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Overhead Lifeline Systems For Aircraft Hangars

Site-specific OSHA-compliant overhead Horizontal Lifeline Systems for aircraft MRO facilities. We design, fabricate, and install

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Cable-based Fall Protection For Aircraft Hangars

Our site-specific: OSHA-compliant overhead Horizontal Lifeline Systems (HLL) provide the most customizable pass-through fall protection in the world for aircraft MRO facilities. The flexibility of these aircraft hangar systems allows them to service a wide variety of aircraft and structures: from wide-body jets like the 777 to smaller Cessna units. Flexible Lifeline Systems is recognized as the only true turnkey provider of engineered fall arrest solutions: setting the standard for quality and efficiency. When providing fall protection to aircraft techs and mechanics: we ensure every system meets OSHA 1910.140 and ANSI Z359.6 requirements. These systems utilize a high-tensile stainless steel cable and a patented overhead shuttle: allowing workers to traverse the fuselage: wings: and tail sections without ever needing to disconnect: which effectively eliminates the risks associated with manual transitions at height. 

Contact our fall protection experts to learn more about our safety solutions for working at height on aircrafts and inside hangars.

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Cable-Based – Aircraft Projects

Overhead Lifeline for Southwest Airlines

How does a tension indicator ensure user safety?

 A loose cable increases fall distance: while an overtightened cable puts unnecessary stress on the anchors. Our built-in tension indicators allow a Competent Person to verify at a glance that the system is tuned to engineering specifications. 

What are the risks of using non-serial numbered components?

 Safety components must be traceable. We serial-number every bracket and shuttle to ensure a complete maintenance history: which is critical for identifying potential manufacturing defects or “end of life” fatigue. 

How does the system account for the low-clearance areas of an aircraft wing?

Cable systems involve “dynamic sag.” We perform precise Total Fall Distance (TFD) calculations: often recommending Self-Retracting Lifelines (SRLs) with the system to ensure the arrest occurs before contact with the wing or fuselage. 

What happens to the hangar structure during a fall event?

 The overhead anchors are designed to manage extreme dynamic loads. After any fall: the entire system must be immediately tagged out: and the structural integrity of the roof beams and anchor points must be validated by an engineer. 

Who is qualified to supervise the use of these systems?

 According to OSHA: a Competent Person must oversee the daily operation and inspection of the lifeline. For the initial design and structural tie-in: a Qualified Person (Professional Engineer) is required to certify the system for specific aircraft profiles. 

Compliance

  • OSHA 1910.140 and 1926.502: Systems are designed to meet federal mandates for personal fall arrest equipment: maintaining a 2:1 safety factor against structural failure. 
  • ANSI Z359.6 Engineering: Every hangar installation is calculated by a “Qualified Person” to account for cable deflection: ensuring the Maximum Arrest Force (MAF) remains within safe physiological limits. 
  • Structural Load Validation: Components are engineered to withstand the unique dynamic loads of aircraft maintenance: often requiring anchorages capable of supporting 5,000 lbs per attached user. 
  • Material Science (316 Stainless Steel): All cables and brackets are manufactured from 316 grade stainless steel to resist hangar environment corrosives and ensure long-term tensile integrity. 
  • Qualified Person Recertification: In accordance with industry standards: all overhead lifelines must be annually inspected and recertified to ensure the tensioning and energy absorbers are fully functional. 
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Single Span Lifelines

Single Span Lifelines

Single span systems are economical, cable-based, stainless steel fall arrest systems that provide fall protection for up to three users and a span of 200 feet.

Multi-Span Lifelines

Multi-Span Lifelines

Our multi-span systems accommodates horizontal, inclined, curved and vertical requirements, allowing a user to travel unlimited lengths without having to disconnect and re-connect to the system.

Overhead Cable System Features

Versatility

The systems we design offer unparalleled flexibility. Our engineers are able to develop and install both single and multi-span overhead horizontal lifelines that accommodate all your protocols.

Multi User

With multi-span lifeline systems, multiple workers have comfortable and safe access to working areas to service the fuselage, wing, tail, or engine on aircrafts ranging in size from 777s and C-130s, to Cessna and Challenger aircrafts.

Patented Overhead Shuttle

The unique and patented overhead shuttle unit glides freely over stainless steel cables providing continuous protection over the entire length of the system. A built-in user-friendly tension indicator  and in-line energy absorber to reduce end loads also insure the safety of the user. All components are serial numbered for easy tracking and maintenance when needed.

Modular

Overhead lifeline systems come in single span lengths of up to 200 feet and unlimited length multi-span systems allowing systems to be easily expanded when needed.

Affordable

Simple and economical installation of overhead lifeline systems make them an affordable aircraft hanger fall protection solution.

All Weather

Overhead cable based systems are all-weather meaning they can be engineered for inside the hanger or for outside-use systems as well for optimum productivity.

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