Cars, planes, and cruise ships seem to be the most popular ways to get around, yet Amtrak reports continued increases in passenger service, and 1.5 billion tons of freight are moved annually along rail lines.
Keeping railcars operating reliably along 140,000 miles of track nationwide requires constant inspections and maintenance. However, the nature of this work—often performed at height on large, cumbersome equipment—presents significant fall hazards.
A comprehensive safety strategy, integrating engineered work access platforms, overhead rigid rail, and davit arms, is essential for protecting personnel, maintaining operational efficiency, and complying with regulations.
On board with work access platforms.
The first line of defense in railcar maintenance safety is providing safe and stable access to work areas. Conventional tools such as ladders and makeshift stands are inherently risky and inefficient. Purpose-built work access and rail car inspection platforms create a dedicated and controlled environment for tasks like roof inspection, cleaning, and repair.
Work access platforms feature:
- Anti-slip aluminum or glass-reinforced nylon treads for stairs and decks. The treads are perforated to allow snow, ice, or spilled fluids to drain through.
- Aluminum or galvanized steel frames for stability, durability, and corrosion resistance.
Integrated guardrails for additional fall protection and compliance.
Modular, component-based design for easy set-up—or reconfiguration—without welding or drilling.
Static (fixed) work platforms are designed for permanent installation. They can be designed for specific work areas or to surround the railcar, offering 360-degree access while withstanding the harsh conditions of a railyard. By eliminating the need for workers to climb onto the car itself, they reduce the risk of slips and falls from the initial point of access.
Mobile work platforms feature heavy-duty locking casters. They are ideal for facilities with multiple tracks or different car designs. Since they can be moved into position or stored as needed, they provide exceptional flexibility.
Rigid rail for advanced fall protection from overhead.
Depending on the railyard’s layout, facilities, and the specific tasks being performed, overhead rigid rail is often the fall protection method of choice. The engineered track-and-trolley system provides a continuous anchor point for a self-retracting lifeline. It allows the worker to move freely and work safely and efficiently along the entire length of a railcar.
Advantages of rigid rail:
- Arrests a fall in a minimal distance.
- Eliminates the swing-motion pendulum effect of cable-based lifelines.
- Constructed of strong, durable, corrosion-resistant materials.
- Requires less clearance—as low as 4 feet—where there is limited headroom.
- Available in spans from 6 to 100 feet.
- Can accommodate up to 6 workers.
Davits lend a helping arm.
In situations where an overhead system is not feasible, davit arms present a versatile alternative. These portable or fixed base-mounted masts can be installed on the edge of a platform or a rooftop. When used in pairs with a beam, they create a temporary but robust anchor point for fall arrest. Davits are particularly useful for tasks requiring access to the center of a railcar roof, providing reliable protection without the need for overhead infrastructure.
Ensuring compliance through work-at-height operations.
When investing in railway maintenance equipment, railroad executives and facility managers must be mindful of safety regulations. The Occupational Safety and Health Administration (OSHA) sets forth clear regulations for fall protection systems used to inspect and maintain railcars.
- OSHA 29 CFR 1910.29 specifies that guardrails must be 42 inches high (+/- 3 inches), have a mid-rail halfway between the top rail and walking-working surface, and withstand 200 lbs. of force applied against the top rail.
- OSHA 1910.140(c)(13) specifies that anchorages in fall arrest systems must be capable of supporting at least 5,000 pounds (22.2 kN) for each employee attached; or be designed, installed, and used, under the supervision of a qualified person, as part of a complete personal fall protection system that maintains a safety factor of at least two.
See us for your safety solutions.
A proactive approach to railcar maintenance access safety protects your most valuable asset, your workforce, and enhances productivity by creating a safer, more efficient work environment. Shifting from ladders and stands to purpose-designed access platforms, rigid rail systems, and davit arms builds a foundation of safety that drives success for years to come.
If you are responsible for safety and fall protection at your rail yard, contact Lighthouse Safety for safety solutions. We will discuss your concerns about regulations and what it will take for you to comply. Our services encompass everything you need, from design, engineering, and fabrication to installation, training, inspections, and other support.
