512 EM 385-1-1 Chapters 16-22

Sections

21-8. General Requirements.

Fall Protection Threshold Height Requirements

Fall protection is required at 6 feet (1.8 m) for most work and at 4 feet (1.2 m) for work on or near open-sided floors, platforms, or unprotected edges in USACE-owned or operated facilities.
Workers must use guardrails, work platforms, safety nets, or personal fall protection systems when exposed to fall hazards.
For steel erection, connectors must be 100% tied off when working at connecting points.

Fall Protection Control Measures

Eliminate or prevent fall hazards by modifying work areas or tasks to remove the need to work at heights.
Use passive controls like guardrails or covers to isolate fall hazards from work areas.
Apply active controls such as personal fall protection systems and introduce administrative controls like warning systems or worker training.

Personal Fall Protection Equipment Systems and Sub Systems

Use personal fall protection equipment that meets ANSI/ASSP Z359 standards for working at heights.
Select personal fall protection equipment based on work type, environment, worker characteristics, and anchorage details.
Ensure anchorages can support required loads, use appropriate anchorage connectors, and select suitable connecting means like lanyards or self-retracting devices.

Hardware, Body Harnesses, and Personal Fall Arrest Systems (PFAS)

Ensure hardware like snap hooks and carabiners are self-closing, self-locking, and meet required strength standards.
Use only full-body harnesses with necessary attachment points and equip them with fall-arrest indicators and suspension trauma preventers.
Configure PFAS to limit free-fall distance and arrest force, and choose appropriate lanyards based on the anchor point's location relative to the dorsal D-ring.

Specialized Systems and Additional Requirements

Follow specific guidelines for flexible horizontal lifelines (HLLs), single anchor lifelines, and climbing ladder fall arrest systems (CLFAS).
Consider using a restraint system over fall arrest on flat or low-sloped surfaces and ensure anchorage strength meets requirements.
Use positioning systems in conjunction with other fall protection systems, ensuring appropriate anchorage strength and worker tie-off.

Knowledge Check Choose the best answer for the question.

21-6. What is the required height for fall protection required for most work?

4 feet

5 feet

6 feet

10 feet

You forgot to answer the question!

EM 385-1-1 Paragraph 21-8 (a.–c.).

21-8. General Requirements. (a.–c.).

a.  Fall Protection Threshold Height Requirements.  Floating plant and vessels are excluded from these requirements, except where specifically cited in chapter 19.  See chapter 25 for fall protection requirements in excavations.  (21-8.a)

(1)  Unless specified differently below, the fall protection threshold height requirement is 6 feet (1.8 m) for all work covered by this manual.  This requirement applies to both government and contractor workers and includes steel erection activities, systems-engineered activities (for example, prefabricated), metal buildings, residential wood construction, scaffolding work, installing or removing sheet piles, cofferdams, h-piles, or other interlocking materials.

Note.  Do not use sheet pile stirrups as a fall protection method.

(2)  For all work performed on USACE-owned or operated permanent facilities, the threshold height requirement when working on or near open-sided floors, platforms, or unprotected edges is 4 feet (1.2 m).

(3)  Workers exposed to fall hazards must be protected from falling to a lower level by the use of standard guardrails, work platforms, temporary floors, safety nets, engineered fall protection systems, personal fall protection systems, or the equivalent in the following situations:

(a)  Where there is a possibility of a fall from any height onto dangerous equipment, into a hazardous environment, or onto an impalement, provide hazard fall protection, regardless of height.

(b)  Whenever workers are exposed to falls from unprotected sides or edges, access ways, fixed ladders over 24 feet (7.3 m) in height, unprotected roof edge or floor openings, holes and skylights, unstable surfaces, leading edge work, scaffolds, formwork, work platforms, rebar assembly, steel erection, and engineered metal buildings.

(d)  For steel erection activities, when connectors are working at the same connecting point, they must connect one end of the structural member before going out to connect the other end.  The connectors must always be 100% tied off.

b.  Fall Protection Control Measures.  Use the following hierarchy of controls for fall protection to abate fall hazards.  Select and use a fall protection method(s) to protect workers performing work at heights:  (21-8.b)

(1)  Elimination/Prevention.  Remove the hazard from work areas or change the task, process, controls or use other means to eliminate the need to work at heights with its subsequent exposure to fall hazards.  Use the most effective control method, such as build roof trusses on ground level and then lift into place or lower the location of a meter or valve at high locations to the worker’s level.

(2)  Passive Controls (same-level barrier).  Isolate and separate fall hazards from work areas by erecting same-level barriers such as guardrails, walls, covers, or parapets.

(3)  Active Controls (Personal Protective Systems and Equipment).  Use of personal fall protection systems, including and in order of effectiveness:  restraint, positioning, or PFAS. All systems require the use of full body harness, connecting means, and safe anchorage system.

(4)  Administrative Controls.  Introduce new work practices that reduce the risk of falling from heights, or to warn a person to avoid approaching a fall hazard (for example, warning systems, warning lines, audible alarms, signs, training of workers to recognize specific fall hazards).

c.  Personal Fall Protection Equipment Systems and Sub Systems (Active Fall Protection Systems). All personal fall protection systems must meet the requirements contained in ANSI/ASSP Z359 standards.  All newly purchased equipment will meet the latest ANSI/ASSP standards.  Equipment manufactured to ANSI/ASSP Z359.1 prior to
2007 is not permitted on USACE project sites. (21-8.c)

(1)  Use personal fall protection equipment and systems whenever a person is working at heights and exposed to a fall hazard.

Note. It is understood that the provision of fall protection for the first person who establishes anchorages may be difficult because this first person is the source of the initial anchorage. In this situation, fall protection may not be required.  This decision will be made by the CP and documented in the AHA for the task.  After anchorages are installed, fall protection is required.

(2)  Base the selection of personal fall protection equipment on the type of work being performed, the work environment, worker characteristics (for example, weight, size, shape), the type and position and the location of anchorage, and the required length and type of the connecting means needed to perform the work activity.

(3)  Anchorage System (Anchorage PFAS).

(a)  Anchorages used for attaching the PFAS must be independent of any anchorage used to support or suspend platforms.  They must be capable of supporting at least 5,000 pounds (22.2 kN) per worker attached for non-certified anchorages or be
        designed by a QP for twice the maximum arrest force on the body for certified anchorages.

Note.  Do not use electric conduits, utility pipes, ductwork, or unstable points as anchorages for personal fall protection systems.

(b)  Anchorage Connectors.  Use anchorage connectors to attach the PFAS to the anchorage. When anchorage connectors are used to attach the PFAS to the anchorage, they must be capable of withstanding without breaking a 5,000 pounds (22.2 kN) load per attached worker.  Do not attach more than one connecting means (that is, worker) to an anchorage connector, unless designed and designated by a QP or the manufacturer (for example, tripod or davit style anchorage connectors.

(4)  Connecting Means.

(a)  Connecting means and subsystems may include energy absorbing lanyards with snap hooks or carabiners at each end, self-retracting devices (SRDs), or fall arresters (for example, rope or cable grabs).

(b)  Lanyards must be ropes, straps, or webbing made from synthetic materials or steel.

(c)  Energy absorbing lanyards, including rip stitch, tearing, and deforming lanyards must be capable of sustaining a minimum tensile load of 5,000 pounds (22.2 kN).

(d)  Single or "Y" lanyards used in PFAS must not be longer than 6 feet (1.8 m) in length.

(e)  Use a 6 feet (1.8 m) free-fall energy-absorbing lanyard only when the tie-off point is located above the dorsal D-ring, creating a free-fall distance of less than 6 feet (1.8 m). When the energy absorber is deployed during a fall, the average arrest force on the body must not exceed 900 pounds (4 kN) under ambient dry conditions, with a maximum deceleration distance of 4 feet (1.2 m) and the maximum arresting force is 1,800 pounds (8 kN).  (See ANSI/ASSP Z359.13)

(f)  When an anchor point is located below the dorsal D-ring, a free-fall distance greater than 6 feet (1.8 m) is created.  For these situations, use a 12 feet (3.7 m) free- fall energy absorbing lanyard according to the manufacturer’s instructions and recommendations. When the energy absorber is deployed during a fall, the average arrest force on the body must not exceed 1,350 pounds (6 kN), with a maximum deceleration distance of  5 feet (1.5 m) and the maximum arresting force is 1,800 pounds (8 kN). (See ANSI/ASSP Z359.13)

Note. A 12 feet (3.7 m) free-fall energy absorbing lanyard does not refer to the lanyard length.  Instead, it refers to a free-fall distance that is greater than 6 feet (1.8 m) and up to 12 feet (3.7 m) that is created by the anchor point being located below the dorsal D-ring.  The maximum length of the lanyard used must not exceed 6 feet (1.8 m).

(g)  The 6 feet (1.8 m) and 12 feet (3.7 m) free-fall energy absorbing lanyards must meet the requirements of ANSI/ASSP Z359.13.

(h)  Do not loop lanyards over or through an object and then attached back to themselves, unless permitted by the manufacturer.

(i)  "Y" Lanyards (that is, double leg).  When using a lanyard with two integrally connected legs for 100% tie-off, attach only the snaphook, located at the center of the lanyard near the energy absorber, to the fall arrest attachment element of the harness.

(i-1)  The two legs of the lanyard and the joint between the legs must withstand a force of 5,000 pounds (22.2 kN).

(i-2)  When one leg of the lanyard is attached to the anchorage, do not attached the unused leg of the lanyard to any part of the harness except to attachment points specifically designated by the manufacturer for this purpose (for example, lanyard parking attachment element).

(i-3)  The 6 feet (1.8 m) free-fall "Y" lanyard may only be used when the tie-off point is located above the dorsal D-ring height, creating a free-fall distance of less than
            6 feet (1.8 m).

(i-4)  When the tie-off point is located below the dorsal D-ring, the free-fall distance is greater than 6 feet (1.8 m), so a 12 feet (3.7 m) free-fall "Y" lanyard must be used.

Note. A 12 feet (3.7 m) free-fall energy absorbing "Y" lanyard does not refer to the lanyard length.  Instead, it refers to a free-fall that is greater than 6 feet (1.8 m) up to 12 feet (3.7 m) which is created by the anchor point being located below the dorsal D-ring.  The maximum length of each leg of the "Y" lanyard used must not exceed 6 feet (1.8 m)

(i-5)  The maximum arrest force on the body must not exceed 1,800 pounds
            (8 kN).

(i-6)  The 6 feet (1.8 m) and 12 feet (3.7 m) free-fall energy absorbing "Y" lanyards must meet ANSI/ASSP Z359.13 requirements.

(j)  Equip all single and "Y" energy absorbing lanyards with at least one deployment indicator. Design personal energy absorbing lanyards such that it is obvious if they have been activated, or include a warning, flag or label that indicates activation.

(5)  Self-Retracting Devices (SRDs).  All SRDs must meet and be used according to the requirements of ANSI/ASSP Z359.14. Select the type and class most appropriate for the fall hazard and work activities performed.

(6)  Fall Arresters.  Fall arresters (that is, rope grabs) that are designed to be used with a single anchor lifeline or climbing ladder fall arrest systems (that is, ladder climbing devices) must be approved by the manufacturer for such use.  Fall arresters must have a minimum ultimate strength of 3,600 pounds (16 kN).

(a)  For single anchor lifelines climbing ladder fall arrest systems, use the automatic fall arresters.

(b)  The requirements for fall arresters in ANSI/SSP Z359.15 supersede the corresponding requirements prescribed in ANSI/ASSP Z359.1.

(7)  Hardware (Snap hooks, Carabiners, D-rings, and Connectors)

(a)  Snaphooks and carabiners must be self-closing and self-locking, and capable of being opened only by at least two consecutive deliberate actions.

(b)  Snaphooks and carabiners must have a minimum gate strength of 3,600 pounds (16 kN) in all directions (see ANSI/ASSP Z359.12).

(c)  Snaphooks and carabiners must have a minimum tensile strength of 5,000 pounds (22.2 kN).  D-rings, O-rings, snaphooks and carabiners must be capable of withstanding a tensile load of 5,000 pounds (22.2 kN).

(d)  Connectors, adjusters, and any buckles used as adjusters must be capable of withstanding a minimum tensile load of 3,372 pounds (15 kN).  They must be made of drop forged, pressed, or formed steel, or made of equivalent materials.  They must have a corrosion resistant finish and all surfaces and edges must be smooth to prevent damage to interfacing parts of the system.

(e)  All connecting components used in PFAS must be compatible and used properly.

Note.  The requirements for hardware and connectors prescribed in ANSI/ASSP Z359.12 supersede the corresponding requirements prescribed in ANSI/ASSP Z359.1.

(8)  Body Harnesses.

(a)  Full Body Harness.  PFAS require the use of a full-body harness.  Do not use body belts.

(b)  Only full body harnesses meeting the requirements of ANSI/ASSP Z359.1 or Z359.11 are permitted.

(c)  All full body harnesses used in PFAS must permanently incorporate a dorsal attachment element (that is, D-ring), may contain any combination of other elements, and must permanently include a load bearing sub-pelvic strap.  All full body harnesses must permanently incorporate a waist belt, back strap, or other means of controlling the separation of the shoulder straps on the back of the bull body harness.  The dorsal D- ring must be integrally attached and positioned at the wearer’s upper back between the shoulder blades. The dorsal D-ring may also be used in travel restraint and rescue.

(d)  Only use sternal attachment points when determined acceptable by the CP
        and where there is no chance to fall in a direction other than feet first and fall distance is no greater than 2 feet (0.6 m).

Note.  The sternal attachment may also be used for ladder climbing with guided fall arrester, or ladder climbing with an overhead self-retracting lifeline, during fall arrest, work positioning, travel restraint, rescue, or rope access.

(e)  The frontal D-ring is located at the waist for use as a ladder climbing connection for guided type fall arresters where there is no chance of a fall in a direction other than the feet first.  The frontal D-ring is also used in suspended rope access system, work positioning, travel restraint and rescue.

(f)  Equip all full body harnesses with suspension trauma preventers (for example, stirrups, relief steps) to provide short-term relief from the effects of suspension trauma.

(g)  Equip all harnesses with at least one fall-arrest indicator and at least one lanyard parking attachment element having a disengagement load of not more than
        120 pounds (0.5 kN). Use the lanyard parking attachment element to attach the unused leg of the "Y" lanyard to the harness.

(h)  Lineman’s Equipment (electrically rated harnesses).  Body harnesses used around high voltage equipment or structures must be an industry designed "linemen's fall protection harness" that will resist arc flash, such body harnesses must meet the requirements of ASTM F887 and ANSI/ASSP Z359.11 and must bear a label or similar stating such.  The arc flash harnesses must either have straps or plastic-coated D-rings and positioning side-rings in lieu of exposed metal D-rings and exposed metal positioning side-rings. All other exposed metal parts of the linemen's harnesses (for example, buckles and adjusters) must also be plastic coated.  The harness may have no metal above the waist or, if there is, must be equipped with insulated metal components.

(9)  Personal Fall Arrest Systems (PFAS).

(a)  PFASs are generally certified for users within the capacity range of 130 to 310 lbs. (59 to 140.6 kg) and include the weight of the worker, equipment, and tools.

(b)  Do not exceed the 310 lbs. (140.6 kg) limit unless permitted in writing by the manufacturer.

(c)  For workers with body weight less than 130 lbs. (59 kg), use a specially designed harness and a specially designed energy absorbing lanyard that will properly deploy if they were to fall.

(d)  When stopping a fall, the PFAS must limit the maximum arresting force on the body of the employee to 1,800 pounds (8.0 kN) when used with a full body harness.

(e)  Rig PFAS such that a use can neither free-fall more than 6 feet (1.8 m) nor contact any lower level or other physical hazard in the path of the fall.  The free-fall distance of 6 feet (1.8 m) can be exceeded if the proper energy absorbing lanyard is used and there is adequate clearance distance.

Note.  Free-fall distances should always be kept to a minimum.  PFAS must be rigged so an employee cannot free-fall in excess of 6 feet (1.8 m), provided the employer can demonstrate the manufacturer designed the system to allow a free-fall of more than
        6 feet (1.8 m) and tested the system to ensure a maximum arresting force of
        1,800 pounds (8 kN) is not exceeded.

(10)  Flexible HLL.

(a)  Do not use locally manufactured flexible HLLs unless they are custom designed for limited use or site-specific applications by an RPE who is also qualified in designing HLL systems.  See paragraphs 1-2 or 2-2, as applicable, for RPE definition.

(b)  Commercially manufactured HLLs must be designed, installed, certified, and used under the supervision of a QP, as part of a complete PFAS.  The CP may, if deemed appropriate by and under the direction of the QP, supervise the assembly, disassembly, use, and inspection of the HLL systems.

(c)  The design must include drawings, required clearance, instructions on proper installation and use procedures, proof testing reports, and inspection requirements.

(d)  An RPE must design all HLL anchorages who is also trained and qualified in designing HLL systems (see ANSI/ASSP Z359.6).

(e)  The design of all HLLs must be approved by the USACE supervisor or accepted by KO or COR as part of the Fall Protection and Prevention Plan.

(f)  Do not use steel cable or wire rope guardrails as a HLL unless it meets the requirements of an HLL.

(11)  Single Anchor Lifelines.  A single anchor lifeline must have a minimum tensile strength of 5,000 pounds (22.2 kN) and may only be attached to a single overhead
anchorage.  Each worker must be attached to a separate lifeline system.  Single anchor lifelines can be used in horizontal, vertical, and sloped applications.

Note.  The requirements for single anchor lifelines prescribed in ANSI/ASSP Z359.15 supersede the corresponding requirements prescribed in ANSI/ASSP Z359.1.

(12)  Climbing Ladder Fall Arrest Systems (CLFAS).  CLFAS include the carrier, carrier mounting brackets, and the carrier sleeve.  The carrier is a track that is at least 20 feet (6.1 m) in length and consists of a rigid or flexible member that is securely attached to the climbing fixed ladder or to the adjacent structure.  The carrier sleeve (cable grab) is connected to the harness and travels along the carrier during climbing.

(a)  Anchorage strength must be a minimum of 3,000 pounds (13.3 kN) or
        2,700 pounds (12 kN) according to ANSI Z359.16.  The applied load transferred to the system because of a fall must be at least 2,700 pounds (12 kN).

(b)  The carrier sleeve located between the front D-ring of the harness and the carrier must be 9 inches (23 cm) long.

Note. Effective two years from date of this publication, all carrier sleeves used must be equipped with panic grab.

(d)  Ensure that there is 100% transition at the top of the CLFAS for safe access to above work surface or roof.

(e)  Do not install CLFAS on ladders that have three-quarter (3/4) inch (1.9 cm) rungs (for example, commercial off-the-shelf ladders) unless the ladders are designed to withstand the fall forces.

(13)  Restraint System.

(a)  Consider using restraint system over fall arrest.  Restraint is an active fall protection system that prevents the user from reaching an area where a free-fall could occur.

(b)  Anchorages used for restraint systems must be capable of supporting at least
        3,000 pounds (13.3 kN) per worker attached for non-certified anchorages or be designed by a QP for twice the maximum foreseeable force for certified anchorages.

(d)  Select and rig the connecting means to allow travel of the user only so far that they are not exposed to the fall hazard.

Note. When lanyards are used as the connecting means, the lanyard may be longer than 6 feet (1.8 m) and the length can either be adjustable or fixed.

(14) Positioning System.  A positioning system uses some of the same equipment as an active fall protection system (for example, arrest, restraint).  However, a positioning system used alone does not constitute fall protection and an additional fall protection system must be used in conjunction (for example, PFAS).  The following are system requirements for positioning systems:

(a)  They must be rigged such that a worker cannot free-fall more than 2 feet
        (0.6 m).

(b)  Anchorages used for attached positioning systems must be capable of supporting at least 3,000 pounds (13.3 kN) per worker attached for non-certified anchorage or twice the potential impact load of a worker fall for certified anchorage or, whichever is greater.

(d)  Use attachment points for positioning on the full body according to the manufacturer’s instructions (for example, sides or front of the harness).

(e)  Positioning lanyard can be adjustable or fixed.