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

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.

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.

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.

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.

43% of workplace fall fatalities were in the construction industry. Injuries and illnesses from falls are considered preventable incidents that can be minimized or reduced with proper fall protection. Are you in compliance? Read more.

How many times have you gotten the question “When do I need to replace my harness”? The first thing you would do is look to ANSI Standards or OSHA Regulations for an answer. Coincidentally, they leave it up to the manufacturer to determine how long a harness or lanyard should be left in service. Read more.

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.

In this blog we will discuss leading edges and the new self-retracting lifeline issued for leading edges.  What constitutes a leading edge, how the fall protection system and equipment is used as well as understanding OSHA and ANSI standards for leading edges can be difficult and confusing for employers and employees.  Part of the confusion stems from the different definitions OSHA and ANSI have for leading edges as well as the PFAS used by the worker to protect them from the leading edge. 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.