800-353-9425

Fall Protection for Aircraft Hangars

Protect aviation teams with fall protection systems designed for aircraft hangar environments.

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Overhead fall protection for aviation inspection, maintenance & repair

Whether in the hangar or on flight line, aviation technicians and mechanics often conduct their work well above the hangar floor and tarmac. Environmental conditions, hydraulic fluid, sloped fuselages, and narrow stabilizers can increase the risk of a fall when working on aircraft. Adding to the complexity of providing fall protection for aircraft are factors such as aircraft positioning, work on a variety of different aircraft, unique building structures and the need for limited work interruption during installation and usage. FLS' team of fall safety specialists and engineers take all of these factors and more into consideration when designing a fall protection solution.

Solutions for commercial, corporate, aircraft manufacturers and military bases often have different needs based on the level of maintenance and repair performed.  Compliance with both OSHA 1910, AFOSH and ANSI Z359 is necessary to have a compliant fall protection solution.

FLS offers a wide range of compliant solutions to provide fall protection for aircraft, both fixed wing and rotary. Our turnkey approach, including site visits, design and engineering, fabrication, installation, testing, certification, and training are performed in accordance with our ISO 9001:2015 certified quality management program. This ensures that the work and products we provide are of the highest quality and we are continually working to improve our processes and the systems we deliver to our customers.

Shorter Fall Distance

Rigid rail systems have the advantage over cable-based lifeline systems because they reduce fall distance and are often preferred when work is performed less than 12’ above a lower level.

Easy to Use

Although fall arrest systems require proper safety training and a rescue procedure, overhead rigid rail lifeline systems are completely hands-free and enable users to concentrate on the task at hand.

Reliable

Our enclosed track rigid rail systems are the most reliable engineered fall protection in use today and the 1:100 movement-to-weight ratio keeps the lifeline directly overhead eliminating in-line swing fall.

Durable

Structural components are hot-dipped galvanized for added durability and corrosion control and trolleys feature Teflon wheels with sealed bearings resulting in years of maintenance free use.

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Aircraft Overhead Fall Protection Hanger Demo

How does the self-leveling stair mechanism prevent injuries?

 Fixed-angle stairs become dangerous when a platform is raised or lowered. Our self-leveling design ensures the tread remains perfectly horizontal at any height: preventing the ankle strains and slips common with traditional ladders. 

Can these platforms withstand the load of heavy specialized tooling? 

Yes: but the platform’s total load capacity must be verified. Our engineering team provides clear load-rating signage for every stand: ensuring the combined weight of personnel and equipment never exceeds the structural limits. 

What are the hazards of “gap” spaces between the stand and the aircraft?

 Gaps larger than a few inches pose a significant trip and fall risk. We mitigate this through Auto-Lock Sliders and profile-conforming edges that extend to meet the aircraft: ensuring a continuous and safe walking surface. 

How do environmental hangar conditions like oil or hydraulic fluid affect safety?

 Traditional metal decks become skating rinks when exposed to fluids. We use a patented: self-draining: anti-slip tread that allows fluids to pass through while maintaining high-traction “omni-directional” contact for the technician’s boots. 

What happens if a technician forgets to lock the casters? 

Unlocked casters create a severe tipping and “drift” hazard while a worker is at height. Our stands feature heavy-duty: easy-access locking and leveling systems: but it is a mandatory safety protocol to verify all wheels are secured before ascending. 

Who is qualified to perform structural repairs on these stands? 

Any structural repair or modification must be performed or approved by a Qualified Person: ideally the original manufacturer. Unauthorized welding or drilling can compromise the 4:1 safety factor required by OSHA and ANSI. 

What types of fall protection are used for aircraft maintenance?

Aircraft maintenance fall protection solutions include Overhead Rigid Rail & Track Systems, Overhead Bridge Systems, Cable-Based Lifeline Systems, Portable Systems, Maintenance Stands, as well as Custom Solutions when special circumstances arise.

Aircraft Fall Protection OSHA Regulations and FAQs

ANCHORAGES:

1910.140(12) Anchors used to attach to personal fall protection equipment must be independent of any anchorage used to suspend employees or platforms on which employees work. Anchorages used to attach to personal fall protection equipment on mobile work platforms on powered industrial trucks must be attached to an overhead member of the platform, at a point located above and near the center of the platform.

PERSONAL FALL PROTECTION:

1910.140 Personal Fall Arrest Systems: The employer must ensure that each personal fall protection system used must comply with the requirements in this section:

  1. Limit the maximum arresting force on the employee to 1,800 pounds; 1910.140(d)(1)
  2. Bring the employee to a complete stop and limit the maximum deceleration distance the employee travels to 3.5 feet; 1910.140(d)(1)
  3. Have sufficient strength to withstand twice the potential impact energy of the employee free falling a distance of 6 feet, or the free fall distance permitted by the system; and… 1910.140(d)(1)
  4. Sustain the employee within the system/strap configuration without making contact with the employee’s neck and chin area. 1910.140(d)(1)

REGULAR INSPECTIONS:

In the absence of a specific requirement for Inspection, OSHA Sec 5.a.1 becomes default: OSHA Sec 5.a.1 (a) Each employer – (1) shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; 29 USC 654 (2) shall comply with occupational safety and health standards promulgated under this Act. (b) Each employee shall comply with occupational safety and health standards and all rules, regulations, and orders issued pursuant to this Act which are applicable to his own actions and conduct.

Following manufacturer’s requirements is considered a reasonable effort to satisfy this general rule and employee responsibility. Flexible Lifeline Systems follows the requirements set by the manufacturer of the components that are used to build your system. Additionally, ANSI Standards ANSI/ASSE Z359.2 Z.359.6-2016 9.2, while not codified as law, are considered to be “best practices” and often required by many companies – insurance, banking, etc., to provide coverage such as worker compensation or professional insurance, or to assess capital asset values. These standards speak directly to importance of regular inspection of fall protection systems.

customer testimonial

It is said that the people make the company – FLS is a true testament to this. Their fall protection specialists are knowledgeable and experienced in their field and it shows in their work.

~ Frank (United Airlines)

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Commercial Aviation

Commercial Aviation

FLS has long term relationships with most of the major commercial airline companies.  Most commercial aviation companies have long had fall protection.  They continue to grow and build new hangars, purchase new aircraft with different dimensions and evolve their maintenance schedules and positioning in the hangar.  Our work with commercial airlines is most often to improve, modify or reconfigure their existing fall protection to accommodate these frequently changing environments.

Military Aviation

Military Aviation

Protecting those who serve and protect our country is something we are very proud of at FLS. Massive military aircraft like the C-5 and C-17 require a unique approach. In most cases these depot level maintenance facilities perform a wide range of work from painting, major repairs and maintenance. Oftentimes this work requires many personnel to access the aircraft at one time. Solutions that include multiple rails, intersections and curved tracks offer a lot of benefits to these operations.

Corporate Aviation

Corporate Aviation

One of the significant challenges we encounter when designing fall protection solutions is the limited space on aircraft. Arresting a fall before a technician reaches the ground in a fall arrest situation can be quite difficult. FLS has developed systems and technologies that can arrest a fall in less than 2 feet, making the use of fall protection on low-wing aircraft, such as the G5 or Falcon Jet, much more feasible.

Aircraft Manufacturers

Aircraft Manufacturers

Providing fall protection for workers during the assembly process can be quite challenging. Typically, maintenance stands are used, which offer effective access and fall protection for tasks performed around and beneath the assembly area. However, these stands often do not protect workers who are on top. Additionally, the presence of overhead cranes presents another challenge for implementing traditional overhead fall protection. FLS specializes in designing and developing custom solutions that integrate seamlessly with the manufacturing and assembly process, ensuring that production is not compromised.

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