Reaching New Heights of Safety: Conquering Fall Hazards with Rescue Plans


Fatal falls have continually been a problem in the workplace, with the Census of Fatal Occupational Injuries, reporting that in recent years, it can account for upwards of 15%+ of worker deaths.

If you have employees working at heights, simply providing fall protection equipment is not enough to prevent workers from becoming seriously hurt or even killed.  As an employer, you are held legally responsible for providing a fall protection plan (and fall rescue plan) for each employee who might be exposed to fall hazards, according to OSHA Statute 1926.503(a)(1)

Not sure where to begin?

How to Create A Fall Protection Plan – including a Rescue Plan

  1. Identify potential fall hazards in the work area
  2. Select the proper protection equipment
  3. Create a formal, written fall protection and rescue plan
  4. Train your employees and practice post-fall rescues
  5. Schedule refresher training on a regular basis

Identify Fall Hazards in the Work Area

In order to create a successful fall protection plan, start by identifying any existing and potential fall hazards in your work area.  Failure to identify fall hazards is an OSHA violation that could lead to major fines as well as endanger the lives of your employees.

A safety inspection from a specialist trained in fall prevention is your best asset for quickly and effectively identifying potential fall hazards.  This guidance is not only important to best equip your team, but also provides a foundation for your documented plan.

Determining Proper Fall Protection Equipment

Safety Inspections and Fall Prevention Plans in Dallas TX

OSHA allows some flexibility when it comes to the type of fall protection equipment employers must provide, since there’s no one-size-fits-all solution. However, you’ll want some assistance with specific guidelines for your industry to ensure you’re keeping your employees safe with the proper equipment.

Along with passive fall protection equipment such as guardrails, handrail, and other barriers, employers may be required to include a fall restraint system or personal fall arrest system.

  • Fall Restraint System – Prevents a worker from reaching the edge of a fall hazard by restricting their movement to a specific area.
  • Fall Arrest System – Protects a worker after they fall by stopping the fall before the person hits the surface below.

The fall prevention system you need will depend upon your work environment and best safety practices for your employees.

Fall Protection Training: What to do Before and After the Fall

Your training plan should address four stages of fall protection: before the fall, at fall arrest, suspension, and post-fall rescue. Each stage presents its own safety challenges, and workers need to be trained on how to respond, including:

  • Education on fall hazards associated with the work area
  • Proper use of all personal protective equipment (PPE)
  • Proper fitting and use of personal fall arrest systems
  • How to assemble and disassemble equipment
  • How to maintain and inspect equipment
  • Proper handling and storage of PPE to prevent damage like rust and corrosion
  • Post-fall rescue education on physical hazards
  • Post-fall rescue training

Post-Fall Rescue Plan – It’s the Law

Did you know providing prompt rescue to fallen harnassed workers is also the law? OSHA Statute 1910.140 (c)(21) states that the employer shall provide for prompt rescue of employees in the event of a fall.

Why the Law? Suspension Trauma Kills

Fallen workers could be left hanging too long in their harness, which can lead to suspension trauma.  Also known as ‘harness hang syndrome’ or ‘orthostatic intolerance,’ suspension trauma occurs when blood flow to major arteries is cut off by the harness straps due to the pressure of the body weight and/or damage caused by the fall. Prolonged suspension, in severe cases, causes unconsciousness and leads to cardiac arrest.

Despite best efforts to prevent falls in the work area, there’s always a possibility that someone will fall – and you need train your workers on how to provide a fast rescue.

With post-fall rescue training, workers will have the confidence to respond quickly and effectively. Your employees will know what to do, how much time they have, and how to make a safe rescue.

Client Case Study:

A large equipment manufacturer approached W. W. Cannon with a unique fall protection issue – during the assembly process, employees were required to stand on top of the manufacturing equipment, which is 10’ H x 20’ L x 8’ W. What if an employee fell 10 feet? In addition, the manufacturer was struggling with the following requirements for a fall protection system:

  1. The assembly line had a large overhead crane. This was problematic because it ruled out ceiling-mounted fall protection systems and gantry systems.  There couldn’t be anything in the way of the crane – which included the fall protection system. As an additional requirement, the fall protection system had to be able to be moved out of the way quickly and easily.
  2. There was limited floor space, and the assembly line was very busy. The fall protection system could be bolted to the floor, but the footprint had to be small.
  3. Despite limited space, the fall protection system had to cover the entire manufacturing/assembly unit (10’ H x 20’ L x 8’W) with 100% access to the top of the unit – and maintain safety.
  4. W.W. Cannon recommended the Gorbel Fold-Away Fall Protection System with a motorized add-on. When they needed the system, all they had to do was press a button. It was quick and easy to use. Because it was “fold-away”, it was not in the way of the overhead crane.

There is also a non-motorized version of the system, which is much more cost-effective for employers who, in rare cases, need the system to “fold away”.

Next Steps

Providing fall training and a prompt rescue to workers is every employer’s responsibility.  If you already have a documented plan, review your protocols, train your employees, and practice rescues on a regular basis. Keep an eye out for exposing weaknesses and areas in need of improvement. If you don’t have a fall prevention and rescue plan, our safety specialists will assess your work operation and assist you in creating a formal, written plan to prevent fall-related tragedies from happening.

Get a product or service estimate within 48 business day hours or less with our quick quote form. If you need faster pricing, call 800-442-3061.

Find the Right Solution

How can we help you solve your challenges? Reach out and someone will be in touch soon for more details.


Related Stories

Manufacturer Expands and Separates Plant with Innovative Modular Solutions for an Inclusive Workplace.

Industry:  Leading manufacturer of food, agriculture, industrial and animal nutrition products and services. Challenge: Provide an all-inclusive employee area customized…

How to Choose the Proper Drum Handling Equipment for Your Application

Gather Info for Safe, Ergonomic Drum Handlers Choosing the right drum handling equipment is crucial for ensuring safety, efficiency, and…

Dock Design and Planning Guide

The loading dock is essential to any business. It should operate safely, efficiently, and dependably, as it’s a vital part…