The Official Passport
to Safe Work at Height
Fall Protection Essentials
Get a better view from up high!
This guide, developed by Miller®, aims to help you gain a better
understanding of fall protection.
It is designed to provide you with the correct information to improve your
entire working at height thought process.
It also contains specific information on:
How to select the correct Personal Fall Protection Equipment (PFPE) for
your application and understand how it works
Fall protection equipment standards in Europe (ENs)
A simple and clear approach to understand your needs in Fall Protection!
Who are we?
Honeywell Safety Products (HSP) is a leading global
manufacturer of personal protective equipment (PPE),
including head, hearing, eye/face, respiratory, hand, footwear,
clothing and fall protection.
Honeywell has an unmatched portfolio of head-to-toe protection offerings
as well as unprecedented scale and global reach.
HSP is focused on delivering innovative safety solutions for high-risk
environments, allowing workers in the manufacturing and services
industries to perform their jobs with greater confidence. With its focus
on innovation and continuous product evolution, it also helps businesses
comply with emerging safety legislation and standards.
Miller®, part of the Honeywell Safety Products
family of brands, provides safety at height
products: personal fall protection equipment ;
engineered fall arrest systems ; collective fall
prevention/barrier solutions ; and professional services including training,
audits, consulting, product inspection and repairs.
For over 65 years, products labelled with the Miller brand have protected
those working at height in a wide range of industries including : construction ,
oil and gas , telecommunications , wind energy , transportation , mining ,
general industry , utilities and more.
Our Support
With sales offices and training centres throughout EMEA (Europe,
Middle-East & Africa), the Miller brand is supported at a local level
through our highly trained field sales force, a network of fall protection
specialists and experienced customer service staff. Miller Service Points
are conveniently located throughout the world for maintenance of your fall
protection equipment.
®
®
Offices
• Sales
Centres
• Training
• Manufacturing plants
Miller : Your Right Partner
®
2
3
4
5
6
7
8
9
10
Fall from Height Statistics
Every day in Europe at least one person dies from a fall while working at height.
Falls are one of the leading causes of deaths in the workplace.
• In most countries, falls from height account for around 50% of all fatal
accidents with half of those being in construction or related activities.
• The majority of falls are between 2m and 3m.
• The number of major injuries caused by falls from height is around 75 times
higher than the number of deaths*.
• These statistics illustrate humans instinctively take more care when the danger is obvious. Complacency and a willingness to take shortcuts increases
as the apparent level of danger decreases. We must remember to take care
in these situations.
Where does the problem lie?
Various factors contribute to the cause of accidents at height:
• Lack of personal fall protection equipment.
• Poor equipment management leading to out-of-date or unserviceable equipment
being kept in use.
• Inadequate training for both the users of equipment and those managing
the work at height.
Gravity kills...Watch out!
* Source: Mr. Pat McLoughlin from the British Safety Services - Article from «Working at Height»
in the HSME magazine, February 2008
2 steps before considering the use of Personal Fall
Protection Equipment (PFPE)
First step:
AVOIDANCE
Where at all possible, work at height must be avoided. This is easier said
than done; however, sound reasoning is behind this approach,
as many accidents (often fatal) occur at low levels where falling
has not been considered a likely outcome.
Second step:
COLLECTIVE FALL PROTECTION
Collective protection is designed to protect a
group of people and must be given priority over
personal protection measures.
Consider the following options
before a personal solution:
Guardrails, Scaffolding, M.E.W.P.s,
Safety nets, Air bags
PERSONAL FALL PROTECTION EQUIPMENT
Use personal PFPE as a last resort
These protect only the person wearing the equipment at the time
Reduce the potential of falling (Restraint / Fall Arrest)
Reduce the effects of a fall - calculate fall clearance
elect appropriate connecting devices:
S
• Self-retracting lifelines for low-level applications
• Shock-absorbing lanyards when suitable fall clearance is available
WARNING
These actions are crucial in creating a safe work environment. Bear in mind that
even the highest quality products require regular inspection, especially when
safety and well-being of the user are at stake.
Falls from Height Statistics
3
4
5
6
7
8
9
10
Recommendations
for Safe Working at Height
Responsibilities of the employer & the employee
• European Directive 89/656
1-Employer
Analyses and evaluates risks
Decides what PFPE is provided,
how it is used, maintained and stored
Provides PFPE
Inspects and ensures equipment
is compliant
Manages PFPE periodical inspection
and updates of safety registers
Ensures PFPE training
2-Employee
Transmits information up
Uses PFPE at their disposal
Inspects PFPE before use
Follows manufacturers
instructions
Follows PFPE training
Before any work at height, it is absolutely necessary
to answer the following 3 questions:
1 • How to access a high area safely?
2 • How to move and work at height safely?
3 • In case of problems, how to evacuate safely?
Working
at height
Access
Evacuation
Training will help provide you
with answers to these questions.
Recommendations for Safe Working at Height
4
5
6
7
8
9
10
Understanding PFPE
The ABC’s • Your Personal Fall Protection Equipment
• Personal fall protection equipment is used to protect a worker from falls
from height. It consists of three parts:
A • Anchor Device
B • Full Body Harness
C • Connecting Device
+ Training
A simple way of remembering the core components
of a fall arrest system is the “ABC” of Fall Arrest
Quite simply, without one part, the system does not work
This equipment is designed to secure a person to an anchorage point
in such a way that a fall from height is either totally prevented or safely
arrested.
The systems can only be used if a suitable anchorage point is located close
to the work area.
A
B
A • Anchor Device
DEFINITION:
Used to join the connecting
device (work restraint, fall arrester)
to the anchorage, commonly
referred to as the ‘tie-off point’
(I-beam, scaffolding or other structural point)
ANCHOR DEVICE MAY BE ONE OF 2 TYPES:
1 • Permanent anchor device
C
(e.g. horizontal cable lifeline,
horizontal rail systems...)
2 • Temporary anchor device
(e.g. steel strops, scaffold hooks, webbing
anchorage slings, beam grips and dead-weight anchor...)
B • Full Body Harness
DEFINITION:
Used to hold a worker after a fall
• Full body harness must be worn for Fall Arrest situations
• Work restraint belts cannot be used for Fall Arrest
C • Connecting Device
DEFINITION:
Used as intermediate attachment to connect
the worker’s harness to the anchor device
(e.g. shock absorbing lanyard,
self retracting lifeline, fall limiter, rope grab...)
CONNECTING DEVICE MAY BE ONE OF 2 TYPES :
1 • Fall Restraint: a fall restraint system prevents
workers from reaching a hazard
2 • Fall Arrest: a fall arrest system allows workers to
reach a hazard and then protects them if they should fall
Understanding PFPE
5
6
7
8
9
10
Working at Height Categories
Your working at height environment reflects the equipment that must be used.
The categories summarised below have been defined by European Standards
and are used as the base for all high access operations.
Fall Arrest
Equipment used to prevent the operative from hitting
the ground in the event of a fall.
Typical fall arrest system consists of:
Anchor device
Full body harness
Connecting device
Work Positioning*
Equipment holding an operator in their place of work
Typical work positioning system consists of:
Anchor device
Full body harness with a positioning belt
Connecting device (work-positioning lanyard)
Work in Suspension*
Designed to lower and support a worker which allows
a hands-free work environment.
Typical suspension system consists of:
Anchor device
Full body harness
2 ropes: • equipped with a descender
• equipped with a rope grab
* The positioning and suspension systems are not designed for Fall Arrest. A back-up Fall Arrest
system must be used.
Work Restraint (Travel restraint)
Equipment used to prevent the wearer from
approaching a position from which they can fall.
Typical work restraint system consists of:
Anchor device
Work restraint belt or full body harness
Connecting device (restraint lanyard)
Personal Fall Protection Equipment (PFPE) selection
This table shows the minimum harness requirements for each work category.
Some overlap occurs for the application of multi-function harnesses.
Harness
Type
European
Standard
Work
Restraint
Work
Positioning
Work
Positioning
Belt
EN 358
ok ok
Full Body
Harness
EN 361
ok
ok
ok
Full Body
Harness
for workpositioning
EN 361
EN 358
ok ok ok
ok
Multifunction
Full Body
Harness
EN 358
EN 813
EN 361
ok ok ok ok ok
Work in
Fall Arrest Suspension
Rescue
WARNING
An energy absorber MUST be included in the system when using
an EN361 harness for fall arrest purposes.
Working at Height Categories
6
7
8
9
10
Anchor Device
Possibly the most important part of the entire PFPE system, the anchor device
must be 100% reliable.
This should:
• Be located at a safe distance above any lower obstacles.
• Be as vertical as possible to the work station to avoid any pendulum effect.
The anchorage point will form the basis of the whole system.
Poor selection may result in a total system failure.
Anchors Devices • EN795
Standard defines 5 categories
The anchor device may be one of 2 types:
• Temporary
• Permanent
Temporary Anchor Devices
Class B*
Mobile anchorages
A temporary transportable anchor device.
(e.g. steel strops, scaffold hooks, webbing
anchorage slings, tripod and beam grips).
* Class B is PFPE
Class E*
Dead weight anchor
A dead-weight anchor for
use on horizontal surfaces.
* Class E is PFPE
Permanent Anchor Devices
Class A
Fixed anchorages
An anchor device designed
to be secured to vertical, horizontal
and inclined surfaces (e.g. anchor plate).
It could be mounted on wall, inclined roofs, at ground level...
Class C
Horizontal cable lifeline
An anchor device employing
horizontal flexible anchor lines.
Class D
Horizontal rail systems
An anchor device employing
horizontal rigid anchor rails.
WARNING
All anchor devices are tested to hold a fall. Their minimum resistance
is imposed by norms and depends on the recommendations of the
manufacturer or installer.
Anchor Devices
7
8
9
10
Full Body Harness
Selecting the Right Harness
Fall Arrest Anchorage • EN361
Rear Anchorage: The rear D-ring on a
harness is the basic attachment point
for fall arrest. It is suitable for standard
site work where the worker only needs
to be attached for safety and does not
need to work in suspension.
Front D-Rings and Front Anchorage Loops:
Used for a comfortable, fall arrest anchorage
point, usually in conjunction with a guided type
fall arrester. Used for a variety of confined space,
rescue, climbing.
Side D-rings • EN358
Side D-Rings on belt: A work-positioning lanyard is
attached to the side D-rings to enable the operator to
work with his hands free. These are not suitable for
fall arrest.
Work in Suspension • EN813
Used to suspend an operator into a work-station.
Adjustment buckles
Mating Buckle: To connect the
mating buckle, push the centre bar
buckle completely through the
square link and allow it to fall into
place. Pull web end to tighten.
Quick-Connect Buckle: Belt
and leg straps interlock similar
to a seat belt for easy donning
and feature a dual-tab release
mechanism to prevent accidental
opening.
Cam Buckle: The locking tabs of the
cam buckle trap the webbing to
prevent unintentional slippage. Lift
the locking tab for easy, one-hand
adjustment/release.
How to put on a harness?
6 easy steps that can save your life
1
Hold harness by back D-ring.
Shake harness to allow all straps to fall
in place.
3
Slip straps over shoulders so D-ring
is located in middle of back between
shoulder blades.
5
Connect chest strap and position in
midchest area. Tighten to keep shoulder
straps taut. If harness has black elastic
strap, thread strap through final slot to
secure it.
2
If chest, leg and/or waist straps are
buckled, release straps and unbuckle
them.
4
Pull leg strap between legs and
connect to opposite end. Repeat with
second leg strap. If belted harness,
connect waist strap after leg straps.
6
After all straps have been buckled,
tighten all straps so that harness fits
snug but allows full range of movement.
Pass excess strap through loop
keepers.
Full Body Harness
8
9
10
Connecting Devices
Shock-absorbing lanyards
• Maximum length 2 metres. For work requiring
limited movement and where there is a sufficient
potential fall distance.
Shock-absorbing lanyards
• A portable connection between a worker at height and an anchor point.
• Ideally attached above the shoulder.
• Up to 2.0m in length.
• Fall arrest lanyards must incorporate an energy absorber.
Twin lanyards
• Used to ensure connection to an anchorage at all times
when climbing on and around an open structure.
• The unused leg of the twin lanyard must be stowed on a
designated “detachable” point on the harness.
• Keeping the “live” lanyard as high as possible minimises fall
clearance, reducing the effects of a fall by stopping impact
with structures or the ground when working at low levels.
• Two single energy-absorbing lanyards should never be used together.
NO
NO
YES
Restraint and work-positioning lanyards
• Rope, wire rope and web lanyards are recommended
for “work positioning” and “restraint” only.
Self-retracting lifelines
• 1.75m - 54m. Self-retracting lifelines are viable alternative connecting
devices to shock-absorbing lanyards.
• For workers who need to move relatively quickly up and down on a worksite.
• The automatic braking system arrests
a fall in seconds, making this especially
suitable for low-level work.
These are available with webbing or cable.
Webbing retracting lifelines
Cable retracting lifelines
Rope • Rope Grabs
• Commonly found on access ladders.
• The rope grab is your lifeline.
Make sure it is attached to an upper
attachment point on your harness
and DO NOT let it pull the rope up as you climb.
This will not protect you if you fall.
WARNING: Check the user manual
to ensure the rope and rope grap are compatible.
Fall Arresters on Rigid Lines & Rails
Shuttle for cable systems
• For a safe and smooth climbing
on a cable based Fall Arrest System.
Shuttle for rigid rail systems
• For a comfortable and ergonomic
climbing on rigid rail Fall Arrest
System.
Permanently installed climbing systems are tested and certified as a complete
system. Make sure the different components of the system are compatible.
“Edge Tested” Connecting Devices
There are specific products
specially dedicated and tested
for use near edges.
Edge Tested
Always follow the
manufacturer ‘s instructions
when using connecting devices
Connecting Devices
9
10
Fall Clearance
The basics of fall factors • how to reduce the risks?
The fall clearance distance is the maximum vertical distance that a worker
could potentially fall and still avoid contact with a lower level.
Fall distances
Absorber
elongation
FALL
CLEARANCE
Height
of the person
Ground and
dangerous osbacle
VERTICAL CLEARANCE
Length of
the connector
(lanyard)
Best
Length of
the connector
(lanyard)
Absorber
elongation
FALL
CLEARANCE
Safety
distance
Factor 2
Height
of the person
Ground and
dangerous osbacle
Safety
distance
Length of
the connector
(lanyard)
Height
of the person
FALL
CLEARANCE
Factor 1
Ground and
dangerous
osbacle
Safety
distance
VERTICAL CLEARANCE
Good
VERTICAL CLEARANCE
Ok
(only with an energy
absorber)
Factor 0
Calculating Fall Clearance
When using a shock-absorbing lanyard it is important to understand how to
calculate the potential fall distance to avoid contact with the lower level.
The calculation below gives the minimum vertical clearance required
between the anchorage point of the lanyard and the lower level.
Length of lanyard
+ Fully activated energy absorber
+ Body height from feet to harness attachment
+ Additional safety clearance
Length of
the connector
(lanyard)
Absorber
elongation
FALL
CLEARANCE
Height
of the person
Ground and
dangerous osbacle
Safety
distance
VERTICAL CLEARANCE
Examples of calculations using the following
length lanyards are as follows:
2m lanyard: 2m (lanyard length) + 1.75m
(energy absorber) + 2m (body height) +
1m safety = 6.75m
1.5m lanyard: 1.5m (lanyard length) + 1.5m
(energy absorber) + 2m(body height) +
1m safety = 6m
A personal fall limiter limits the fall distance making it an ideal solution
when working at low levels or when fall clearance is critical
The Pendulum Effect
If the lifeline is not anchored vertically over the
working place, the worker will swing laterally
in the event of a fall, and may get injured.
Alternatively two anchorage points either
side of the worker can be used to prevent
any swing.
Anchor
Understanding Regulations
and Standards
We all know that nothing in life can be 100% safe. We strive to make things
as safe as possible by conducting a risk assessment, considering the dangers
and applying suitable controls.
Understanding these requirements is key to ensuring a
safe work environment
Fall arrest equipment legislation
• An important European Directive relates to Personal Protection Equipment
(PPE): Directive 89/656/CEE: Specifically targets the use of PPE at work.
This directive examines the correct usage conditions for PPE, and its role in
improving health and safety conditions in the work place. Referred to in this
directive, PPE is defined as: «...all equipment designed to be worn or held
by the worker with a view to protecting him/her from one or more risks that
are liable to threaten his safety or his health in the workplace...»
• This directive is the one which regulates Miller Safety at Height products.
®
Standard Heading*
EN12841/C
EN 341
EN 353-1 EN 353-2 EN 354 EN 355 EN 358 EN 360
EN 361 EN 362 EN 363 EN 795
EN 813 Rope Access Systems: Back-up Devices
Descender Devices (like AG10 & RG9)
Guided Type Fall Arresters - Rigid Anchorage Line & Rails
Guided Type Fall Arresters - Flexible Anchorage Line
Lanyards
Energy absorbers
Work Positioning Systems
Retractable Type Fall Arresters (Self-Retracting Lifelines)
Full Body Harnesses
Connectors
Fall Arrest Systems
Anchorage Devices - Types a-e.
Sit Harnesses
*Contact Honeywell for any further information
The personal protective equipment manufactured by Honeywell includes
Fall Protection Systems designed to save the life of the worker.
(Category 3 – PPE against mortal or serious and irreversible danger).
Each product conforms
to the harmonised European Standards.
Fall Clearance & Standards
10
Care & Maintenance of PFPE
Care and maintenance of our PFPE is essential for the safe system of work.
Cuts, abrasions, burns and other faults will affect its safety. Multiple cuts
have led to energy absorbing lanyards failing before the energy absorber has
activated. These accidents could have been prevented by effective pre-use
inspections.
Inspection procedure
Textile equipment
Inspect visually for:
Cuts:
A 2mm edge-cut will reduce the webbing
strength by as much as 40%.
Abrasion:
Abrasion across this piece of textile acts in the same way
as a cut when it breaks through the webbing threads.
Burns:
Either from a heat source or from contact
with corrosive chemicals or materials. In particular,
polyamide is susceptible to damage from acids and polyester from alkalis.
Ultra-violet degradation:
The main causes are through sources such as welding.
Inspect
for signs of heavily faded webbing.
Stitching:
Inspect for loose, cut, missing or worn threads.
Comfort pads:
Inspect for any signs of rips or wear.
Mechanical Devices (e.g. rope grab, self-retracting lifelines)
Correct operation
Any wear
Loose components
Distortion
Corrosion
Cleaning
Basic care of all safety equipment will prolong their durable lifetime and contribute
toward the performance of its vital safety function:
• Proper storage (clean, dry and free of exposure to fumes, corrosive elements or UV).
• Cleansing the equipment of dirt, corrosives or contaminants.
Please refer to user manual to correctly clean your PFPE.
Mandatory annual inspection
To maintain proper service life and high performance, PFPE must be inspected
annually by a competent person.
Requirements for Rescue
• Why do we need to have rescue procedures when working at height?
The planning for rescue and emergencies is a legal requirement
as part of the European Temporary
Work at Height Directive
(2001/45/EEC).
• Suspension Trauma
Suspension trauma refers to the
physiological effects of hanging
after a fall (often referred to as ‘PostFall’) in a harness, usually a full body
harness. It is a relatively infrequent
occurrence, and the effects can be
minimised and managed with an
efficient rescue procedure followed
by immediate first aid plus the correct actions by paramedics - as long
as they are informed of the potential problems. This could be you on their
attendance to a rescue site, or part of their own training.
RESCUE KIT SELECTION GUIDE
Miller RescueMighty Reach Rope
INDY SafEscapesling Evac Pole grab
Elitetriangle
Emergency Evacuation
Scaffolder
Construction
Fork lift
Warehouse
Horizontal lifeline
Lift to release lanyard / PFL
Lift to safety
Evacuate to ground
No harness ?
Climber ‘out-of-reach’ ?
Operator competency - AVERAGE
Operator competency : LOW
Low technicality
Average technicality
Care & Maintenance of PFPE
Rescue
• Rescue Units - Operation
This section describes how to operate various Miller® rescue units. Some
are evacuation systems; others allow the retrieval of a worker who has
fallen. Please note, these are simple systems to operate and any training
should include the use of a back-up system, when using a “live casualty.”
• Indy Rescue - Self evacuation
1. Check harness is fitted correctly/don rescue harness and
chose appropriate fastening loops.
2. Attach anchor sling around anchorage and/or connect
karabiner to anchor point and rope to karabiner.
3. Connect Indy karabiner to harness.
4. Drop rope bag to ground (unless it could become snagged
and impede your descent).
5. Hold spare rope end with one hand and Indy with the other.
6. Position your feet shoulder-width apart and weight the
system by bending your knees.
7. Squeeze the Indy descent handle and descend to the
ground. The Indy will stop if you press too hard.
• Miller SafEscape ELITE rescue & evacuation
1. Make contact with the fallen climber.
2. Identify an anchor point to attach the rescue unit.
3. The Hub B model is supplied with a ladder
mount. Attach this about 3-4 rungs above the
incapacitated climber.
4. E xtend the rope from the unit and attach it to the fallen
climbers harness - try to attach it to the point which
the person is suspended from. It ensures body position
remains stable (unless there is good reason to use a
different point).
5. Pull any slack rope through the unit and place the spare
end through the ‘pig’s tail’. Locate it securely back through
the locking cleat.
6. Raise the climber until their fall arrest connection (lanyard / PFL/ SRL,
etc) is able to be released from the anchor point. This will generally
take 10-15 handle turns. Stop every 3-4 turns to pull the developing
slack rope through the cleat.
7. Stabilise the Hub A unit by placing your spare hand on the device as you
wind.
8. Remove the fall arrest connection device from the anchor and re-attach
it loosely to the rescue rope, ensuring it cannot snag during the descent.
9. Hold the spare rope tightly and remove from the locking cleat.
10. Release your grip and begin to evacuate the climber from the fall zone.
• MightyEvac - Fall arrest/emergency evacuation
1. This device operates as a self-retracting lifeline. It becomes a rescue
device once a fall has occurred.
2. Release the black arm from the fastening and extend the handle.
3. Pull out plunger to activate winch mechanism.
4. Winch casualty up or down as required.
5. Reset unit by pulling plunger and pressing against base of the handle
at the same time.
6. Ensure cable is free-running and fall indicator has not been activated
before re-using. Return to local service point if either is not the case.
Rescue Scenario Help
• Rescue from Horizontal Lifeline:
1. Locate rescue kit (Miller SafEscape ELITE) and attach to lifeline - either
directly with karabiner or additional sling around lifeline.
2. Attach live rope to fallen worker (may require addition of reach pole to
facilitate this).
3. Lift climber until their lanyard becomes loose.
4. Continue lifting if being brought back up. Two extra personnel will be
required to assist lifting fallen worker over the edge. The additional
personnel must be restrained from falling.
5. Remove lanyard connection from lifeline.
6. Lower to ground.
Key Planning Factors
Observe the following to provide maximum protection
levels at height:
Warnings
Always read all instructions and warnings contained on the product and
packaging before using any fall protection equipment.
Inspection
All fall protection equipment must be inspected prior to each use.
Training
All HSE managers and workers should be trained by a competent person
to prevent falls from height and in the proper use of fall protection products.
Rescue planning
Minimizing the time between a fall occurring, rescue and first aid treatment
is vitally important.
Product preferences
If there are any doubts about which Fall Protection products to use, call
Miller Technical Support directly.
®
System components
Only components that are fully compatible with one another should be
used. Fall arrest systems are designed and tested as complete systems and
should be used in this way.
What to do after a fall
After a fall occurs, all components of the fall arrest system must be removed
from service to be inspected.
WARNING
This document provides an overview of Fall Protection. It does not provide
important product warnings and instructions. Miller recommends all users of
fall protection equipment undergo thorough training and that all warnings and
instructions provided with the products be thoroughly read and understood prior
to use. Failure to read and follow all product warnings and instructions could
result in serious injury or death.
®
TECHNISERV:
Phone: +49 (0) 23 01-96 29 219
or +49 (0) 23 01-96 29 220
Email: [email protected]
Honeywell Safety Products
Dubai:
Phone: +971 4 450 5800
Email: [email protected]
India:
Phone: +91 124 6722732 / 6722833
Email: [email protected]
United Kingdom:
Phone: +44 (0) 1256 693 200
Email: [email protected]
International:
Phone: +33 (0)1 49 90 79 79
Email: [email protected]
www.honeywellsafety.com
DOC3159
10/2013
© 2013 Honeywell International Inc
Lead them to safety – Build an enduring culture of safety through comprehensive education,
innovative technologies, and comfortable, high-performance products that inspire workers
to make safer choices on their own.