Celebrity culture has an outsized place in our collective consciousness. Sports and weather take up an outsized amount of time on local news broadcasts. The debate over which condiments belong on a hot dog has an outsized role in our society. Or roll.
These examples are harmless, though. Regarding consequential outsize, the United States manufacturing sector has 657,322 entities, employs 7.7% of the workforce, and accounts for 10.3% of the Gross Domestic Product (GDP).
Yet, 15% of workplace injuries are in manufacturing, and according to the National Safety Council, manufacturing and production is the third-highest occupation resulting in days away from work. The Bureau of Labor Statistics (BLS) recently reported that work-related fatalities due to falls, slips, and trips increased by 1.8%, with 81% of the falls to lower levels. That is not harmless.
Identifying the fall hazards in manufacturing plants.
Falls from height can occur during various tasks, and resultant non-fatal injuries can include contusions, lacerations, broken bones, herniated discs, dislocations, internal bleeding, sprains, concussions, and other problems.
The disruption to the life and career of the injured worker can be devastating. For the manufacturer, losses can hurt employee morale and the company’s reputation, lead to lawsuits and higher insurance rates, and cause a decline in productivity.
The most common fall hazards in a manufacturing plant are:
• Venturing near open pits and tanks and temporary work areas not adequately marked or protected.
• Working from elevated platforms and scaffolds.
• Accessing the roof for building systems service and other duties.
• Using faulty ladders or not using them correctly.
• Walking along mezzanines and catwalks.
• Loading and unloading at docks and from trailers.
• Maintaining overhead cranes and conveyors, gantries, and other elevated equipment.
• Climbing on large machinery.
• Retrieving materials and inventory.
Fall protection measures for manufacturing.
To address the risks associated with working at height, manufacturers can use “active” and “passive” fall protection measures to help prevent falls and minimize their impact.
Active Fall Protection
Active fall protection involves the user directly using personal protective equipment (PPE). It requires frequent inspections of the equipment and qualified training to use and inspect.
A. Lifeline systems provide work restraint or fall arrest. Work restraint limits the distance a worker can travel, thus avoiding an unprotected edge. Fall arrest systems limit the distance a worker can fall. (A fall arrest system requires a rescue plan.)
B. Rigid rail systems are mounted overhead and limit the distance a worker can fall. A modular rigid rail is an economical track and trolley system that can be installed and later relocated if necessary.
Passive (or Collective) Fall Protection
Passive fall protection systems do not require worker involvement, special equipment, or training. Guardrails and barriers are prime examples. These systems are often preferred because they provide continuous protection for multiple workers.
A. Guardrail systems for loading docks, mezzanines, rooftops, hatches, and other open or unsafe areas should probably be the most ubiquitous fall protection in a manufacturing facility. Pipe-fitted modular guardrails are installed without welding. Aluminum and galvanized steel railings are robust, durable, and corrosion-resistant.
B. Walkway systems that feature aluminum or glass-reinforced nylon treads are slip-resistant to help prevent falls, non-bounce for stability, and self-draining to avoid water accumulation. They can be installed as catwalks or roof walkways and fitted with guardrails.
C. Access platforms provide unmatched versatility in a manufacturing facility. They incorporate walkway treads for steps and platform desks with modular frames and guardrails to provide fall protection at machinery and equipment, loading and unloading zones, racks and shelves, and other elevated areas.
Static (or fixed) work platforms are ideal for permanent installation where tasks are performed frequently. Mobile platforms fitted with handrails and locking casters are safer and more efficient than ladders. Engineered platforms can be customized for adjustable height, shop services, racks, shelves, self-closing safety gates, and other features.
See us for your safety solutions.
Work-at-height fall protection in manufacturing plants is essential to safeguarding employees and maintaining a productive work environment. With falls from height being a leading cause of injuries in the manufacturing sector, employers must implement comprehensive active and passive fall protection measures.
If you are responsible for safety at your organization, contact Lighthouse Safety for OSHA-compliant safety solutions. We will discuss your concerns about regulations and what it will take for you to comply. Our services can include as little or as much as you need, from design, engineering, and fabrication to installation, training, inspections, and other support.
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