Project Overview
During the construction of a new steel manufacturing facility in Martinsburg, West Virginia, Lighthouse Safety was engaged to design and install a compliant overhead crane fall protection system.
The project required fall protection across nine buildings to allow safe inspection and maintenance of overhead bridge cranes. Due to the layout of the crane runways and structural obstructions, traditional guardrail systems were not feasible.
A fully engineered horizontal lifeline solution was required to protect workers while maintaining access along the full crane bay.
The Challenge
The maintenance platforms servicing the overhead bridge cranes:
- Had no existing guardrails or passive fall protection
- Spanned long distances with high clearances
- Included structural obstructions limiting system options
- Required continuous access along the entire bay
Employees could not safely inspect or perform maintenance without exposure to serious fall hazards.
Because of interference points and workflow requirements, a passive guardrail system could not be installed. The customer needed an engineered active fall protection solution that would:
- Comply with OSHA requirements
- Align with ANSI best practices
- Integrate with construction drawings
- Be installed efficiently within active build timelines
The Solution
Lighthouse Safety designed and installed a horizontal lifeline system.
Scope of work included:
- Reviewing and completing construction drawings provided by the contractor
- Conducting a site visit to verify field conditions and coordinate scheduling
- Installing twenty three Horizontal Lifelines across nine buildings
- Installing approximately 2,640 linear feet of cable
- Completing the installation within two weeks across two mobilizations
The Horizontal Lifeline now runs the full length of each crane bay, providing continuous tie off capability for crane inspection and maintenance activities.
The Benefits
The installed system significantly improved safety throughout the facility by providing:
- Continuous overhead fall protection across crane platforms
- Reliable protection across large spans and high elevations
- OSHA compliant and ANSI aligned performance
- Increased worker confidence during inspection and maintenance
By implementing engineered horizontal lifelines instead of a passive system, the facility gained full crane access while maintaining compliance and reducing fall risk.
A post construction inspection was recommended to ensure long term system integrity and continued safety performance.
Project Highlights
