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Cable Based Horizontal Lifeline Systems

FLS Cable based horizontal lifeline systems are a versatile fall protection solution that provides a safe means of tie off for workers.

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Versatile Fall Protection Solution

Flexible Lifeline Systems (FLS) cable based horizontal lifeline systems provide a safe means of tie off for workers across a vast range of industrial applications. With spans reaching up to 180 feet and the capacity to support multiple users, Horizontal Lifeline Systems (HLL) provide an economical and efficient solution for workers at height. Whether designed for an overhead application, such as an aircraft hangar, or at foot level on a roof, a properly engineered FLS cable lifeline ensures the safety of personnel exposed to fall hazards. These systems are designed to meet or exceed OSHA 1910 and ANSI Z359.6 standards, incorporating pass: thru capability that allows workers to traverse intermediate support points without ever disconnecting. By balancing structural loads with high: tension 316 Stainless Steel cable, we provide a versatile system that adapts to your facility's unique geometry while maintaining 100% tie: off compliance. 

Cable Versus Rigid Rail

There has been much debate about which is better, cable or rigid rail horizontal lifelines. When designed correctly, both cable and rigid rail lifelines offer excellent levels of fall protection. Rigid rail systems have the advantage of lower fall distances and are often preferred when work is performed less than 12’ above a lower level. Cable based lifelines have the advantage of practicality in scenarios where a rigid rail system is less feasible, such as on roofs, arena rigging grids and along overhead crane rails.

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How does ‘Pass-Thru’ technology improve worker safety? 

Traditional systems require workers to unhook and re-hook at every support post. Our pass:thru shuttles glide over intermediate brackets, eliminating the “human error” risk of being disconnected from the line at any point. 

What is the significance of the 5-year recertification? 

Standards and building codes change over time. A 5:year recertification by Flexible Lifeline Systems is a full engineering audit to ensure your system still meets modern safety requirements and hasn’t been compromised by structural shifts in the building. 

How do energy absorbers protect the building’s structure?

 A fall event generates thousands of pounds of force. Our energy absorbers act like “crumple zones,” deploying at a specific load to dissipate that energy, protecting both the worker’s body and the building’s structural steel. 

Can I install a lifeline myself if I have the parts?

 No: OSHA requires that horizontal lifelines be installed under the supervision of a Qualified Person. Incorrect installation, such as improper cable tensioning or inadequate anchor torque, can lead to system failure during a fall. 

What is ‘Cable Deflection’ and why does it matter? 

When a fall occurs, the cable stretches and sags (deflection). If this isn’t properly calculated by an engineer, a worker might strike the ground before the system fully arrests the fall. We provide precise deflection data for every span. 

Why is 316 Stainless Steel preferred over galvanized cable?

 While galvanized cable is cheaper, it is prone to internal corrosion that isn’t always visible during a standard inspection. 316 Stainless Steel provides the chemical resistance necessary for lifelines to last 20+ years in industrial and coastal environments. 

Compliance

  • OSHA 1910.140 and 1926.502: Systems are engineered to provide a safety factor of at least two against the Maximum Arresting Force (MAF) for every worker connected to the line. 
  • ANSI Z359.6 Standard: All HLL designs follow the American National Standard for active fall protection, which dictates specific requirements for cable tension, energy absorbers, and structural anchorage. 
  • Material Integrity: We utilize 7×19 316 Stainless Steel cable for superior corrosion resistance and longevity, ensuring the lifeline remains viable for over 20 years in harsh outdoor or industrial environments. 
  • Energy Absorption Technology: Every FLS lifeline incorporates high-capacity energy absorbers designed to reduce the dynamic loads transferred to the building’s structure during a fall event. 
  • Qualified Person Certification: In accordance with OSHA mandates, every horizontal lifeline is designed and certified by a Qualified Person (Professional Engineer) who verifies that the supporting structure can withstand the predicted impact forces. 
Continuous Fall Protection

Continuous Fall Protection

FLS Cable trolleys and shuttles on all cable based lifelines feature pass thru capability of intermediate support points. Eliminating the need to use double lanyards or disconnect from the lifeline reduces risk and improves user efficiency.

VERSATILE APPLICATION

VERSATILE APPLICATION

Flexible Overhead Horizontal Lifelines are commonly used in work at height applications such as Railcars, Trucks, Pipe Racks, Overhead Cranes, Industrial Applications, and Aircraft hangars.

Durability

Durability

All Flexible Lifeline Systems are available in 316 stainless steel cable and components, ensuring they will last for 20+ years.

MULTI-USER FALL PROTECTION

MULTI-USER FALL PROTECTION

Our high tension lifeline systems can provide multiple spans with up to 100’ between supports for 1 to 2 users. Parallel lifelines provide by pass capability for multiple users.

STANDARDS COMPLIANT

STANDARDS COMPLIANT

FLS Multi Span Lifelines has been third-party tested. They meet both OSHA and ANSI requirements as well as standards set by CSA 13-04 & 16-04.

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A Lifeline System That Suits Every Industry

Our rigid rail system is designed for warehouses, factories, hangars, depots, and similar facilities. It accommodates both high and standard roof heights, regardless of the layout. This system is perfect for maintenance and repair work, as well as tank filling and loading tasks.

Aviation

Our overhead lifeline system enhances safety for mechanics and aircraft maintenance teams while they repair, maintain, or assemble aircraft. Its versatility makes it compatible with the roof layout of any hangar or factory.

Railway & Trackside

Our lifeline system is designed for safe access to and around trains in maintenance and repair depots.

Transportation

Vehicle fleets of any size necessitate regular maintenance and repairs. In areas where access is difficult with other safety systems, our lifeline systems offer a safe approach to the tops and sides of various vehicles, including trucks, buses, coaches, trailers, and other heavy transport equipment.

Distribution & Manufacturing

Accessing machinery, tall racks, and other elevated areas can be challenging. An overhead fall protection system is often the only safe solution available. Our lifeline systems allow for safe and efficient maintenance in these high-reach areas.

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