How FallProof Solves “Impossible” Safety Challenges

August 17, 2025, 6:43 pm | by Ray Nardo

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)

Swing Arm With Fixed-Track Lifeline While Loading In Steel Manufacturing Plant

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.

Turnkey Fall Protection Projects from Start to Finish

August 4, 2025, 5:36 pm | by Ray Nardo

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.

Rigid Lifeline Foldaway Track Fall Protection System

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.

Demonstration during competent person training.

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: Why One Size Doesn’t Fit All

July 22, 2025, 9:30 pm | by Ray Nardo

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

June 24, 2025, 4:45 pm | by Ray Nardo

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.

 

  1. 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.

  1. 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.

  1. 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.

  1. 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

Preventing Worker Falls in High-Rise Construction

January 4, 2019, 1:49 pm | by Ray Nardo

Netting Systems Save Lives

Horizontal_Perimeter_System_For_Building_FallProof_TorontoHorizontal 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.

Engineered Single Point Anchors: A Custom FallProof Systems Project

January 24, 2018, 3:39 pm | by Scott Daly

Custom Single point anchor application created for clientFallProof 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.

Fall Protection for HVAC Chillers

March 20, 2017, 4:41 pm | by Ray Nardo

Fall hazards for industrial HVAC systemsIndustrial 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.

The Fall Protection Experts Are Taking Your Questions

February 2, 2016, 8:24 am | by Ray Nardo

FAQs about fall protection systems and equipment from FallProof experts.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.

FallProof Has A New Website With You In Mind!

September 15, 2015, 9:34 pm | by Ray Nardo

FallProof Website Redesign AnnouncementIn addition to FallProof working hard to make America’s workplaces safer with installations of fall protection systems, we have been busy redesigning our website to serve you better! New features include:

  • Improved and refined navigation;
  • Responsive to all device sizes;
  • Contact and request a quote forms with document upload;
  • One-click calling by mouse, Skype or phone app;
  • Internal site search;
  • New sidebar menus;
  • Blog posts by topic; and
  • Patriotic color scheme.

Read more.

Debris Netting on the Pulaski Skyway

February 20, 2015, 9:29 am | by Ray Nardo

Pulaski Bridge Debris NettingYou’re probably familiar with the Pulaski Skyway from the opening of the TV show, The Sopranos. It’s the bridge with the black steel truss girders that Tony Soprano drives over on his way home to his New Jersey mansion.

Opened in 1932, the Pulaski Skyway is New Jersey’s most famous elevated roadway. It was built in the 1920s as one of America’s first “super-highways,” and is listed on the National Register of Historic Places. The skyway is named for General Casimir Pulaski, a Polish cavalry officer who led American troops in several New Jersey battles during the Revolutionary War. Read more.