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Rigid Rail Fall Protection Systems

Overhead Fall Protection With Very Short Arrest Distances

Custom Rigid Rail Fall Protection

When properly utilized, rigid rail overhead protection outperforms traditional cable-based lifeline products by arresting falls in a much shorter distance than other lifeline products. Lighthouse Safety provides versatile rigid fall protection in a range of permanent and mobile fall designs. All our solutions comply with US OSHA 1910, ANSI Z359.6 & Canadian CSA Z259.2 standards for Engineered Fall Protection.

Rigid Rail System Features

Increase Productivity

The systems are designed to support as many as 8 users with optional by-pass on a single overhead solution enabling more efficient and effective work routines without jeopardizing safety.

Easy to Use

Although fall arrest systems require proper safety training and a rescue procedure, overhead lifeline systems are completely hands-free and enable users to concentrate on the task at hand.

Shorter Fall Distance

Our systems have the advantage over cable-based lifeline systems because they reduce fall distance and are often preferred when work is performed less than 12’ above a lower level.


Our enclosed track rigid rail systems are the most reliable engineered fall protection in use today and the 1:100 movement-to-weight ratio keeps the lifeline directly overhead eliminating in-line swing fall.

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Rail Safety Solutions

Overhead Rail

Rigid Rail overhead protection systems traditionally outperform cable-based lifeline products by arresting falls in a much shorter distance than other lifeline products. This makes our systems the go-to choice for a variety of industries where crews are required to operate a short distance above the work floor. Designed and fabricated to fit your particular requirements, these track & trolley systems provide overhead protection with optional bypass capability.

overhead rigid railhanger rigid rail system

Aircraft Maintenance Rail

Each year, Lighthouse designs, manufactures and installs miles of Single Rail fall arrest solutions. The enclosed track design offers up superior trolley movement, allowing the retractable lifeline to stay directly above the user at all times.

The rigid construction minimizes fall distances allowing for protection at working levels as low as 4'. The Single Rail system is highly configurable with intersections, curves, turntables and span capabilities from 6'-100'.

Available in a variety of finishes, including hot-dipped galvanized, safety yellow and custom colors; the System can match the conditions of your environment and required aesthetics. Major uses for the rigid rail system include aircraft, railcar trucks and a variety of industrial applications.

aircraft overhead rigid railrigid rail systems

Economic Modular Rail

Our Pre-Engineered Rigid Rail is ideal for situations where the fall distance is short and when the work being performed requires extended periods of precision, technical or mechanical, on vehicles with low ground clearances. The unique range of mounting options available ensures a secure installation for a wide variety of roof designs. It is particularly effective when users work at short free-fall distances, such as carrying out operations on trains, trucks, and aircraft with low ground clearances. The lightweight trolley with sealed bearings allows complete hands-free movement throughout the system.

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modular rigid rail system

Truck & Trailer Rail

The enclosed track design of our Truck & Trailer Rail completely eliminates snow or ice build up providing unprecedented ease of movement for outdoor systems. No other rail fall protection system provides bypass capability combined with the benefits of an enclosed track design. The modular construction of these systems makes it simple to add additional sections when you expand your capacities.

rigid rail for trucks

Railcar Rail

Protecting your workforce as they access the top of railcars and tankers is critical to having a safe, compliant, and trouble-free operation. Any loading, unloading, inspection, or maintenance activities on top of tankers and railcars poses a hazard that our Systems are expertly designed to eliminate. Lighthouse Safety's experts take into account the unique requirements of our customers to ensure that each system is designed exclusively for your specific workflow.

Railcar Rigid Rail

Overhead Fall Protection Resources



What is a Rigid Rail fall arrest system?

One of the most common fall arrest solutions, Rigid Rail is an overhead track and trolley fall arrest system, paired with a self-retracting lifeline for workers at height and provide fall arrest solutions in environments that require very short arrest distances.

What rail lengths are available?

With splicing, rails can be engineered to any required length. Typical maximum length to fit on a truck is about 40’.

What fall clearance is required?

Many factors determine fall clearance requirements when using fall protection systems. The lowest clearance requirements can be as little as 2’ up to over 20’ depending on equipment used, system deflection and other safety factors .

Who can install a Rigid Rail system?

Certified installers that are also Competent Persons and under the direct supervision of a QP. Additional trainings and certifications in areas such as lift operation, rigging, and steel erection are often required.

Can Rigid Rail be relocated after it has been installed?

Yes, provided new location can sustain loads and sufficient clearance exists. Inspection and certification is required to verify condition of components before relocation occurs.

Is a Horizontal Lifeline or Rigid Rail system better?

Depends on the application, task, clearance, and feasibility of installation. Rigid Rail offers superior fall distances while Horizontal Lifelines can be installed places Rigid Rail may not be feasible.

What is the minimum ground clearance?


What are the annual inspection requirements?

The frequency will depend upon the environment, location and usage but should be at least every 12 months.

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