Modular Rigid Rail System Improves Roof Safety in Home Manufacturing Facility

Project Overview

A national manufacturer of factory built homes contacted Lighthouse Safety after a fall incident occurred at one of their production facilities. The company designs and builds manufactured homes, modular homes, park model RVs, and vacation cabins within controlled manufacturing environments.

Because roofing systems are constructed at height during production, fall protection is a critical component of their safety program. Following the incident, leadership sought an engineered solution to eliminate future fall risk and strengthen employee protection.

The Challenge

• Employees regularly work at height while assembling roof systems. This includes:
• Roof framing and truss installation
• Sheathing and decking
• Final roof assembly
• The company needed to reduce exposure to fall hazards without slowing production.
• Their goals were to:
• Eliminate fall risk during roof construction
• Provide continuous overhead protection
• Allow workers to move freely and efficiently
• Implement a permanent engineered system within the facility
• Temporary safety measures were not sufficient. They required a reliable long term fall protection solution that supported both safety compliance and operational productivity.

The Solution

Lighthouse Safety recommended and installed a Modular Rigid Rail Fall Protection System designed specifically for elevated manufacturing work.

The rigid rail system was selected because it:

Provides continuous overhead fall protection
Allows smooth horizontal movement
Reduces swing fall hazards
Supports hands free mobility
Integrates into indoor production environments

The system enables workers to move along the roof construction area while remaining continuously protected.

Lighthouse Safety responded quickly and was on site within one week of initial contact. Installation was completed within the required timeline to ensure the safety upgrade did not disrupt production schedules.

The Benefits

• Improved Workplace Safety
• The engineered system significantly reduced fall exposure during roof construction activities.
• Greater Worker Confidence
• Employees can now perform their tasks with mobility and confidence while remaining securely protected.
• Efficient Implementation
• Lighthouse Safety delivered a cost effective solution with a fast turnaround to meet the company’s timeline.
• Trusted Expertise
  • The manufacturer relied on Lighthouse Safety’s fall protection expertise to design and implement a solution tailored to their production environment.

The Result

With the Modular Rigid Rail system in place, the manufacturer strengthened its safety program, reduced fall risk during roof construction, and created a safer working environment for employees without compromising productivity.