⛑️ Fall Protection Management Playbook
Falls are the leading cause of death in construction. Managing fall protection isn't just harnesses and lanyards — it's inspections, rescue planning, training, and documentation. This playbook keeps your workers safe and your program compliant.
Why This Matters
| Without Fall Protection Management | With Fall Protection Management |
|---|---|
| Falls from elevation — #1 cause of construction fatalities | Systematic control of fall hazards |
| Harnesses damaged or misused; workers don't know | Inspected equipment; trained workers |
| No rescue plan — suspended worker waits too long | Rescue plan in place; drills conducted |
| OSHA citations for fall protection violations | Documented inspections, training, rescue readiness |
| Anchor points untested or inadequate | Anchor points documented and verified |
Suspension Trauma
A worker suspended in a harness can lose consciousness in 15–30 minutes. OSHA requires a rescue plan before work at heights begins. Rescue within 4–6 minutes is the goal.
Roles and Responsibilities
| Role | Responsibilities |
|---|---|
| Competent Person | Inspect fall protection systems; identify hazards; authorize corrective measures |
| Foreman / Supervisor | Ensure workers use fall protection; verify pre-use inspections; enforce rescue plan |
| Safety Director | Maintain inspection program; track training; conduct rescue drills; audit compliance |
| Workers | Inspect harness before each use; wear fall protection when required; participate in rescue drills |
| Anchor Installer | Install and document anchor points per engineered specifications |
When Fall Protection Is Required
OSHA 1926.501 — Construction: 6-foot rule
| Situation | Fall Protection Required |
|---|---|
| Unprotected sides and edges | 6+ feet above lower level |
| Leading edges | 6+ feet (special rules for leading edge work) |
| Holes | Any size — cover or guard |
| Formwork and rebar | 6+ feet |
| Excavations | 6+ feet (sloping or other protection) |
| Scaffold | 10+ feet (4 feet in some states — check) |
| Steep roofs | 4:12 pitch or steeper |
| Low-slope roofs | 6+ feet from edge |
Note: Some states have stricter rules (e.g., 4 feet). Know your jurisdiction.
Types of Fall Protection
| Type | Use Case | Key Points |
|---|---|---|
| Guardrails | Permanent or temporary edges | 42" top rail, 21" mid-rail, toe board; 200 lb top rail load |
| Safety nets | Under work area | Must be within 30 feet of work surface; certified installation |
| Personal Fall Arrest Systems (PFAS) | When guardrails impractical | Harness + lanyard + anchor; 5,000 lb anchor capacity |
| Positioning systems | Work positioning (e.g., rebar) | Restrain fall; not arrest — used with PFAS |
| Hole covers | Floor openings | Must support 2x intended load; marked "Hole" or "Cover" |
| Controlled Access Zones | Leading edge (eoph roofing) | Limited use; specific rules; trained personnel |
Harness and Lanyard Inspection
Before Each Use (Worker)
| Component | Check For |
|---|---|
| Webbing | Cuts, fraying, burns, chemicals, discoloration |
| Hardware | Cracks, bends, rust, loose parts |
| D-rings | Distortion, cracks, sharp edges |
| Stitching | Broken or pulled threads |
| Lanyard | Cuts, abrasion, shock absorber deployed |
| Snap hooks | Gate function; no damage |
| Connectors | Self-locking; no defects |
If any defect: Remove from service. Tag "Do Not Use." Replace immediately.
Formal Quarterly Inspection (Competent Person)
- Full inspection per manufacturer criteria
- Document: date, inspector, result (pass/fail)
- Failed equipment: destroy or render unusable
- Retain records for life of equipment
Anchor Point Requirements
| Requirement | Detail |
|---|---|
| Capacity | 5,000 lbs per worker (or 2x max arrest force per engineer) |
| Location | Above attachment point; limit free fall to 6 feet |
| Certification | Engineered anchors: documentation on file |
| Temporary anchors | Competent person approval; documented |
Document: Anchor ID, location, capacity, installation date, last inspection.
Rescue Plan Requirement
OSHA requires a rescue plan before work at heights.
Rescue Plan Elements
| Element | Detail |
|---|---|
| Method | How will you retrieve a suspended worker? (Descent device, ladder, another worker) |
| Equipment | Rescue kit on site; trained user |
| Personnel | Who performs rescue? Trained responder(s) identified |
| Communication | How does worker call for help? (Radio, whistle, buddy) |
| Response time | Goal: 4–6 minutes to retrieval |
| Practice | Rescue drills at least annually; document |
Rescue Drill Frequency
- Annual minimum — Full rescue drill
- When crew changes — New workers must participate
- When location changes — Different site may need different method
Training Tracking
| Training | When | Retraining Triggers |
|---|---|---|
| Initial | Before first work at heights | — |
| Retraining | When required | New equipment; new hazard; new procedure; incident; behavior indicates need |
Document: Trainee name, date, trainer, topic, verification (quiz or demonstration).
Leading Edges and Controlled Access Zones
- Leading edge: Unprotected edge of floor, deck, or form
- Controlled Access Zone (CAZ): Area where leading edge work is done; access limited to authorized workers
- CAZ requirements: Warning line 6–15 feet from edge; plan in writing; trained workers only
Hole Covers and Floor Openings
| Requirement | Detail |
|---|---|
| Covers | Must support 2x intended load; secured to prevent displacement |
| Marking | "Hole" or "Cover" — no "Do Not Remove" without securing |
| Guardrails | Alternatively, guard all open sides |
| Immediate | cover or guard before leaving; no overnight open holes |
App Integration Tips
BLDR Pro — Inspection Documentation
Document harness inspections, anchor point verification, and rescue drills in BLDR Pro. Attach photos of equipment condition. Track inspection due dates so nothing falls through the cracks. Pull inspection history for audits.
Safety Meetings App — Training
Use Safety Meetings app to track fall protection training — initial and retraining. Record attendance and completion. Integrate with worker records so you know who's qualified before they go up.
Metrics to Track
| Metric | Target | Frequency |
|---|---|---|
| Fall protection training % | 100% of workers at height | Before work |
| Harness inspections completed | 100% before each use | Daily spot-check |
| Formal (quarterly) PFAS inspections | 100% on schedule | Quarterly |
| Rescue drills conducted | At least annually per crew | Annual |
| Open fall hazards | Zero | Daily inspection |
Common Mistakes
| Mistake | Problem | Fix |
|---|---|---|
| No rescue plan | Worker suspended; no one knows how to retrieve | Develop and document plan before work; drill annually |
| Skipping pre-use inspection | Damaged harness used; failure in fall | Make it habit; foreman verifies; remove defective gear |
| Anchor above feet only | Excessive free fall; injury on arrest | Anchor at shoulder height or above; limit free fall to 6 ft |
| Wrong lanyard for application | Shock load too high; anchor fails | Use correct length; consider self-retracting lifeline |
| No training records | Can't prove workers were trained | Document every training; retain records |
| Cover removed, not replaced | Workers fall through holes | Guard or cover immediately; secure covers |
Troubleshooting
"Workers won't wear harnesses"
- Root cause: Uncomfortable, slowed down, or don't see the risk.
- Fix: Proper fit (different sizes); training on why; enforce consistently; involve workers in choosing equipment.
"We don't have rescue equipment"
- Requirement: You must have a way to retrieve a suspended worker. No rescue plan = don't start work.
- Fix: Purchase descent device or arrange for fire department (confirm they can respond in time). Train responders.
"Anchor points aren't documented"
- Requirement: Engineered anchors need documentation. Temporary anchors need competent person approval.
- Fix: Audit all anchors; document capacity and location; create anchor log.
"Quarterly inspections never get done"
- Fix: Calendar it. Assign to safety director or competent person. Make it part of monthly safety checklist. No inspected harness = no work at height.
Related Resources
| Resource | Link |
|---|---|
| Site Safety Inspection Playbook | Site Safety Inspections |
| JSA/JHA Playbook | JSA/JHA Process |
| Incident Reporting Playbook | Incident Reporting |
| Safety Compliance Guide | Compliance Guide |
| Toolbox Talk — Fall Protection | Fall Protection Talk |