Rigid Rail Fall Protection

Rigid Rail Fall Arrest Solutions

Overhead Rigid Rail Fall Protection Systems

One of the most common fall arrest solutions, our rigid rail systems provide fall arrest solutions in environments that require very short arrest distances. If a worker should fall while properly utilizing the system, the rigid lifeline setup will arrest the fall in a much shorter distance than similar lifeline products. This makes rigid lifelines ideal for applications such as aircraft maintenance, where a fall from a wing needs to be arrested in a short distance.

The versatile nature of our systems allow us to configure a solution to your specific needs. Fully modular, the design of our single rail systems ensure the trolley always stays overhead even with retractable lifelines exceeding 85’ in length. Flexible Lifeline Systems' full family of rigid rail fall protection solutions include: Single Rail, Cartesian Bridge Rail, and Twin Rail.



Multi-track systems provide multiple users the added benefit of bypass resulting in increased safety and productivity. You no longer have to worry about users disconnecting from the system in order to pass each other.



We design Rigid Rail systems with future expansions and modifications in mind thanks to the modular nature of our overhead solutions.



All structural components are hot-dip galvanized in accordance with ASTM A-123 for added durability and corrosion control. The teflon wheels of the sealed bearing trolleys on our rigid rail systems do not damage the coating, resulting in years of maintenance free use.



The design of the enclosed track prevents the build up of dust, debris, ice, and snow allows the rigid rail system to function properly both indoors as well as outdoors.



Our Rigid Rail System is capable of curves and intersections allowing increased user productivity. By combining parallel FlexRail tracks, the Twin FlexRail allows user to by-pass each other. This feature frees users up to work with full mobility without worrying about getting tangled up with each other.



Complies with US OSHA 1910, ANSI Z359.6 and Canadian CSA Z259.2 standards for Engineered Fall Protection.

Aircraft Overhead Fall Protection Hanger Demo

Rigid Rail Projects

Aircraft Fall Protection for U.S. Military

FLS engineered, fabricated and installed a total of twelve enclosed track and trolley systems capable of supporting three users each. FLS designed the safety systems at elevations below HVAC and fire protection equipment to prevent interference with other hangar systems.

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Greif St. Gabriel Case Study

Overhead fall protection was needed to safely access the tanker trucks in the inside truck bays as well as the railcars along a 300’ section of track.

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CRRC Chicago Enterprise Center Case Study

As part of the new development, FCL Builders contracted Flexible Lifeline Systems for the design, fabrication, supply, inspection, load testing and certification of the FLS’ rigid rail fall arrest solution, FlexRail.

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Merfish Pipe And Supply Case Study

Merfish came as a new customer for Flexible Lifeline Systems, seeking out a fall protection solution for its employees climbing stacks of pipe in order to attach rigging hardware for lifting with overhead cranes.

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Rigid Rail FAQs

Can the system be powder coated?

Yes, however it may result in a tighter fitting clamshell and splice.

What are the annual inspection requirements?

The frequency will depend upon the environment, location and usage but should be at least every 12 months.

What is the level tolerance of the system?

+/- 3 degrees – to allow for installation variance, but generally intended to be horizontal.

What type of SRL shouldbe used with the system?

The front section of the IFU and O&M outline the requirements for PPE that is attaching to the system.

What is the minimum ground clearance?

6 ft.

What is the maximum number of users?

Four. This depends on building structure and purlin spacing.

What is a self-retracting lifeline?

A self-retracting lifeline is a type of lanyard that allows a user to move around freely within an area without requiring them to manually retract the cable. The lanyard extends and retracts based on the user’s movement.

Is a Horizontal Lifeline or a Rigid Rail system better?

Depends on the application, task, clearance, and feasibility of installation. Rigid Rail offers superior fall distances while Horizontal Lifelines can be installed places Rigid Rail may not be feasible.

What is the maximum number of users?

Rigid Rail can be designed for any required number of users but typically 2-4. Bypass systems with multiple rails would be recommended for systems with more than 2 users.

Can I hoist or suspend materials from Rigid Rail FP systems?

You cannot hoist or suspend materials from Rigid Rail Fall Protection Systems. An independent rail may be added for material handling purposes if the work tasks require it.

Can Rigid Rail be relocated after it has been installed?

Yes, provided new location can sustain loads and sufficient clearance exists. Inspection and certification is required to verify condition of components before relocation occurs.

Who can install rigid rail systems?

Certified installers that are also Competent Persons and under the direct supervision of a QP. Additional trainings and certifications in areas such as lift operation, rigging, and steel erection are often required.

What is the fall clearance required?

Many factors determine fall clearance requirements when using fall protection systems.  The lowest clearance requirements can be as little as 2’ up to over 20’ depending on equipment used, system deflection and other safety factors .

What rail lengths are available?

With splicing, rails can be engineered to any required length.  Typical maximum length to fit on a truck is about 40’.

What is the working radius of Rigid Rail?

Rigid Rail can be curved to a radius as small as 24”.

Does outdoor Rigid Rail exist?


What is a Rigid Rail fall arrest system?

One of the most common fall arrest solutions, Rigid Rail is an overhead track and trolley fall arrest system, paired with a self-retracting lifeline for workers at height and provide fall arrest solutions in environments that require very short arrest distances.

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