Attachment_4_PR_F2KDAC4091A001_Leader's_Guide.pdf

LEADER’S GUIDE:

FALL PROTECTION PROGRAM

Leader’s Guide: Fall Protection Program Preface

Falls are the leading cause of work-related injuries and fatalities in construction accidents nationwide, and are ranked as second in general industry. According to the Bureau of Labor Statistics (BLS), most work-related injuries and fatalities are on the decline. However, the number of fall-related injuries and fatalities is increasing, accounting for more than 13% of the total number of fatal work injuries. In the United States, approximately 3 fall-related fatalities occur each working day.

From an Army perspective, injuries to soldiers and civilians sustained from falls can significantly impact resources and hinder mission capability. Protecting the workforce is a responsibility shared by everyone, at all levels of the organization. However, it is you, the leader, who makes a unique contribution to job safety in that you are aware of the skills, physical condition, capabilities, and limitations of your people. You know the job, and have the authority to inspect, correct, and direct. No one is in a better position to prevent accidental falls in the workplace than you. This Leader's Fall Protection Safety Guide is designed to establish criteria for fall protection programs in order to heighten awareness and protect Army personnel exposed to fall hazards in the workplace.

Table of Contents

Section I

INTRODUCTION ----------------------------------------------- 5

Section II

DEFINITIONS ---------------------------------------------- 7

Section III

RESPONSIBILITIES ------------------------------------- 14

Section IV

TRAINING REQUIREMENTS ------------------------ 18

Section V

FALL PROTECTION PROGRAM ---------------------------- 22

Section VI

FALL PROTECTION SYSTEMS AND GUIDELINES ------------------ 24

Section VII

INSPECTION, MAINTENANCE, STORAGE AND CARE PROCEDURES FOR FALL PROTECTION

EQUIPMENT ---------------30

Section VIII

TIE-OFF CONSIDERATIONS -------------------------------------- 34

Section IX

FALL PROTECTION AND PREVENTION (FP&P) PLANS & RESCUE AND EVACUATION

PLANS (REP) ------------- 34

Section X

FALL PROTECTION SYSTEM DESIGN REQUIREMENTS ------------------------- 38

Section XI IDENTIFICATION, USE, CERTIFICATION AND RE-CERTIFICATION OF ANCHOR POINTS --------- 47

Section XII

FALL PREVENTION CONSIDERATIONS DURING PLANNING AND DESIGN --------50

Section XIII

REFERENCES -------------------- 54

Appendices

Appendix A.

PART I INSTRUCTIONS FOR USING FALL PROTECTION WORK PLAN MATRIX ---------------- 55

PART II HOW TO IDENTIFY FALL HAZARDS IN THE WORK PLACE UTILIZING WORK PLAN

MATRIX ----------- 57

SECTION 1: FALL PROTECTION PLANNING ----------- 57

SECTION 2: DESCRIPTION OF FALL ARRREST/ RESTRAINT METHODS ---------60

SECTION 3: INSPECTION AND INSTRUCTIONS FOR ASSEMBLY/DISASSEMBLY AND

STORAGE --------- 64

SECTION 4: WARNING SYSTEMS AND FALLING OBJECT PROTECTION ------------------65

FALL PROTECTION WORK PLAN MATRIX -------------------------------------------68

Appendix B.

FORMS ----------------------------------------------------- 69

1-1 EMERGRENCY RESCUE PLAN FORM ------------------ 69

1-2 FALL PROTECTION TRAINING ROSTER ------------- 70

Appendix C.

SAMPLE FALL-PROTECTION PROGRAM ------------------71

Appendix D.

FALL-PROTECTION EQUIPMENT INSPECTION CHECKLIST --------75

Illustrations ---------------------------------------------------------------- 77

Section I Introduction

This guide provides leaders with the basic tools necessary to establish, implement and sustain a Fall Protection Program in accordance with Chapter 3 of AR 385-10, The Army Safety Program, which adopts OSHA safety standards and directs Army compliance. The goals of the program are:

a. To prevent the occurrence of falls by Army personnel (soldiers, DA civilians, and contractors) from elevations. The threshold limit for providing fall protection is mandated by the US Code of Federal Regulations (CFR). Depending on the standard applied, this height can be from 4 to 6 feet. The standard fall protection height for personnel is 4 feet in accordance with (IAW) 29 CFR 1910; construction site workers will adhere to the threshold height of 6 feet IAW 29 CFR 1926.500, Subpart M, and US Army Corps of Engineers Safety and Health Requirements Manual 385-1-1. Protecting personnel from falls can be achieved through effective education, engineering and administrative controls, use of fall protection systems, and aggressive enforcement of standards.

b. To apply a hierarchy of control measures to every job site where fall hazards have been identified through a comprehensive job hazard analysis.

c. To reduce fall-related accident costs associated with lost time and worker’s compensation claims.

d. To improve mission capability and increase overall well-being and productivity of the work force.

In the program goals which were discussed above, a reference was made to a hierarchy of control measures which are targeted toward eliminating, or significantly reducing the risks associated with fall related hazards in the workplace. This hierarchy of control measures consists of the following:

Elimination- Removing identified hazards or hazardous work practices (e.g., lowering devices or instruments such as meters or valves to the worker’s level) whenever possible. This is the most effective control measure.

Substitution- Substituting or replacing the hazards or hazardous work practices with those that are less hazardous (e.g., prefabricating of structures on the ground in lieu of erecting the components at heights in excess of the applicable standard).

Isolation- Isolating or separating the hazards or hazardous work practices from personnel (e.g., installation of a guardrail at an opening or leading edge).

Engineering controls- When hazards cannot be eliminated, substituted or isolated, engineering controls are preferred method to control the risk (e.g., pre-drilled holes for attachment of fall arrest systems to attach anchorage connections.

Administrative controls- This includes measures or practices designed to reduce the risk of personnel falling (e.g., posting warning signs or restricting certain areas).

Personnel protective equipment (PPE)- This should be considered only when other control measures are not practical, or to increase the level of fall protection as a secondary system. While PPE typically refers to eye, face, hand, and foot protection, fall arrest systems also constitute personal protection.

Section II Definitions

Activation Distance: Distance required to lock-off or to activate a self-retracting lifeline/fall arrestor.

Anchorage: A secured structure that can safely withstand forces exerted by fall arrest and rescue equipment. The structure can be in the form of a beam, girder, column or floor. Anchorage is either engineered or improvised. The anchorage must be capable of withstanding a minimum force of 5,000 pounds per person or engineered by a qualified person for twice the maximum arresting force.

Anchorage Connector: The means by which a fall arrest system is secured to the anchorage. This can include a steel cable sling, anchor strap, load-rated eye bolt, tripod, davit arm or any other device designed to suspend human loads and capable of withstanding forces generated by a fall. (See Illustrations, page 72, figures 1 and 2)

Arresting Distance: Total vertical distance required to arrest a fall. This includes activation and deceleration distance. It does not include free-fall distance.

Arresting Force: Force exerted on a worker or test weight when a fall protection system stops a fall. The amount usually expresses the peak force experienced during a fall.

Authorized Person (End User): A person approved by the employer to perform a specific type of work at heights and at a specific location; a person who is trained on the use of fall arrest systems.

Body Belt: A strap with means both for securing it about the waist and attaching it to a lanyard, lifeline or deceleration device. (Use in a fall arrest system prohibited after January 1998)

Body Harness: Means of configuration of connected straps secured about the employee in a manner that will distribute the fall arresting forces over at least the upper thighs, waist, shoulders, chest and pelvis, with means for attaching a lanyard to other components of the personal fall arrest system. Full-body harness is the only body support device allowed by OSHA when a free-fall distance exceeds 2 feet. (See Illustrations, page 72, figure 3)

Body Restraint System: An application of the fall protection equipment, in which horizontal travel is restricted, preventing exposure to fall hazards. The system consists of a strap device, such as chest harness or full body harness that can be secured around a worker and attached to a load-bearing anchorage in order to restrict travel and limit fall hazards. The strap can be single or multiple. (See Illustrations, page 72, figure 4)

Buckle: A connector used for attaching the strap or webbing segments together or to themselves. (See Illustrations, page 73, figures 5 and 6)

Cable Grab: A fall arrest device that locks by either a cam lock (Locking arm) or inertia when a free fall is sensed. It is attached to a worker directly or by a lanyard that slides up or down a fixed or vertical cable or rope lifeline. (See Illustrations, page 73, figure 7)

Carabiner: A connector component generally consisting of an oval or trapezoidal shaped body with a closed gate or similar arrangement. Only self-locking carabiners are accepted or used. (See Illustrations, page 73, figure 8)

Competent Person (CP) for Fall Protection: A person who is capable of identifying hazardous or dangerous conditions in the personal fall arrest system or any component thereof, as well as in their application and use with related equipment (29 CFR 1910.66 Appendix C). Note: The OSHA CP definition {29 CFR 1926.450 and 1926.32(f)} also requires that a CP have the authority to take prompt corrective measures to eliminate the hazards of falling. (See “Qualified Person” for design knowledge)

Connector: A device that is used to couple (connect) parts of the personal fall arrest system together. It may be an independent component of the system, such as a carabiner, or it may be an integral component of part of the system (such as a buckle or D-ring sewn into a body harness, or a snap hook spliced or sewn to a lanyard or self-retracting lanyard).

Connecting Means: The method to connect a body support to an anchorage, such as a lanyard or a carabiner for the purpose of providing a protected mobility for an elevated work task.

Controlled Access Zone (CAZ): A zone to restrict access to leading edge work. The CAZ is bound by a control line and should run the full length of the leading edge and connect on each side to a guardrail or wall. The control line can be made of rope, wire, tape or equivalent material and shall be supported by posts and marked with a highly visible material. CAZ is used when a guardrail system, fall arrest systems or safety nets cannot be used or installed.

Conventional Fall Protection Systems: Guardrail systems, personal fall arrest devices, or safety nets.

Critical Sag: Is the deflection of the Horizontal Life Line (HLL) where the arresting force exactly equals the weight of the worker. The worker's speed of fall does not decrease until the sag of the line is greater than the critical sag. Critical Sag is a very important consideration for long span HLL with in-line energy absorber.

Deceleration Device: Any mechanism, such as a rope grab, rip-stitch lanyard, specially-woven lanyard, tearing or deforming lanyards, automatic self-retracting lifelines/lanyards, etc., that serves to dissipate a substantial amount of energy during a fall arrest, or otherwise limit the energy imposed on an employee during fall arrest.

Deceleration Distance: The additional vertical distance a falling employee travels, excluding lifeline elongation and free-fall distance, before stopping, from the point at which the deceleration device begins to operate. It is measured as the distance between locations of an employee’s body harness attachment point at the moment of activation (at the onset of fall arrest forces) of the deceleration device during a fall, and the location of that attachment point after the employee comes to a full stop.

D-ring: A connector used in a harness or a positioning belt as an attachment element or fall arrest attachment. It is also used in lanyards, energy absorbers, lifelines, and anchorage connectors as an integral connector. D-rings can be used for work positioning and restraint.

Energy (Shock) Absorber: A component whose primary function is to dissipate energy and limit deceleration forces that the system imposes on the body and the anchorage system during fall arrest, (See Illustrations, page 74, figure 9).

Engineered Anchor: An anchorage designed and approved by a qualified person.

Failure: Load refusal, breakage, or separation of component parts. Load refusal is the point where the ultimate strength is exceeded.

Fall Arrest System: A combination of equipment and components connected together, designed to stop a person from striking a lower level or an obstruction during a fall.

Fall Prevention: The elimination and minimization of potential fall hazards, lessening the chance of employee exposure to falls. Any same-level means used to reasonably prevent exposure to a fall hazard; examples of fall prevention are guardrails, walls, floors and area isolation.

Fall Protection: Action and procedures to effectively protect a worker from fall hazards.

Fall-Restraint System: A system designed to restrain a worker from reaching an exposed fall hazard. The system includes personal fall protection equipment, acceptable anchorage systems, and trained worker and administrative procedures. (See Illustrations, page 72, figure 4)

Force Factor: The ratio of peak arresting force using rigid weight compared to a human body having the same weight, both falling under identical conditions. For comparison between rigid weight and human body weight, multiply the rigid weight by 1.4 to allow for body comparison.

Free Fall: The act of falling before a personal-fall-arrest system begins to apply force to arrest a fall.

Free-Fall Distance: The vertical distance from the onset of a fall to a point where a fall-arrest system is activated or engaged. (This is the vertical displacement of the fall arrest attachment point on the employee’s body harness between onset of the fall and just before the system begins to apply force to arrest the fall. This distance excludes deceleration distance, and lifeline/lanyard elongation, but includes any deceleration device slide distance or self-retracting lifeline/lanyard extension before they operate and fall arrest forces occur).

Full Body Harness: See “Body Harness”.

Horizontal Lifeline (HLL): A fall arrest system that uses a line made from rope, wire rope or metal railing that spans horizontally between 2 end anchorages. The assembly includes the necessary connectors, turnbuckles, in-line energy absorbers, shackles, etc., and may include intermediate anchorages. This is a component of a fall protection system, which consists of a trained worker wearing appropriate fall protection equipment that enables them to safely traverse/work in the horizontal plane. The HLL shall be designed, installed, and used under the supervision of a qualified person. (See Illustrations, page 74, figures 10 and 11)

Ladder Climbing (Safety) Device: A device or climbing sleeve connected to the front D-ring on the climber’s full body harness that slides up or down a rigid rail or cable.

Should a fall occur, the device is designed to lock by inertia or cam action to arrest the fall. (See Illustrations, page 75, figure 12)

Lanyard: A flexible line of rope, wire rope, or strap that generally has a connector at each end for connecting the body harness to a deceleration device, lifeline, or anchorage. (See Illustrations, page 74, figure 9)

Leading Edge: The unprotected side and edge that exposes a worker to a fall hazard.

It means the edge of a floor, roof, or formwork for a floor or other walking/working surfaces.

Lifeline (LL): A component consisting of a flexible line for connecting to an anchorage at one end, to hang vertically, or for connection to anchorage at both ends to stretch horizontally, and which serves as a means for connecting other components of a personal fall arrest system to the anchorage.

Maximum Arresting Force: The peak force exerted on the body or test weight when a fall protection system stops a fall.

Personal Fall Arrest System: A system used to arrest an employee in a fall from a working level. It consists of an anchorage system, connecting means, body harness, and may include a lanyard, deceleration device, lifeline, or suitable combination of these.

Platforms: Any elevated surface designed or used primarily as a walking or working surface. Other elevated surfaces upon which employees are required or allowed to walk or work while performing assigned tasks on a predictable and regular basis

Positioning Belt: A single or multiple straps that can be secured around a worker’s body to hold the user in a work position.

Positioning Device System: A combination of equipment that permits the user to have both hands free while being supported on an elevated vertical surface (See Illustrations, page 75, figure 13).

Predictable and Regular Basis: Means employee functions such as, but not limited to, inspections, service, repair, and maintenance which are performed: (a) At least once every 2 weeks, or (b) For a total of 4 man-hours or more during any sequential 4-week period (e.g., 2 employees once every 4 weeks for 2 hours=4 man-hours per 4-week period).

Qualified Person (QP) for Fall Protection: A person with a recognized degree or professional certificate, and with extensive knowledge and experience in the subject field of fall protection, who is capable of performing design, analysis, evaluation and specifications in fall protection systems and equipment. (Note: for additional qualifications see Responsibilities, Section III)

Restraint (Tether) System: See “Fall Restraint System”.

Retracting Lifeline: Same as “Self-Retracting Lanyard”.

Rollout: An action by which a snap-hook or carabiner unintentionally disengages from the component to which it is attached.

Rope Access: A rope access suspended system consisting of 2 lifelines independently anchored at the top to protect the authorized person from falling. The ropes directly suspend the person. The technique is used on buildings, bridges, and other structures for conducting inspection, cleaning, and painting.

Rope Grab: A deceleration device that travels on a lifeline and automatically, by friction, engages the lifeline and locks to arrest the fall of a worker. A rope grab usually employs the principle of inertial locking, cam/level locking, or both. (See Illustrations, page 73, figure 7)

Sag: The distance the wire rope deviates from the horizontal plane established by the end anchor points. This is defined by the line between 2 anchor points and measuring downward at the mid-point of the wire rope.

Self-Retracting Lanyard (SRL): A deceleration device containing a drum-wound line that can be slowly extracted from, or retracted onto, the drum under slight tension during normal employee movement, and which, after onset of a fall, automatically locks the drum and arrests the fall. (See Illustrations, page 75, figure 14)

Shock Absorber: A component of a fall protection system that dissipates energy by deformation, or extending the deceleration distance. (See Illustrations, page 74, figure 9)

Snap Hook: A connector comprised of a hook-shaped body with a normally closed gate or similar arrangement, which may be opened to permit the hook to receive an object and when it is automatically released, closes to retain the object. Only self- locking (single or double locking) snap hooks are acceptable for use (See Illustrations, page 75, figure 15).

Swing fall: A pendulum-like motion that can result from moving horizontally away from, or toward, a fixed anchorage when falling. Swing falls generate the same amount of force when falling the same distance vertically. Swing fall has the hazards in both the horizontal (swinging into an obstruction) and vertical (falling onto obstructions or the ground) directions.

Toe-board: A deck level protective barrier that will prevent the fall of materials and equipment to lower levels.

Total Fall Distance: The vertical distance between the anchorage location and connecting point on the body (generally, the harness D-ring) after the fall is arrested, which includes the free fall and deceleration distances.

Vertical Life Line (VLL): A vertically suspended flexible line connected at the upper end to an overhead anchorage and along which a fall arrester travels.

Warning Line System: A barrier erected on a roof to warn workers that they are approaching an unprotected roof, side, or edge and which designates an area where roofing work may take place without the use of guardrail, body harness or safety net system to protect workers in the area. Work performed outside barriers will require fall protection systems. The difference between CAZ and Warning Line system is that in the CAZ, approved anchorages cannot be provided to tie off the worker (See Illustrations, page 76, figure 16).

Walking/Working Surface: Any surface, whether horizontal or vertical, on which an employee walks or works, including, but not limited to, floors, roofs, ramps, bridges, runways, form work, and concrete reinforcing steel (but not including ladders, vehicles, or trailers), on which employees must be located in order to perform their job duties.

Section III Responsibilities

Successful implementation of a Fall Protection Program requires a coordinated effort.

As you design the program for your installation or facility, give careful thought to who the participants should be, and make sure they are involved in the process from the beginning. Below is a list of individuals and a brief description of their respective roles in the developmental process:

Commanders of Major Army commands (MACOMs), and Regional Installation

Management Agency (IMA) Directors. Commanders/directors will ensure their subordinate commanders/directors implement a Fall Protection Program and strictly enforce compliance.

Installation Commanders. Installation commanders will implement a Fall Protection

Program in accordance with AR 385-10, The Army Safety Program, OSHA Standards 1910, General Industry, and 1926, Construction, and US Army Corps of Engineers Safety and Health Requirements contained in EM 385-1-1. They will provide the necessary resources, and delegate sufficient authority to subordinate commanders/directors and division chiefs to implement the program.

Installation Safety Manager. The installation Safety Manager will develop and implement the installation Fall Protection Program for the installation commander. The program should consist of a comprehensive written program document for facilities management. The Safety Manager and his/her staff may be called upon to provide guidance and technical assistance to commanders/directors regarding implementation of and compliance with elements of the Fall Protection Program, and should integrate the program elements into existing Standard Army Safety and Occupational Health Inspection (SASOHI) criteria in order to ensure compliance during evaluations. In addition, the Safety Staff may be called upon to provide, or assist with training.

Supervisors. Supervisors of activities where fall hazards have been identified through comprehensive job hazard analyses will ensure that all personnel who have a potential exposure to fall hazards adhere to established fall protection requirements.

They will also ensure that affected personnel have the training necessary to identify specific fall hazards and to understand the control measures and how to apply them. In addition, supervisors will also provide training that enables personnel to know when personal fall arrest equipment is necessary, what type of equipment is necessary, and how to properly don, remove, adjust and wear it. Individuals must also know and understand the limitations of the equipment, and the proper care, maintenance, useful life and disposal requirements. Personnel should be able to demonstrate their understanding of the training through practical application. Supervisors are also responsible for the following:

a. Ensuring that training classes for personnel are properly documented.

Documentation should consist of a training log or dated employee signature sheet.

b. Ensuring that all required fall protection equipment is provided for personnel, that it is being used safely and is inspected stored and maintained properly.

c. Ensuring that the individual components of the issued equipment are properly compatible and in good working order.

d. Conducting frequent evaluations of the workplace to identify any fall hazards associated with new job requirements or work practices.

Employees. Employees exposed to fall hazards as part of their duties will participate, as directed, in all fall protection and personal protective equipment training.

In addition, they will also comply, to the fullest extent possible, with all safety and health standards outlined in their installation or facility Fall Protection Program, maintain their fall protection equipment in a safe and sanitary condition, and report directly to the first-line supervisor any problems observed which could compromise worker safety or health.

Civilian personnel officer. The civilian personnel officer will provide support to supervisors and other individuals responsible for enforcing the Fall Protection Program requirements. An example of support would be to develop job descriptions, which address requirements for personnel assigned to work in fall hazard areas, and the necessity to utilize fall protection equipment as a condition of employment. In addition, the civilian personnel officer will advise supervisors with respect to appropriate disciplinary measures when personnel fail to comply with established fall protection requirements.

Qualified Person (QP):

The Qualified Person duties and responsibilities consist of the following:

a. Prepare, review, approve, and modify Fall Protection and Prevention (FP&P) Plans, and Rescue and Evacuation Plans (REP).

b. Design, select, certify, evaluate and analyze fall protection systems and equipment.

c. Review, prepare and approve Fall Protection (FP) specifications.

d. Advise/assist the contracting officer in the preparation of contract documents for FP systems.

Competent Person (CP):

The Competent Person duties and responsibilities consist of the following:

a. Implementation of FP&P Plans and REP.

b. Identification of hazardous and dangerous conditions in the work place.

c. Inspection and installation of approved fall protection systems.

d. Compliance with FP&P Plans and REP.

e. Training of all workers exposed to fall hazards.

f. Understanding and knowledge of fall protection systems and equipment.

g. Conducting inspections and accident Investigations.

h. Having full responsibility and authority to implement the FP&P Plans and REP in the work place.

i. Monitoring worker compliance with FP&P Plans and REP requirements.

FP Program Manager/Administrator:

The FP Program Manager/Administrator’s duties and responsibilities consist of the following:

a. Managing the fall protection program at the activity.

b. Writing FP procedures.

c. Developing FP training programs.

d. Developing and approving equipment purchase lists.

Contracting Officer (CO). The contracting officer, typically through the Contracting Officer’s Representative, will ensure that the requirements of the installation Fall Protection Program are integrated into all applicable contracts, and that contractors understand when either they or their sub-contractors perform work on the installation or facility, they must adhere to the established guidelines set forth in the program document. Contractors will be informed of this requirement as well as the on-site construction rules that apply during the pre-construction conference.

Contracting Officer’s Representative (COR):

The COR shall ensure all construction contracts, prior to start of construction, include specific sections which address fall protection, and that contractors comply with the USACE manual 385-1-1 IAW FAR 52.236-14. It is the contractor’s responsibility to provide fall protection to all workers exposed to fall hazards, and to ensure that they have been properly trained. Contractors shall submit a written FP&P Plan as part of the contract, which includes training requirements for their workers as well as subcontractor workers, to the COR for review and approval. The COR shall ensure that the contractor does not begin any construction-related activities until the submitted FP&P Plan has been approved. Fall protection will be one of the main topics discussed during the Pre-Construction Conference.

In-house Design:

Responsible individuals should strive to eliminate fall hazards in the design of new buildings and facilities through engineering-in various systems and modifications designed to eliminate the need to use fall protection. Individuals shall ensure all designs requiring fall protection, whether during the construction phase, or future maintenance and repair work, integrate the requirements into the design effort. If feasible, fall protection systems shall be permanently installed for future maintenance and repair work. The designer shall identify the required location of the safe points of connection (anchor points) for future work.

Army Design Managers:

The Army Design Managers shall ensure that architects and engineers incorporate the following requirements in the design effort:

a. The “Occupational Safety and Health Planning and Design Guide”.

b. That Fall Protection requirements are integrated into the design work and added to the specification sections of the contract.

c. Utilization of the Activity Hazard Analysis system.

Maintenance Work:

The COs/CORs and Army Safety personnel shall ensure that all maintenance contract work performed by contractors, to include work encompassing fall protection requirements, is performed in accordance with USACE manual EM 385-1, 29 CFRs 1910 and 1926, and applicable ANSI standards. Army maintenance workers shall be trained to recognize the hazards of falling in the work place and the use of fall protection equipment.

Section IV Training Requirements

Personnel who are exposed to fall hazards in their work environment shall be trained to recognize the hazards of falling and how to minimize such hazards.

Exposed personnel shall be trained by a competent person in the following areas:

a. Nature of fall hazards.

b. Fall protection systems.

c. Use and operation of fall protection/prevention systems.

d. Inspection of fall protection equipment.

e. Role of each employee in the safety monitoring systems.

f. Handling, storage, care and maintenance of fall protection systems.

Prior to the use of any fall protection equipment, personnel must be trained in its safe use. It is recommended that all personnel exposed to fall hazards receive a minimum of 16 hours training, or be trained to a level deemed appropriate to safely execute their duties. Training should consist of the following elements:

a. Application limits.

b. Proper anchoring and tie-off techniques.

c. Estimation of free fall distance, including determination of deceleration distance, and total fall distance.

d. Methods of use, inspection, and storage of the system.

e. Supervisors and workers should become familiar with applicable guides and total fall distance.

f. Limitations of equipment.

g. Specific lifelines which may be used IAW USACE Manual 385-1-1. Each worker who might be exposed to fall hazards shall be trained by a competent person qualified in the safe use of fall protection systems and the recognition of hazards related to their use, including the nature of fall hazards in the work area, and correct procedures for constructing, erecting, maintaining, using and dismantling fall protection systems.

h. The maximum intended load-carrying capacities of fall protection systems, applicable requirements contained in the USACE Manual 385-1-1, and limitations on the use of mechanical equipment during the performance of roofing work on low-sloped roofs. Retraining shall be provided as necessary for personnel to maintain an understanding of these subjects.

Retraining of workers shall be provided as necessary in order to maintain an understanding of requirements and procedures.

A written certification of training is required and shall be maintained at job sites for the duration of the work. The certificate shall identify the individuals trained, the date of the training, and the signature of the trainer. Additionally, a determination shall be made as to whether the training provided has resulted in personnel acquiring the skills and knowledge necessary to safely perform the work. (See Appendix B, page 66, Form 1-2) A daily “tool box” meeting should be conducted prior to the start of work in order to discuss fall hazards for that day, and to remind workers to comply with the established fall protection procedures. Workers who receive adequate training in fall protection will be tracked in the tool box meetings.

For workers who may be in a situation that requires climbing involving the use of fall arrest systems, the Authorized Person Training shall also include practical climbing in a controlled situation in the presence of a Competent Person. Additionally, authorized workers shall be trained in rescue and self rescue procedures. Hands-on training is also required for both investigation and inspection work.

Architects, engineers, and in-house designers involved in planning and designing buildings, facilities, structures and equipment should be trained to incorporate fall protection and prevention control measures into their design work in order to help contractors during the construction phase, and to provide protection to workers who will be required to perform maintenance.

Fall protection training should emphasize that fall hazards should be eliminated whenever possible, and when they cannot, there should be a mechanism in place to protect workers from fall hazards.

Prior to the start of a job, workers exposed to fall hazards shall read, understand and sign the FP&P Plan, acknowledging that they have been trained on job hazard recognition (all contractors and subcontractor workers exposed to fall hazards shall be trained accordingly). In addition, workers shall be trained in the proper use of fall protection equipment. All workers newly assigned to a job must review the FP&P Plan and sign the roster. If the fall hazards, fall protection equipment, or methods change during the course of the job, the FP&P Plan must be reviewed and signed again by personnel working at the job site. The written FP&P Plan and REP shall be part of the written Accident Prevention Plan which is maintained at the job site. If additional requirements arise or change at the job site as work progresses, the FP&P Plan and REP shall be reviewed and updated by a Qualified Person and signed by all workers exposed to fall hazards.

“Train the Trainer”:

Administering the Fall Protection Training Program in a “pyramid” fashion.

a. Initial training is provided by fall protection experts in order to develop trained fall protection personnel.

b. The trained fall protection personnel in-turn:

(1) Train others at the installation/facility level, including supervisors and workers.

(2) May also train special assistants, who can help with recognizing fall-related hazards. The special assistants may be representatives from each department or division who assist other department members in recognizing and reporting fall hazards.

Education requirements:

a. The Installation Safety Manager, or his/her designated representative should have:

(1) A minimum of 40 hours of formal fall protection training. Formal training consists of classroom instruction, exercises, supervised work-site assessment, and individual learning assignments.

(2) Training and experience sufficient to identify Fall Protection Hazards and risk factors.

b. Trained fall protection personnel should have:

(1) A minimum of 40 hours of formal Fall Protection training.

(2) Training and experience sufficient to identify fall protection hazards and risk

c. Core fall protection subcommittee members, support and advisory fall protection subcommittee members, and installation level personnel providing assistance in recognizing fall protection hazards should have basic fall protection training provided by trained fall protection personnel.

Training requirements:

Personnel responsible for administering the installation Fall Protection Program should receive appropriate special training. Training is necessary for Active Army, Army Reserve, and Army National Guard personnel as well as all levels of civilian personnel to enable them to understand and recognize potential fall hazards, and actively participate in their installation/facility fall protection efforts.

a. Personnel requiring training:

(1) All DA personnel who are potentially exposed to fall hazards.

(2) Supervisors.

(3) Managers.

(4) Engineers and maintenance personnel.

(5) Installation safety and occupational health personnel.

b. Personnel who may conduct training:

(1) Trained fall protection personnel.

(2) Suitable health care personnel to conduct specific portions of training, such as those related to health risks.

c. Types of training:

(1) General training. Workers who are potentially exposed to fall hazards should receive formal instruction on hazards associated with their jobs and equipment.

They should receive training at an initial orientation and annually thereafter.

(2) Specific training. New and reassigned military and civilian personnel who are potentially exposed to fall hazards should receive an initial orientation and hands– on training from trained fall protection personnel and their immediate supervisor prior to being placed in a full–production position. The initial orientation should include: a demonstration of the proper use and care of, and proper operating procedures for, all tools and safety equipment, and work procedures, such as proper lifting techniques.

Section V Fall Protection Program

Each Army activity that has workers exposed to falls from heights is required to establish a fall protection program. The program includes identification and elimination of fall hazards, whenever practical, through engineering controls, training of personnel, proper installation and use of fall protection systems, and required rescue equipment and procedures.

A managed Fall Protection Program should include the following elements:

a. Command policy

b. Duties and responsibilities

c. Workplace assessment and surveys of fall hazards

d. Fall hazard prevention and control, including the preparation of a Fall Protection and Prevention Plan

e. Education and training requirements

f. Inspection, storage, care, and maintenance of the equipment

g. Rescue and evacuation procedures

h. Audits and evaluations

Fall hazard assessments and surveys. Workplace assessment and survey will help identify potential fall hazards at the workplace. The gathered information will provide documentation to assist in the development of viable solutions to protect workers exposed to fall hazards. Understanding work procedures and how a person conducts the required task is very important in the selection and development of the most appropriate fall protection method. Fall hazard assessment and surveys will help identify options for fall hazard elimination and/or selecting other control measures. The survey information required to identify fall hazards at a building or facility may include:

a. Interview of Authorized Person(s) and their supervisors

b. Work paths and movement of the Authorized Person

c. Range and mobility in each Fall-Hazard Zone

d. Location and distances to obstructions

e. Potential anchorage location if a fall hazard cannot be eliminated

f. Total fall clearance

g. Number of personnel exposed to fall hazards

h. Frequency and duration of exposure

i. Lockout/tagout hazards

j. Potential severity of the fall

k. Access to Fall-Hazard Area

l. Floor and other surfaces

m. Review of any mishap reports at the facility

n. Identify the presence of any:

(1) Hot objects, sparks, flames and heat-producing objects

(2) Electrical and chemical hazards

(3) Sharp objects

(4) Abrasive surfaces

(5) Moving equipment and materials

(6) Impact of weather factors

(7) Any other maintenance, work environment issues or conditions

Fall-Hazard Analysis. After conducting the survey, a fall hazard analysis can be performed to determine risk based on hazard severity and fall mishap probability. This will be beneficial in prioritizing of hazard ranking and the selection of the most viable fall protection solutions.

The primary goal is to eliminate/remove potential fall hazards.

Section VI Fall Protection Systems and Guidelines

It is very important for a fall protection Qualified Person to plan, evaluate, design and select the most appropriate, safe and efficient fall protection systems. As there are many fall protection systems available, it is of the utmost importance to select the right system for the specific work application. Complete understanding of work procedures will enable the Qualified Person to select the most appropriate fall protection system.

In every fall hazard situation, it is always advisable to have two protective systems: a primary and secondary system. If the primary system fails, the secondary system will be activated to protect the worker from falling. As an example, when approaching the leading edge of a work area, a worker's primary protective system would be their feet.

Therefore, a secondary protective system is required as a backup, such as a fall arrest/restraining system or guardrails. When climbing a ladder or a pole, the worker’s primary fall protective system would be their hands and feet. In this case, a ladder-climbing device would be required as a secondary backup system.

Fall Protection Systems.

a. Every worker exposed to a fall hazard shall be protected from falling to a lower level by the use of fall protection systems. The main fall protection systems are:

Guardrail System: A guardrail system is a conventional method for the prevention of falls from heights. A guardrail is composed of a top rail, mid rail, posts and toe boards.

Safety Net: A safety net is installed below the leading edge for worker protection, or when working over water.

Fall arrest System: A fall arrest system is composed of the following subsystems and components:

(1) Anchorage System - includes anchorage point and anchorage connection.

(2) Connecting Means - includes lanyard (may include shock absorber, snap hooks and carabiners, self retracting lanyards, or fall arrestors).

(3) Body Support.

(4) Rescue and escape - self-rescue or assisted rescue.

b. Other fall protection systems include:

Horizontal Lifelines (HLL) Vertical Lifelines (VLL) Ladder Climbing (Safety) Devices Positioning Device Systems

Restraint (Tether) Systems Controlled Access Zone (CAZ) Warning Line System Arial Lifting Equipment, Working Platforms, and Catwalks Falling Object Protection Covers

Note: Fall arrest systems are “passive” systems that become active when a fall is arrested. Fall arrest systems are considered secondary systems when a primary system is present.

Fall Protection Guidelines:

a. Communication Towers:

Maintenance Work:

The preferred method for accessing exiting towers to perform maintenance work is by the use of fixed ladders with attached climbing devices because it provides conventional fall protection during ascent and descent of the structure.

To secure permanent anchorage on the tower, the first worker up requires a portable anchor, full body harness, use of self retracting lanyard (SRL), ladder climbing device or rope grab.

After permanent anchorage is secured in place, workers that follow the first person up will require full body harness, SRL, vertical lifeline, ladder climbing device and/or rope grab.

When working on towers, workers are required to wear fall protection equipment at all times.

Erection of Towers (OSHA CPL 2-1.36 Interim inspection procedures during communication tower construction activities):

For accessing the tower during construction activities, workers must be protected from falls using a fall arrest system or ladder climbing devices.

For tower access, workers can be hoisted using a gin pole or other hoisting mechanism.

A hoist line may be used to hoist workers for access to tower work. The rigging line or hoist shall have a safety factor of 10 against failure during personnel lift.

A trial lift and proof testing shall be conducted on the hoisting equipment prior to lifting of employees.

When working on towers, 100% fall protection is required at all times.

b. Roof Work:

On sloped roofs: use full body harness, SRL, and roof brackets/anchors for anchorage points (single or multiple connections designed for 5000 pounds per person). Also use slide guards.

On flat roofs with no parapet or guardrails: When working 6 feet from the edge, use full body harness, restraining system and or lanyard/SRL. Establish a warning line system 6 to 10 feet away from the leading edge or temporary guardrails for workers without a fall arrest system. Personnel working within the warning line system do not require fall protection.

NOTE: Whenever danger of roof collapse is imminent (e.g., performing emergency roof repair) as determined by a Qualified Person, appropriate fall protection will be required.

c. Leading Edge Work:

Use horizontal lifeline, full body harness, lanyard/SRL, roof anchors, guardrail system, and a restraining system.

d. Scaffold Work:

Use guardrails, cross bracing or full body harness and lifelines. During erection and dismantling operations it is highly recommended to have a fall protection system.

On supported scaffolds over 20 feet high, use staircases instead of ladders to access the scaffold.

e. Suspended Scaffolds (single and two point suspended scaffolds), Work Platforms:

The scaffold shall have guardrails and the use of an independent vertical lifeline for every worker connected to a full-body harness. (See figure 17).

f. Aerial Lifting Equipment:

Use full body harness and lanyard connected to approved anchorage.

Workers will require fall arrest system if the lifting equipment is positioned outside the wheel-base, even if the equipment has a guardrail system.

When using scissors lift, it is highly recommended to tie off to an approved anchorage connection using a full body harness at all times.

Aerial Lifting equipment can be modified by the manufacturer to install approved anchorage connections for a fall arrest system. Usually, guardrails in the aerial lifting equipment are not designed to arrest a fall.

g. Confined Space Entry:

When entering a confined space, if there is a hazard of exposure to vertical fall, the person entering such space shall be tied to a lifeline or SRL, and rescue/ retrieval equipment. A co-worker should be able to retrieve the victim utilizing the retrieval mechanism from outside the confined space without any difficulty (See figure 18). (Note: Refer to your installation/facility safety office for the required list of confined spaces – address those that require fall protection!)

h. Excavated Trenches or Holes More Than 6 Feet Deep:

Provide temporary guardrail systems on both sides of the trench or around holes, or establish a warning line system. Any person crossing this line or guardrails is required to have fall protection.

i. Covers:

Covers shall be capable of supporting without failure, at least twice the weight of a worker, their equipment, and their material combined.

When installed, covers shall be secured, color-coded and clearly marked with the word 'HOLE, or COVER".

j. Scissors Lift/Mobile Scaffold:

Use guardrails.

When using scissors lift, it is highly recommended to tie off to a manufacturer approved anchorage connection using full body harness at all times in addition to the guardrail.

Workers will require fall arrest system if the lifting equipment is positioned outside the wheel base, even if the equipment has a guardrail system.

Safe Work Practices on Ladders and Stairs:

a. Fixed Ladders:

Workers shall not perform work from a fixed ladder unless they are wearing fall protection, such as a full body harness attached to a ladder climbing device or self-retracting lanyard, which in turn is attached to a properly designed and installed anchorage.

If the total length of the climb on a fixed ladder equals or exceeds 20 feet, the following requirements must be met: fixed ladders must be equipped with either

(a) ladder safety devices; (b) self-retracting lifelines, or (c) a cage or well.

All ladder climbing safety devices must permit the worker to ascend or descend without continually having to hold, push, or pull any part of the device, leaving both hands free for climbing. These safety devices must be activated within 2 feet after a fall occurs. Ladder climbing safety devices shall be attached to a frontal centered D-ring or other specifically designed centered frontal attachment point on a full body harness.

The side rails of through or side-step ladder extensions must extend 42 inches above the top level or landing platform served by the ladder.

NOTE: Although allowed by OSHA, ladder cages are not a safe fall protection method. They cannot stop a fall.

b. Portable and Extension Ladders (Non-Self Supporting):

The ladder shall be so placed as to prevent slipping, or it shall be lashed, or held in position.

An worker may perform work from a non-self supporting portable ladder placed at the correct angle and properly secured (e.g., lashing top and bottom), if they are facing the ladder and their body is between the side rails, and they use one hand to grasp the…