Fall Hazards, Anchor Points and Fall Clearances OSH-2 August 7, 2017 @ 0900 Phil Fincher, CIH, CSP Overview ANSI & OSHA Fall Protection Standards Definitions, Roles, & Responsibilities of Authorized, Competent, Qualified Person Equipment Performance and Limitations Clearance Factors Fall Clearance Calculations (Math & Physics) Clearance Tools/Apps OSH-2: Fincher Page 1
What we re not going to talk about Passive fall protection Guardrails Nets Hole covers Travel restraint Controlled access zones Ladders Key Statistics (2015 OSHA/BLS) Falls were second leading cause of work related fatalities 4,836 workers killed on the job 800 Fatal Falls 81% were falls to a lower level 2 out of every 5 were falls of 15 feet or less. OSH-2: Fincher Page 2
Key Statistics (2015 OSHA/BLS) ANSI Fall Protection Standards ANSI Z359: Fall Protection Code 16 Standards (First published 1992) Z359.1 2016: Safety Requirements for Personal Fall Arrest Systems Z359.2 2017: Min Requirements for a Comprehensive Managed Fall Protection Program Z359.13 2013: Personal Energy Absorbers and Energy Absorbent Lanyards OSH-2: Fincher Page 3
OSHA Standards 1910.21 67 Walking Working Surf (Sub. D) 1910.140 Personal Fall Protection 1926.500 503 Fall Protection (Sub. M) 1926.750 Steel Erection 1926.700 Concrete & Masonry 1926.451 Scaffolds 1926.1053 Stairs and Ladders 1926.453 Aerial Lifts 1926.603 Pile Driving 7 Summary: 1910.140: Personal Fall Protection Equipment specifications & performance criteria Anchorage capable of supporting 5,000 lbs or designed/engineered by qualified person with a 2X safety factor Anchorage annual inspection by QP Anchorage certification by QP Pre use inspection for mildew, wear, damage, deterioration, etc Prompt rescue OSH-2: Fincher Page 4
OSHA Trigger Heights 4 feet General Industry 6 feet Construction 10 feet Scaffolding 15 feet Steel Workers 30 feet Steel Connectors Authorized/Competent/Qualified Person Authorized Person (1910.21): means an employee who the employer assigns to perform a specific type of duty or allows in a specific location or area. Competent Person(1910.140): person capable of identifying existing and predictable hazards in any fall protection system or component, application of use, and has authorization to take prompt corrective action to eliminate the hazard. Qualified Person (1910.21 & 1910.140): person who possesses degree, certificate, training, experience and has demonstrated ability to solve or resolve problems relating to the subject matter. OSH-2: Fincher Page 5
Qualified Person (QP) Engineering and design: Anchor Points: Design for 2X max loading Selection of Certified Anchorages Horizontal lifelines Duties of Qualified Persons Anchorage: initial certification and at least every 10 years Lanyards and vertical lifelines QP to inspect each knot before use Horizontal lifeline designed, installed and used under the supervisor of QP Rope descent system: annual inspection OSH-2: Fincher Page 6
Competent Person (CP) Fall Hazard Survey Fall Protection Plan Equipment Selection Verify Clearance is Adequate Train workers (Authorized Person) Stop Work Equipment Inspection (Quarterly Annually depending upon usage) Authorized Person Properly use, inspect, maintain, store and care for fall protection equipment Pre use inspection of all fall protection equipment Notify CP of damages or defects OSH-2: Fincher Page 7
Other Roles/Responsibilities (ANSI Z359.2-2017) Competent Rescuer Authorized Rescuer Trainers Classic Fall Protection Considerations Max Free Fall= 6 FT Deceleration Distance= 3.5 FT (full lanyard deployment) Harness Stretch= 1 FT Clearance Margin/Safety Factor= 2 FT Anchor Point= 5000 LB capacity (non certified); 2X (certified) per person Arresting Forces <1800 LBS Prevent contact with lower level/object OSH-2: Fincher Page 8
OSHA-Free Fall Distance OSHA Letters of Interpretation (Dec 4, 1996) OSHA will permit > 6 ft free fall max arresting force must not exceed 1800 lbs 1910.140 (2)(ii) (Nov 18, 2016) A free fall may > 6 ft if employer can demonstrate that the manufacturer designed systems to allow > 6 FT FF to limit arresting forces to 1800 lbs Weight, Distance and Deceleration OSH-2: Fincher Page 9
Physics 101 Arresting Forces Weight, free fall distance, and arresting distance Fall Forces- Non-Shock Absorbing Lanyard Non shock absorbing web lanyard with 220 pound steel weight OSH-2: Fincher Page 10
Fall Forces-Shock Absorbing Lanyard Miller Shock absorbing web lanyard with 220 pound steel weight Source: Miller Fall Protection TL 048 Potential Fall Arrest Forces Anchor Points 5000 lbs (non certified) 2X max load (1800 x2) (certified by QP) Common building systems (non certified) I beams Trusses Columns OSH-2: Fincher Page 11
Anchors Structural Anchor for Equip Maintenance OSH-2: Fincher Page 12
Roof Anchors Temporary Anchors OSH-2: Fincher Page 13
Free Standing Anchors Counter Weight Jib 28 OSH-2: Fincher Page 14
I-Beam Anchors Equipment/Hardware Shock Absorbing Lanyard Self Retracting Lifelines Rope & Cable Grabs Carabiners Cross Arm Strap Full Body Harness OSH-2: Fincher Page 15
Fixed Length Lanyards Elongate at a prescribed force Absorbed energy= Force x Distance Elongation increases clearance below the anchor point and platform Energy Absorbing Lanyards ANSI Z359.1 6 FT Free Fall Up to 310 lbs, 3.5 FT max elongation ANSI Z359.13 Increased test mass/weight from 220 to 282 lbs Increased elongation from 3.5 FT to max of 4 FT 6 FT Free Fall & 12 FT Free Fall Design 6 FT: Labels with Black Print on White Background 12 FT: Labels with White Print on Black Background OSH-2: Fincher Page 16
ANSI Z359.13-Energy Absorber Classes 6 FT FF Lanyard Max 6 FT FF worker weights 130 310 lbs 4 FT Elongation for 6 ft FF 12 FT FF Lanyard Max 12 foot free fall worker weights 130 310 lbs Max 6 ft FF worker weights 310 420 lbs 5 FT Elongation for 12 ft FF 3.5 FT Elongation for 6 ft FF Anchor & D-Ring Extensions D ring Extension (+ 1.5 FT) Cross Arm Anchor Independent Energy Absorbers (+ 5.5 FT) OSH-2: Fincher Page 17
SRLs 35 SRLs Applications Fall Restraint, Arrest and Rescue ANSI Z359.14 SRL SRL R (integral rescue for confined space, etc) SRL LE (leading edge) Class A: Max arresting distance= 24 inches Class B:Max arresting distance=54 inches OSH-2: Fincher Page 18
SRL Considerations Weight Limit/Capacity Swing hazards/swinging falls Work location/distance from vertical position Limit swing drop distance to 4 FT See Chart 1 (opposite) 37 Visual Load Indicators OSH-2: Fincher Page 19
Equipment Testing-ANSI Z359.14 Test Mass Test weight = 282 lbs Represents 310 lb worker Old test weight was 220 lbs OSHA has used 1.4 multiplier ANSI uses 1.1 multiplier Harness Stretch Normal harness ~ 1 ft Comfo harness ~ 2.5 ft ~3 FT ANSI Z359.6, 7.2.4 Stretch Out Assume 2.5 FT if manuf. info not available OSH-2: Fincher Page 20
Normal Harness Stretch-Suspended Load Comparing Harness Stretch OSH-2: Fincher Page 21
Types of Clearance Available Clearance Required Clearance What if required is > available What tools do we need to assess clearance Understating of equipment use and limitations Spatial relations Math/Physics/Engineering OSH-2: Fincher Page 22
Types of Clearance Clearance below the anchor point (Ca) Clearance below the platform (Cp) Ha= Height of anchor above platform Ca=Ha+Cp Clearance Anchor Point 18.5 FT Required clearance below anchor= 17.5 FT Length of Lanyard= 6 FT Elongation=3.5 FT Final Height of Worker= 6 FT Clearance= 2 FT OSH-2: Fincher Page 23
Clearance Factors Free Fall Deceleration Distance Fixed length Automatic Harness Stretch Worker Stretch Out (kneeling & lying workers for SRL) Clearance Margin/Safety Factors 2 FT fixed anchor Important Terms for Lanyard Performance F avg : average deployment force (LBS) F max : maximum deployment force W: weight of worker (lbs) X max : maximum rated extension of PEA H max : maximum free fall distance permitted by the system (ft) OSH-2: Fincher Page 24
PEA Deployment Forces 6 FT FF Lanyard Favg=900 lbs 12 FT FF Lanyard Favg=1,350 lbs *Note: Use average deployment force (Favg) for clearance calculations. Source: 3 M Lanyard Manual Personal Energy Absorber Equation (PEA) ANSI Z359.6 X PEA : Deployment of PEA (ft) W: weight being dropped (lbs) H:Free fall heigh (ft) F PEA : average PEA deployment force (lbs) * NOTE: This formula is for a PEA used with a rigid anchor point all absorbed energy goes into PEA. OSH-2: Fincher Page 25
The PEA Equation Most are taught to assume full PEA deployment Overestimates clearance for short free falls and light workers Can be used by QP to accurately calculate lanyard deployment Manufacturer Lanyard Deployment Data *12 FF Lanyard may be required for 6 FF for 310 lb worker OSH-2: Fincher Page 26
Problem 1: Solve for Favg from Table 1 Table 1 Gives Us: W 310 lbs Free Fall 6 ft X PEA 4 ft Favg? Favg )= 310( Favg= 775 lbs Problem 2: Let s Try it with 6 FT FF Lanyard What is the lanyard deployment for the following: Worker weight= 310 lbs Free Fall= 6 FT Lanyard Favg= 900 lbs X PEA = 3.2 FT = OSH-2: Fincher Page 27
Problem 3: Let s Try again with a 12 FF Lanyard What is the lanyard deployment for the following: Worker weight= 310 lbs Free Fall= 6 FT High Force Lanyard Favg= 1350 lbs = X PEA = 1.8 FT Fixed Length Lanyard Clearance below the anchor (Ca): Ca=Ly+ X PEA +Hw+CM Given values from previous example (Problem #3) Ly=6 FT X PEA =1.8 FT Hw=6 FT CM=2 FT Ca=6+ 1.8+6+2 Ca= 15.8 FT OSH-2: Fincher Page 28
What else can we solve for? Max free fall height (h max )if we have maximum PEA deployment (X max ) and average deployment forces (F avg ) ) Max worker weight (W max ) if we have average deployment forces (F avg ) maximum PEA deployment (X max ) and free fall height (h) W ) Problem 4: Max Free Fall Height Using values from Problem 3 ) )4 7.6 OSH-2: Fincher Page 29
Problem 5: Max Worker Weight Using values from Problem 3 4: W ) W 900 ) We know from ANSI that a Z395.13, 6 FT FF Lanyard Max Worker wt= 310 lbs. SRLs Lock Off Speed (ft/sec) Free Fall (excluding leading edge) 0.5 1.5 FT Deceleration Distance (max) Class A= 2 FT Class B=4.5 FT Arresting Forces (max) Class A=1350 lbs Class B= 900 lbs OSH-2: Fincher Page 30
Worker Stretch Out SRL clearance Kneeling Worker (+2.5 FT) D ring 2.5 ft closer to ground Lying Worker (+ 4 FT) D ring is 4 ft closer to ground Automatic/SRL-Overhead Anchor Clearance below the platform: Cp=FF+DD+Xw+CM + 2.5 ft for kneeling worker +4 ft for lying worker OSH-2: Fincher Page 31
Class A SRL Class B SRL OSH-2: Fincher Page 32
Swing Fall Hazards Dynamic Falls Swing Drop Distance (SDD) Drop in height of D ring from onset of swing to the point where person may impact any structure Swing Fall Distance (SFD) Drop in height of D ring from onset of swing to lowest point it reaches during swing. OSH-2: Fincher Page 33
Clearance Pictograms Source: Elevated Insight (ƩI) Clearance Pictograms OSH-2: Fincher Page 34
Horizontal Life Line Deflection HLL Sag OSH-2: Fincher Page 35
Tip Over/Force Management Anchors Web tools New Tools-Web & Apps http://www.capitalsafety.com/en us/pages/fall Clearance Calculator.aspx https://www.millerfalltraining.com/fallclearance/#home0 Apps http://www.honeywellsafety.com/usa/mobilesafetytools/fall clearance calculator app/ https://play.google.com/store/apps/details?id=com.highengineering.fallclearlt&rdid=com.highenginee ring.fallclearlt&pli=1 OSH-2: Fincher Page 36
On-Line Calculators Lanyard Input OSH-2: Fincher Page 37
Clearance Calculation Output SRL-Anchor Point 6 FT OSH-2: Fincher Page 38
SRL Output-Anchor Point 20 Ft Thank you for your time Contact info: Phillip Fincher, CIH, CSP pfincher@ei1.com OSH-2: Fincher Page 39