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.

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

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.

Fall Protection Basics

Working at heights can be challenging and difficult. The best way for workers to protect themselves is to remember the basics of fall protection systems. The basics consist of an understanding of the ABC’s of fall protection. The ABC’s of Fall Protection consist of (A) anchorage; (B)body wear, and (C) connectors and can be also known as a PFAS- personal fall arrest system. Although the basics can be boring and simplistic an understanding of them can save your life! Read more.

This blog will discuss the difference between Certified and Non-Certified Anchorage. The main differences between Certified and Non-Certified Anchorage are the different categories of anchorage, the design loads for these anchorages, and who is qualified to authorize the usage of the anchor. Anchorages fall under five unique categories: Fall Arrest; Work Positioning; Travel Restraint; Horizontal Lifeline-Rigid Track; and Rescue and ANSI Z359 provides distinct loading requirements for each. The following design loads- the maximum amount of something a system is designed to handle- specified in the ANSI Z359.2-2007. Read more.

In this blog, we will discuss the 4th and last option on the hierarchy of fall protection. Fall Arrest Systems are last on the hierarchy of Fall Protection because the system and equipment are designed to arrest a fall. Basically, if a fall occurs the system will prevent/arrest the worker from falling to his death or a serious injury. Fall Arrest Systems are also known as Personal Fall Arrest Systems because each employee is equipped with the proper PPE-personal protective equipment combined with a system or anchorage designed to arrest a fall with an acceptable force and clearance margins. Read more.

In this blog we will continue to discuss the hierarchy of fall protection and another way for employers to protect their workers. As previously noted, each fall risk situation should be analyzed on a case by case basis so it is important to understand the work being performed, access to the work area, and the frequency of the work. Here, we will discuss the 3^rd solution on the hierarchy of fall protection pyramid- Fall Restraint Systems also known as Travel Restraint Systems.  Sometimes, Passive Fall Protection Systems- like guardrail- which was discussed in last month’s blog- is not an option and is why an employer moves to the next option on the hierarchy- a Fall Restraint System. Read more.

As discussed in last month’s blog understanding the hierarchy of fall protection will help an employer and employees who are working at heights make their work environment as safe as possible. In this blog we will talk a little more about Fall Prevention Systems which is second on the hierarchy of fall protection. Fall Prevention Systems are second on the hierarchy because the first solution– Elimination- preventing access or removing the hazards is always the safest and best first solution. For instance, removing an air handler from the roof to the ground or replacing a ladder with a stairway are ways to eliminate the fall hazard. Ideally, the safest option to ensure worker safety is to completely eliminate the fall hazard. However, if this not possible a Fall Prevention System can be installed to create a barrier which is another way of eliminating the hazard. Read more.