The Problem: Misunderstanding Fall Protection Rules

Falls remain the leading cause of worker fatalities in construction and general industry. OSHA requires fall protection at elevations of 6 feet in construction and 4 feet in general industry, but many worksites either misunderstand these thresholds or apply them inconsistently. Add to that the confusion between OSHA’s minimum standards and ANSI’s best practice guidelines, and it’s easy for a company to believe they are compliant when in reality their workers are still at risk.

Why These Problems Exist

• OSHA vs. ANSI: OSHA standards are law, but they often lag behind industry advances. ANSI standards are voluntary, but they represent the most current thinking on safety. For example:
  • OSHA requires that anchor points support 5,000 pounds per worker, but ANSI clarifies how those anchors should be tested and applied.
  • OSHA requires that a worker’s fall arrest system limit free fall to 6 feet, while ANSI outlines stricter maximum arresting forces to reduce injury risk.
• Training Gaps: Equipment alone doesn’t keep workers safe. If a worker doesn’t know how to inspect their harness, calculate fall clearance, or recognize when a system is improperly installed, the protection fails.
• Site Misconceptions: Supervisors often assume that a “competent person” just means someone with experience, when OSHA requires that person to be trained to identify hazards and authorized to correct them.

These gaps create unsafe environments where a single misstep can lead to a catastrophic fall.

The Correct Solution: Training That Translates Standards Into Practice

This is where structured, hands-on training becomes non-negotiable. FallProof Systems integrates OSHA and ANSI requirements directly into the following programs:

Fall Protection Competent Person Training

• Teaches supervisors and managers how to recognize fall hazards, evaluate systems, and take corrective action.
• Meets OSHA’s requirement that a competent person be present on job sites.
• Covers both OSHA’s baseline and ANSI’s stricter criteria so leaders can exceed compliance.

Authorized User Training

• Gives workers the practical skills to use personal fall arrest systems, harnesses, lanyards, and SRLs correctly.
• Includes pre-use equipment inspection, anchor point selection and fall clearance calculation.
• Reduces the likelihood of improper use, which is a leading cause of harness failure.

General Awareness Training

• Designed for teams, facility staff, or contractors who need an overview of fall hazards.
• Builds company-wide awareness so safety isn’t just the responsibility of supervisors.
• Creates a stronger safety culture across the organization.

How FallProof Integrates Into the Solution

At FallProof Systems, we do more than design and install equipment. We make sure your workforce understands how OSHA and ANSI standards apply to their daily tasks. Training is offered at our Trenton, NJ training center or directly at your facility for convenience. Every class is led by Ray, who brings years of industry knowledge and the ability to translate dense regulations into practical, actionable steps.

The benefits go beyond compliance:

• Lower risk of OSHA citations and fines.
• Fewer accidents and injuries on the job.
• Increased worker confidence and productivity.
• A stronger reputation as a safety-focused employer.

Don’t let confusion over OSHA and ANSI requirements put your workers at risk. Equip your team with the knowledge and confidence to work safely at height.  Contact FallProof Systems today to schedule Competent Person, Authorized User, or General Awareness training.

📞 Let’s get started: (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.

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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.

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.

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.

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.

Much Forethought Goes Into Proper Fall Protection Installation

From a fall protection installation standpoint, the primary goal of the system being installed is to protect workers. The objectives are to get the right system, at the right price, installed on time and on budget, with minimal disruption to the normal activities of the business. Read more.

In our last blog post, we talked about how to form a safety committee at your company. This group should be responsible for developing and maintaining your company’s safety procedures, including your fall protection plan. It should also be responsible for promoting a safety culture at your company, and for ensuring your compliance with OSHA regulations. Read more.

On-the-job safety is a concept that should, of course, extend beyond the use of fall protection systems and fall safety equipment. You should try to develop a culture of safety in your company, and promote that culture in every environment within the facility. Read more.