In this module
Objectives covered: LO 1.9.1. By the end you will be able to:
- Know the heights at which fall protection is required.
- Name the parts of a personal fall arrest system (ABCD).
- Inspect a full-body harness and plan for rescue.
- Choose high-visibility, flame-resistant and chemical protective clothing.
9.1 Why falls matter
Falls from height are one of the leading causes of death in construction worldwide, and in Bangladesh building sites, shipyards and factory roof work. Most falls happen from less than 6 metres: from scaffolds, ladders, roof edges, floor openings and the edges of ship hulls.
9.2 When is fall protection required?
- OSHA construction (1926.501): 6 feet (1.8 m) or more above a lower level.
- OSHA general industry (1910.28): 4 feet (1.2 m) or more.
- Many international companies and the oil and gas industry use 1.8 m or less as their own rule. Any height above machinery, open tanks or water needs protection.
Use the fall-protection hierarchy: eliminate work at height (assemble on the ground), use collective protection (guardrails, covers, nets), then fall restraint (stops the worker reaching the edge), and only then fall arrest (stops a fall after it starts).
9.3 Personal fall arrest system: the ABCD
| Part | What it is | Key requirement |
|---|---|---|
| Anchorage | Secure point the system attaches to | Supports 5,000 lb (22.2 kN) per worker, or designed with a safety factor of 2 by a qualified person (1926.502(d)(15)) |
| Body harness | Full-body harness with dorsal D-ring | Body belts are not allowed for fall arrest |
| Connector | Shock-absorbing lanyard, self-retracting lifeline, locking snap hooks | Only self-locking snap hooks and carabiners |
| Descent and rescue | Plan and equipment to rescue a fallen worker | Prompt rescue must be provided (1926.502(d)(20)) |
OSHA 1926.502(d)(16) also limits the system so that the maximum arresting force on the worker is 1,800 lb (8 kN) with a harness, free fall is no more than 6 ft (1.8 m), and the worker does not hit the level below.
9.4 Fall clearance
A fall arrest system needs space below the anchor. A typical 1.8 m shock-absorbing lanyard needs about 5.5 to 6 m of clear space below the anchor point:
- Lanyard length: 1.8 m
- Shock absorber opening: up to about 1.1 m
- Harness stretch and D-ring shift: about 0.3 m
- D-ring to the worker's feet: about 1.5 m
- Safety margin: about 0.9 m
If there is not enough clearance, use a shorter lanyard, a self-retracting lifeline, or a restraint system instead. Anchor overhead where possible.
9.5 Harness inspection
Inspect before each use, and have a competent person inspect at least every 6 months (or as the maker says). Remove from service if you find:
- cuts, burns, frayed or hard webbing, or paint and chemical damage,
- broken or pulled stitching,
- bent, cracked or corroded buckles and D-rings,
- a deployed shock absorber or fall indicator, or a missing label.
Any harness or lanyard that has arrested a fall must be removed from service.
A worker hanging in a harness can lose consciousness from suspension trauma (orthostatic intolerance) within minutes. Have a written rescue plan and trained people with rescue equipment on site before work at height starts.
9.6 Protective body wear
| Clothing | Standard | Use |
|---|---|---|
| High-visibility vest or jacket | ANSI/ISEA 107 Class 1, 2, 3; ISO 20471 | Near vehicles, cranes and forklifts; Class 3 for roads and night work |
| Flame-resistant (FR) coverall | NFPA 2112; ISO 11612 | Flash fire risk in gas fields, refineries, LPG plants |
| Aluminised clothing | ISO 11612 | Molten metal and radiant heat at furnaces |
| Leather welding apron and jacket | ISO 11611 | Welding and cutting spatter |
| Chemical protective suit | EN 14605 Type 3/4; ISO 13982 Type 5; EN 13034 Type 6 | Type 3 for liquid jets, Type 4 for spray, Type 5 for dust, Type 6 for light splash |
- High-rise construction, Dhaka: bamboo scaffolding is common but is not a reliable anchorage. Good sites install engineered anchor points or steel lifelines on the structure, use guardrails at slab edges and cover lift shafts.
- Ship-recycling yard, Chattogram: cutters working on hull plates wear full-body harnesses connected to a lifeline, plus leather welding jackets and FR clothing.
- Gas field, Sylhet region: all field staff wear FR coveralls rated to NFPA 2112, with hi-vis stripes, plus a portable gas detector.
Learning Check
Answer these two questions to check your understanding. You can try again as many times as you like.