Fall Protection Catastrophic Failure–How does it happen?

Installing an effective safety system in an industrial setting is a large task that requires careful planning, proper engineering, and a variety of calculations. Because there are so many different steps in the process of preparing a fall protection system, there is a large possibility for something to go wrong. But, there is a major difference between a system failure and a catastrophic failure. For the purposes of this blog, we will only be addressing these definitions within the realms of fall protection systems.

When a system failure occurs, some part of a fall protection system has been broken during use. But, overall, no one was injured after a system failure. The system still prevented a fall and worker harm. A system failure within an enclosed track fall protection system could be something like a wheel falling off of a trolley or a track getting bent. However, when these events happen, the end user is able to walk away from the fall event without facing serious injury.

When a catastrophic failure occurs, the entire fall protection system collapses and causes tremendous, irreversible damage. An example of a catastrophic failure is when a ceiling mounted rigid track system becomes dislodged from its ceiling mounts. This sort of failure will alter the construction of the building and most likely cause serious worker injury or fatality. Catastrophic failure can occur after improper installation or incorrect usage. But, using buildings that are not structurally supportive and using parts that are poorly built can also cause catastrophic failure. These different factors each have a variety of opportunities for error.

If a fall protection system is not installed correctly, there is definitely a potential for catastrophic failure to occur. Improper installation can mean that the system is not bolted together soundly. Or, the system may not be appropriately attached to the building or floor. Improper installation can occur if the people building the system do not follow the assembly instructions. This may cause a serious structural deficiency within the components of the system. If there is a serious structural malfunction, there is a greater chance for a catastrophic failure to occur.

It is important to use the system properly to ensure that catastrophic failure is avoided. As defined by OSHA, every fall arrest system must have a “Competent Person” supervise the installation and use of fall protection systems. Two of the most common problems are that people do not wear their harnesses correctly and they do not properly anchor themselves to their deceleration device. Although incorrectly wearing a harness and incorrectly anchoring can cause injury and fatality, those actions do not typically cause catastrophic system failure. However, an incorrect analysis of how a fall arrest system will interact with a building is a huge contributor for catastrophic failure.

During the early planning stages of installing a fall protection system, it’s critical that an architectural engineer determines the structural capabilities of the installation location. If a system is installed in a building that cannot handle the capacity of the system and people, then, there is a potential for catastrophic failure. Early planning is also performed by a “Qualified Person” or fall protection engineer. Fall protection engineers need to review the proposed application for potential catastrophic failures like “leading edge” failures where structural components could sever lanyards. The “Qualified Person” would also review swing fall hazards and fall clearance hazards that could catastrophically injure a worker during a fall.

Preventing catastrophic system failure is a team effort. Everyone who is involved with any part of the system (from design to production to installation) has an important role to play in keeping people safe. If only one person was responsible for the entire system, it would be impossible to have a product of high quality. Fall protection is a group effort and everyone in this industry has an important role in the safety and well-being of other people. Our systems have the potential to save lives and it’s up to us to ensure that they do.

Stay Safe!

Hannah Addison