Evonik Overhead Lifeline Case Study

FLS Fall Protection for Loading Trucks

Evonik is one of the world’s leading specialty chemicals companies. They concentrate on high-growth megatrends, especially health, nutrition, resource efficiency and globalization.

An overhead fall protection system was needed in their Acrylic Bay to access the tops of trucks loading materials for distribution. The overhead horizontal lifeline system allows their worker to tie off to the lifeline before climbing up the truck ladder and remain tied off 100%  of the time while walking along the top of the truck.

Project Details

FLS designed, fabricated, and installed a 20’-8”  overhead horizontal lifeline system.

The initial system design was for a 30’ FlexRail fall protection system to be attached to the Zee purlins, however, structural analysis showed that the purlin structure would not be able to handle the load applied by the system in a fall.

An FLS overhead horizontal lifeline was chosen as an alternative. By adding tension tiebacks, the fall arrest load would be distributed back to the columns (main structure), instead of applying the force of the full load into the Zee purlins.

HSS square tubes at cable end connection fabrications also bridged three Zee purlins to further distribute the load.  This method could have been employed in a FlexRail arrangement as well, but without the tension tieback load distribution, the Zee purlins still had failure potential.

Evonik Acrylic Bay Installation Gallery


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Overhead Lifeline by Industry

Select below for more information about the Overhead Horizontal lifeline for your specific industry of interest.

Overhead Lifelines - Aircraft

Overhead Lifelines - Aircraft

Overhead horizontal lifelines provide the most customizable pass-through fall protection in the world.

Learn More

Overhead Lifelines - Railcar/Truck

Overhead Lifelines - Railcar/Truck

Overhead horizontal lifelines provide the most customizable pass-through fall protection in the world.

Learn More

Overhead Lifelines - Industrial

Overhead Lifelines - Industrial

The FLS flexible horizontal lifeline is a fall arrest alternative used in a wide variety of industrial applications.

Learn More

  • How Can We Help?

    Our fall protection experts are available to answer your questions. Complete this form or call 1-800-353-9425.

  • This field is for validation purposes and should be left unchanged.