provided with a
handrail on the right side descending for enclosed stairs.
2. Stairs with a width of 44 inches must be protected on the open side.
3. Stairs of less than 44 inches must be protected on both sides when
both sides are open.
4. Stairs of more than 44 inches and less than 88 inches must be
protected on each side.
5. Stairs of more than 88 inches in width must be protected on each
side and in the middle.
6. Winding stairs must be constructed so that the handrail prevents
walking on tread with a width of less than 6 inches.
F. Standard Railings:
1. Standard railings consist of a top rail, intermediate rail
(approximately halfway from surface to top rail), and posts and must
be no higher than 42 inches.
2. Stair railing must not have a vertical height of more than 34 inches
nor less than 30 inches.
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3. Wood railings must be 2 inches by 4 inches and span must be six
feet or less.
4. Pipe railings must not be less than 1 and ½ inches in diameter and
the span must not be more than eight feet on center.
5. Structural steel railings must be 2 inches by 2 inches by 3/8 inches
and span more than 8 feet on center.
6. Anchoring must be capable of withstanding 200 pounds applied to
the top rail of approximately all railways.
7. Other acceptable railing must have a smooth-surfaced top rail, 200
pounds capacity and provide for equipment protection.
G. Toe Boards: Must be four inches in vertical height, and no more than ¼
inch clearance from the floor. NOTE: More vertical clearance must be
provided if materials are to be stacked above the toe board.
H. HANDRAILS:
1. Attachments to handrails must offer no obstruction to the user.
2. They must furnish an adequate handhold.
3. They must present no projection hazards into the walking or working
area.
4. The height of the handrail must not be more than 34 inches nor less
than 30 inches.
5. Handrails must be capable of withstanding a 200-pound force.
6. Wood handrails must be 2 inches in diameter.
7. Pipe handrails must be 1 and ½ inches in diameter.
8. All handrails must provide a 3-inch clearance from any object or
wall.
I. Floor Opening Covers:
1. Trench/conduit covers in roads must be able to withstand a rear axle
load of 20,000 pounds.
2. Manhole covers must withstand 20,000 pounds.
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3. Covers must not project more than one inch above floor and no
more than 30-degree angle.
4. Sky light screens must be capable of withstanding a 200 pound load
a) Must be installed to prevent deflection to break glass.
b) The grillwork opening must not be more than 4 inches.
c) Slat work openings must not be more than 2 inches.
5. Wall opening rails must be capable of withstanding 200-pound load.
6. Wall opening grab handles must not be less than 12 inches.
a) Must provide for a 3-inch clearance.
b) Must allow for 3 inches of side clearance.
c) Must withstand a 200-pound load.
7. Wall opening screens must withstand a 200-pound load.
a) Grillwork opening must not be more than eight inches.
b) Slat work openings must not be more than four inches.
J. Fall Protection Equipment: All employees working in areas described in
the preceding paragraphs and not protected in prescribed manner must be
equipped with fall protection harness and lanyard. Care must be exercised
in selection of shock absorbing lanyards to insure the proper length.
K. Replacement Of Railings And Coverings: All rails, covers, etc., removed
for equipment installations will be immediately replaced. In no event shall a
floor or wall opening be left unattended or unguarded in the appropriate
manner.
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