Falls continue to be the leading cause of death in the construction industry. According to the Bureau of Labor Statistics, there were 865 fatalities due to slips, trips and falls in 2022. Sadly, 700 of these fatalities were the result of falls from elevated heights, such as ladders or roofs, to lower levels. That is almost two worker fatalities every day, on average, from falls to lower levels. These alarming statistics are a great concern!!   Four out of the Top 10 Violations are in the Fall Protection World.

Employers play a crucial role in making sure safety measures are followed. While circumstances may vary for each incident, here are 3 simple steps they can and should take to prevent these unnecessary tragedies.

• Plan ahead to get the job done safely – Employers and supervisors overseeing work at heights should proactively plan projects and integrate safety from the beginning. For example, if the surface is slippery or if the winds are strong, does the work need to be done at that time? What can be done to mitigate hazards?

Examine the work site proactively to identify potential hazards and obstacles. Prioritizing safety from the planning stage allows the teams to adapt and reprioritize efforts and resources as needed.

Make sure your JHA/JSA/Safety Plan is current, and all parties understand the current hazards as the construction changes.

Violation #1 Fall Protection 1926.501

• Proper PPE – Workers exposed to fall hazards must have the appropriate tools and equipment for their work conditions. Equip workers with fall prevention safety-compliant equipment such as anchor systems, guardrails, proper scaffolding, personal fall arrest systems (PFAS) and correctly fitted harnesses.

Keep in mind protective equipment designed for men may not adequately fit or provide proper protection for women. Ensure construction workers of all sizes are fitted properly with safety gear and are trained to wear it properly.

Violation #7 Fall Protection Training Requirements 1926.503

• Train everyone. Every worker must be trained to use the equipment to do the job safely. Training should cover safety practices, emergency procedures and correct equipment usage in a language they understand. Imagine a scenario where workers hear a site manager training them say, “Make sure you tie-off” when working at a height. Now imagine those workers understanding that to mean “take the tie off” and remove a rope rather than ensuring they are secured to a point that will keep them from falling to a lower level. Clear communication that workers understand is paramount to ensuring that workers can perform their jobs safely and effectively.

Always have a plan to provide for prompt rescue of employees in the event of a fall or ensure that employees know how to rescue themselves.

We must do more to protect these workers. Employers and supervisors should lead by example when it comes to worker safety. Encourage and motivate safety compliance as a core value through safety programs that promote a safety-conscious culture and reward employees for helping make their workplaces safer.

Let’s work together to prevent fall hazards and remind everyone to prioritize safety management systems. These simple yet critical actions can make all the difference in saving lives.

Follow us on these platforms to stay aware of Fallproof’s protection solutions.

What looks impossible to others is just another puzzle to us.
There are some projects where you look at the space and think, “There’s no way we
can install fall protection here.” That’s where FallProof Systems shines.
We specialize in solving problems that leave other providers scratching their heads —
and we’ve got the success stories to prove it.

Common “Impossible” Scenarios
 No structural overhead support for lifeline systems
 Continuous machine operation — no downtime available
 Facility access restrictions (tight quarters, live wires, historic preservation)
 Non-penetrating solutions needed (no anchoring allowed)

How We Make It Possible
Our process is what makes the difference:
1. Field Engineering & 2D Modeling
2. Structural Load Evaluation
3. Creative Design Solutions — like offset anchors, freestanding bases, or
modular track systems
4. Turnkey Installation with minimal facility disruption

Real-World Example:

One of our clients had a blow-mold machine jammed into a corner with no anchor points
and no clearance for scaffolding. We engineered a cantilevered rigid track system
from adjacent structural steel — installed on a weekend to avoid downtime.

✅ Stuck with a “No Way” Project?
We’ll find a way
📅 Request a site evaluation now

📞 Or call us at (609)-325-5555

Final Thought
Fall protection isn’t about avoiding risk — it’s about engineering solutions that eliminate it.

From Inspection to Installation: A Turnkey Project Walkthrough
Fall protection made simple — because you’ve got enough on your plate.
At FallProof Systems, we don’t just design safety solutions — we deliver them, from your
first call to the final bolt.
If you’ve never partnered with us before, here’s what you can expect from a turnkey fall
protection project.

Step 1: Site Inspection and Hazard Assessment
We walk your facility, take measurements, and identify both compliance issues and
operational risks. Our team documents hazards you may not have even considered.

Step 2: Engineering and System Design
Once we understand the space, we design a system that fits — structurally and
operationally. That includes load analysis, OSHA compliance, and workflow
considerations.
You’ll receive:
-Engineered drawings
-Anchor point layout
-System specs and materials

Step 3: Fabrication and Delivery

Our in-house team fabricates custom components to your exact specs — rails,
brackets, mounts, platforms — ready to install with minimal downtime.

Step 4: Installation and Training
Our trained installers show up, get to work, and leave your facility safer than they found
it. We also provide user training and documentation to close the loop.

Why Go Turnkey?
-Single point of contact
-No finger-pointing between vendors
-Faster timeline and better accountability
-Seamless compliance

Schedule your free fall protection assessment »
Let’s get started: (609)-325-5555

Final Thought
You don’t need a dozen vendors — just the right partner. From walkthrough to walk-off,
FallProof is with you every step of the way.

Custom Fall Protection Solutions for Unique Work Environments

Custom Fall Protection: Why One Size Doesn’t Fit All?
Because safety should adapt to your environment — not the other way around.
Every facility is different. Whether you’re working in a steel mill, food processing plant, warehouse, or on a historic rooftop, one thing is always true: standard fall protection doesn’t cut it.
At FallProof Systems, we know that protecting workers means designing systems that match the environment, operations, and hazards of each specific site.

When “Off-the-Shelf” Doesn’t Work –
Pre-engineered systems often fail in facilities that have:

• Obstructions like overhead cranes, piping, or ductwork
• Unusual rooftop elevations or fragile surfaces
• Tight maintenance access paths
• Historic structures or visually sensitive environments

What Custom Fall Protection Looks Like –
A truly custom solution includes:

• Engineering analysis of structure and workflow
• Unique layout designs based on field measurements
• Custom-fabricated equipment (rails, anchors, platforms)
• Seamless integration into existing infrastructure
  It’s not just about compliance — it’s about real-world usability.

Real Results from Custom Designs
We’ve designed systems for:

• Protecting tanker truck hatches on uneven loading pads
• Installing track systems over machines that never stop running
• Adding fall safety to 100-year-old rooftops without permanent alteration

Let’s Build the Right Fit
Custom doesn’t mean complicated. With FallProof’s turnkey process, we handle everything — from site visit to install.
📅 Schedule a custom fall protection consultation »
📞 Or call us at (609)-325-5555

Final Word
When it comes to fall protection, a tailored solution isn’t a luxury — it’s a necessity.

The Hidden Hazards You Walk Past Every Day

Skylights, hatches, mezzanine pits. Tops of silos, tanks, or HVAC units. These areas don’t always look dangerous — until someone falls.

When it comes to fall protection in general industry, the two most overlooked categories are:

• Openings that aren’t always open
• Machinery maintenance access points

Both are common. Both are deadly. And both are called out clearly in OSHA and ANSI standards.

1. Openings That Aren’t Always Open

Skylights, roof hatches, mezzanine drops, floor cutouts, and pit access points

These are deceptively dangerous areas. Whether they’re used once a month or once a day, any opening that a worker could fall through must be protected.

OSHA 29 CFR 1910.28(b)(3)(i)

“Each employee must be protected from falling through any hole (including skylights) that is 4 feet or more above a lower level by a cover or guardrail system.”

Even temporary cutouts or uncovered leveler pits during cleaning qualify under this standard.

Skylights Are NOT Safe to Stand On

They are considered holes in the walking-working surface per OSHA. If someone can fall through it, it must be protected.

Common Facility Risks:

• Roof hatches left open during inspections
• Floor holes cut during retrofits
• Dock leveler service openings
• Skylights mistaken for solid surfaces
• Mezzanine transfer zones with no guarding

2. Machinery Maintenance Areas

Elevated or awkward areas where technicians access equipment for inspection, service, or repair

When workers climb on top of equipment — like silos, presses, ovens, or production lines — they’re often exposed to fall risks without dedicated anchor points, guardrails, or designated access platforms.

OSHA 29 CFR 1910.23(c)

“Each employee on a walking-working surface with an unprotected side or edge that is 4 feet or more above a lower level must be protected by guardrail systems, safety nets, or personal fall protection systems.”

ANSI Z359.2 & Z359.18

• Z359.2: Requires hazard assessments and formal procedures for elevated service tasks
• Z359.18: Specifies structural anchorage design and use requirements for fall arrest systems around equipment and machinery

Common Maintenance Hazards:

• Standing on top of industrial ovens, chillers, or presses
• Climbing above ducting or piping for access
• Walking on narrow steel beams or catwalks
• Reaching across conveyor belts or hoppers

How FallProof Fixes the Blind Spots

Our team specializes in designing and installing turnkey fall protection systems for the areas most often missed:

For Openings:

• Skylight safety screens (non-penetrating options available)
• Hatch rail systems with self-closing gates
• Custom floor hole covers that meet load rating standards

For Maintenance Access:

• Overhead rigid tracks for SRL systems
• Custom platforms with guardrails for safe access
• Permanent or portable anchor points for fall arrest
• Field assessments to pinpoint blind spots before they become incidents

📅 Schedule a facility walkthrough »

📞 Or speak directly with our safety engineering team at (609)-325-5555

Final Word

Openings and elevated maintenance zones don’t always get flagged as fall hazards — but they should.

They’re the places where workers take shortcuts, and where one slip can become a catastrophe.

Let’s make sure your facility isn’t one hazard away from a headline.

The Most Overlooked Fall Hazards in Industrial Facilities

Don’t let what you don’t see become your next safety incident.

When people think of fall hazards, they often picture ladders, rooftops, or scaffolding. But in our experience at FallProof Systems, the most dangerous hazards are usually the ones that blend into the background.

Below are five of the most overlooked fall risks we encounter in industrial facilities — and why they matter.

1. Openings That Aren’t Always Open

Think roof hatches, skylights, floor cutouts, or mezzanine drop zones. These areas are often left uncovered or unguarded “just for a minute,” but that minute can change everything. Skylights in particular are notorious for being mistaken as solid surfaces — until someone falls through.

2. Machinery Maintenance Areas

Industrial equipment like silos, tanks, and conveyor systems require routine inspection and servicing — often from the top. Without anchor points, portable rails, or engineered lifelines, these become some of the most dangerous areas in a facility.

3. Catwalks and Elevated Platforms

Partial or gapped guardrails are a silent threat. Whether due to outdated design or equipment access needs, these “mostly protected” areas invite risk. One missed step or unguarded edge is all it takes.

4. Temporary Access Structures

Mobile stairs, rented scaffolds, or short-term work platforms may not meet the same safety standards as permanent structures. But OSHA doesn’t care how long something is there — if there’s a risk, protection is required.

5. Loading Docks and Truck Bays

Loading docks are usually just under 4 feet high — but don’t let that fool you. Dozens of injuries occur each year from falls at these edge zones. Workers guiding materials, distracted by forklifts, or navigating poor lighting are particularly vulnerable.

Why These Hazards Get Missed

They don’t look like traditional fall risks. They’re often in spaces no one assumes are hazardous — until someone gets hurt. These “in-between zones” are where safety plans fall short.

FallProof Sees What Others Miss

At FallProof Systems, we take a comprehensive approach to every walkthrough, identifying hidden hazards and designing solutions tailored to your space — from custom guardrails and overhead anchor tracks to mobile anchor units like The Grabber.

✅ Ready to Uncover the Hidden Risks?

Let us help you turn blind spots into protected zones.
📅 Schedule a Safety Assessment Today »

📞 Or call us at (609)-325-5555

This blog is brought to you by FallProof Systems to educate our clients and colleagues on the fall risks associated with different workplaces and jobs.

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A simple question we get every day is….” Can you just give me some simple tips when my crew is working at heights?”

Well, yes, we can. First of all, falls are deadly! You must be prepared to protect your employees when working at heights. Working at heights refers to any work that is above ground in which a person could injure themselves if no precaution is taken. Fall protection is required when there is a fall greater than 6 feet within a 6 foot leading unprotected edge. Now that we have the simple prerequisites determined, here’s what to do:  Read more.

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This blog will be a two-part discussion on Inspections of Fall Protection Systems. This month we will cover the OSHA (Occupational Safety and Health Administration) and ANSI (American National Standards Institute) standards and how to stay in compliance according to revised Walking-Working Surface Standard which OSHA made effective by January 17, 2017. The revised OSHA Walking-Working Surface Standard along with the ANSI standard define the responsibility of the employer and employee for inspecting Fall Protection Systems in the Construction Industry and General Industry. Read more.