Why Fall Protection Must Be Planned Early

Falls remain one of the leading causes of serious workplace injuries and fatalities. According to OSHA, falls account for more than 30% of all construction-related deaths annually. Whether you’re designing a new facility or managing an existing one, planning for fall protection early is critical.

The approach to fall protection often differs between new construction projects and retrofitting existing facilities — but in both cases, having a well-engineered, OSHA-compliant solution can reduce risk, lower costs, and protect your workers.

Understanding OSHA & ANSI Standards

When planning fall protection, compliance with OSHA and ANSI standards is essential:
• OSHA 1910 Subpart D – Walking-Working Surfaces
• OSHA 1926 Subpart M – Construction Fall Protection
• OSHA 1910.28 – Duty to Provide Fall Protection
• OSHA 1910.140 – Personal Fall Protection Systems
• ANSI Z359.6 – Specifications & Design Requirements for Active Fall Protection Systems
• ANSI Z359.18 – Anchorages & Certification Guidelines

Understanding these standards ensures your systems are safe, compliant, and properly documented.

Fall Protection for New Construction Projects

New construction provides the unique advantage of integrating fall protection systems into the initial design phase. By working alongside structural engineers, FallProof can ensure permanent anchors, guardrails, and horizontal lifelines are seamlessly incorporated into the building structure.

Benefits include:
• Lower installation costs
• Faster OSHA certification
• Reduced retrofit expenses down the road

For example, if roof anchors are installed during steel fabrication, they become part of the structural design rather than requiring expensive retrofitted solutions later.

Fall Protection for Retrofit Applications

For existing facilities, retrofitting fall protection comes with its own set of challenges. These may include limited structural load capacities, existing roof membranes, HVAC equipment, and facility downtime concerns.

FallProof specializes in providing custom-engineered retrofit solutions that balance safety, cost, and operational continuity. Our team designs, installs, and certifies retrofit systems while minimizing disruption to your operations.

Cost & Liability Comparison

Delaying fall protection until after construction often results in higher overall costs. Retrofitting requires additional engineering, material adjustments, and installation challenges that can significantly increase expenses. Additionally, operating without proper fall protection exposes companies to OSHA fines, potential lawsuits, and reputational risks.

By planning fall protection during the design phase, facility owners can achieve significant cost savings and ensure long-term compliance.

Case Study: Engineered Rigid Anchor Track & Single-Point Anchors

• Client: Nestlé Waters – Breinigsville, PA 18031
  • Challenge: Multiple elevated work areas lacked OSHA-compliant fall protection for technicians maintaining overhead equipment.
  • Solution: FallProof performed a comprehensive hazard assessment and installed a combination of rigid anchor tracks and engineered single-point anchors. All systems were designed with certified drawings to meet ANSI Z359.6 specifications and OSHA Subpart D/M requirements.
  • Results: Zero fall incidents since installation, 100% compliance, and predictable long-term maintenance costs through our annual inspection program.

Why Partner with FallProof Systems

FallProof Systems offers end-to-end expertise in engineered fall protection solutions, from initial hazard assessments to certified designs and multi-year maintenance programs.

Our services include:
• Engineered system design & certification
• Annual inspections and multi-year support agreements
• Discounted soft goods, including harnesses and SRLs
• New partnership with Never Let Go for tool tethering solutions

We help facilities remain compliant, safe, and efficient year after year.

Conclusion & Next Steps

Whether you’re managing a new construction project or upgrading an existing facility, fall protection planning must be a priority from the start. The cost of non-compliance is high, but the cost of prevention is manageable with the right partner.

Contact FallProof Systems today for a free safety assessment and consultation to determine the best fall protection solutions for your facility.

📅 Schedule your free fall protection assessment »

📞 Let’s get started: (609)-325-5555

From the street, your building’s roof might look safe enough — flat, quiet, and far from any immediate danger. But step onto that rooftop, and the picture changes fast.

For countless property owners and facility managers, one of the most serious fall hazards is hiding in plain sight: rooftop HVAC units, vents, antennas, or other equipment located dangerously close to unprotected edges.

Why It’s More Dangerous Than You Think

Contractors and maintenance staff often need to work within a few feet of the roof edge to service equipment. They’re focused on repairs, not their footing — and that distraction is all it takes for a serious or fatal fall.

OSHA’s general fall protection requirement under 29 CFR 1910.28(b)(13) states that employers must ensure workers on a low-slope roof within 15 feet of an unprotected edge are protected by a guardrail, safety net, or personal fall arrest system. That means even if your rooftop equipment isn’t right at the edge, you may still be out of compliance.

The Real Costs of Overlooking Rooftop Safety

• Regulatory fines: OSHA citations for fall protection violations can exceed $16,000 per instance.
• Legal liability: One accident can lead to lawsuits, increased insurance premiums, and damage to your company’s reputation.
• Operational downtime: A fall incident can shut down rooftop access, delaying critical repairs and disrupting tenants.

Permanent Rooftop Guardrail: The Compliant, Low-Maintenance Fix

Unlike temporary measures like warning lines or harness tie-offs, a permanent rooftop guardrail system:

• Meets OSHA requirements year-round
• Protects all workers, employees, contractors, and visitors without special training or PPE
• Requires no ongoing adjustment or setup before each job
• Blends with the building’s architecture to maintain a professional look

Per 29 CFR 1910.29(b), a compliant guardrail must:

• Have a top rail height of 42 inches ± 3 inches above the walking/working surface
• Include a mid-rail halfway between the top rail and the working surface
• Withstand at least 200 pounds of force applied outward or downward

A Safer Roof, A Safer Business

By addressing rooftop hazards now, you’re not just complying with OSHA — you’re preventing accidents, protecting your people, and avoiding costly disruptions.

FallProof Systems specializes in engineered rooftop guardrail solutions tailored to your building and your budget. Our turnkey service covers assessment, design, installation, and inspection — so you can focus on running your business, not managing safety risks.

✅ 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

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 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

Netting Systems Save Lives

Horizontal Perimeter Netting (HPN) Systems save lives by catching a falling worker before they hit the ground. With its concentration of skyscrapers and crowded streets, it is no surprise that New York City has led the nation in requiring HPN systems on high-rise construction projects. Due to its close proximity to NYC, Fallproof has been a leader in the design, testing and supply of HPN systems and components for over 20 years. Read more.

FallProof single point anchors provide a cost effective fall protection in manufacturing plants, distribution centers, steel mills, and other industrial facilities. Typical applications for single point anchors include manufacturing equipment maintenance, routine maintenance on elevated equipment, heavy equipment manufacturing, and processing equipment in food manufacturing. Other applications include access to tops of storage tanks, safe access to security cameras and other equipment mounted near a roof edge. Single point anchors also provided fall protection for workers where ceiling features such as pipes or air ducts prevent the installation of long run horizontal lifelines and rigid track systems. An often overlooked use of SPAs is to provide an anchor for a rescue and retrieval system which is required by OSHA as part of a complete fall protection plan. The single point anchor is a versatile fall protection application that offers a variety of solutions for different industries.
Read more.

Industrial size HVAC chillers present multiple fall protection hazards. When located on a rooftop near an unprotected edge, simply approaching the chiller may expose your worker to the risk of falling. Roof edge guardrail, horizontal lifelines, and fixed anchor points can all be designed to protect your workers as they approach and service the lower areas of the equipment. However, from a hazard analysis standpoint, access to the fans from the top of the housing is probably the area with the greatest risk of falling. Read more.

FallProof Systems is excited to announce that it started 2016 by further expanding its website with the addition of a new section dedicated solely to everyday users of fall protection equipment, and existing customers and their workers. This includes an “ask the experts” form and dedicated question and answer pages organized by industry, known as “Frequently Asked Questions” on many websites. Read more.