fall protection for factories and manufacturing facilities

Fall Protection for Consumer Product Manufacturers

Flexible Lifeline Systems OSHA-compliant rooftop & interior fall protection solutions for Manufacturers of Consumer Products.

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Published on: March 12, 2024

The Consumer Products Safety Commission (CPSC) is an independent agency of the U.S. government with the authority and responsibility to investigate, monitor, report, and regulate a wide range of consumer products for safety considerations. Toys that toddlers could choke on, power tools in the hands of “weekend warriors,” plus bicycles and helmets for all ages are just a few examples of the scope of the agency’s purview.

Manufacturers of consumer products must be vigilant throughout the research, design, production, and packaging phases of developing and delivering their products. They do not want to face a product recall, which will result in expenses and bad publicity. They do not want to imagine that their product could cause harm to even one person.

These manufacturers have a dual responsibility for safety; they must also ensure the safety of their workers within the plant environment. Fall protection safety concerns range from the ground floor and up—around machinery, loading docks, and mezzanines, for example—to the rooftop, where workers service building equipment.

Fall protection with room at the top.

Manufacturing plants often install heating, ventilation, and air conditioning (HVAC) equipment on the roof. This is an efficient use of space and facility operations. However, HVAC equipment requires frequent inspection and maintenance to support peak performance and minimize downtime and repairs. Fall protection is essential for employees servicing rooftop HVAC equipment. Fortunately, fall protection systems and equipment are available to protect workers around the roof.

Access Points

Safe roof access is critical when a worker enters and leaves the roof. Ladder access can be protected with guardrails and lifelines. Roof hatches should have hatch railings to prevent workers from falling into the hatch. Both approaches incorporate a self-closing safety gate.

Perimeter Protection

The roof edge is the clearest and most fearful hazard workers confront. For flat and low-slope roofs, a perimeter guardrail or “collective” system is the preferred type of fall protection because it protects multiple workers without needing special equipment or intensive training.

Skylight Protection

Skylights bring sunshine and fresh air into a facility, but they are also considered a hole in the roof through which a worker can fall. Skylight railings and skylight screens can prevent workers from stepping on skylights.

Obstacles & Obstructions

From ducts, cables, and piping to slippery roof services, workers traversing the rooftop face several trip hazards. Anti-slip roof walkways with guardrails and rooftop crossovers can provide fall protection to help avert these obstacles and obstructions.

Fall Protection as an Inside Job

The interior of a modern consumer products manufacturing plant features sophisticated, high-tech production machinery and ancillary equipment. It also presents several safety hazards that can be addressed with elegant solutions.

  • OSHA-compliant Guardrails and Handrails are installed throughout a facility to protect and assist workers on stairs, mezzanines, and high-traffic areas. They provide a barrier to electrical equipment and hazardous zones. ADA-compliant railings can be used to access the building.
  • Pre-assembled Safety Railing Kits can be used around machines and conveyors, loading docks, warehouse areas, and other sections to separate people from hazards and provide fall protection.
  • Versatile Static and Mobile Work Platforms enable employees to reach equipment and inventory and perform other work-at-height operations.
  • Pallet Gates are specialized railing and gate systems that help protect workers from being exposed to higher-level openings when pallets are raised or lowered.

Which Solution is Best for You?

If your company manufactures consumer products where fall protection—inside or outside—is your responsibility, contact Flexible Lifeline Systems. We can discuss your needs and concerns about regulatory compliance, visit your site to conduct a safety audit and map out a plan of action. Our services can include as little or as much as you need, from design, engineering, and fabrication to installation, training, and other support.

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