Published on: December 16, 2025
High-Performance Fall Protection for the Hangar Floor
Hazard: Technicians servicing Bombardier CRJ aircraft on polished, contoured surfaces. Traditional cable systems create too much “deflection” or sag for the low working heights of regional jets, risking both the worker and the $50M aircraft.
Solution: A custom engineered integration of FlexRail and FlexBridge systems mounted directly to the facility existing overhead bridge cranes and gantry.
Benefits: Provided 100% fall arrest coverage that travels with the crane, eliminating “dead zones” and equipment collisions while maximizing the client’s budget through strategic material recovery.
The Challenge: Safety in a Multi-Dimensional Workspace
As a premier regional carrier for American Airlines, PSA Airlines operates a mission critical maintenance hub in Louisville, Tennessee. In the aviation industry, work at height is a daily reality and a significant Your Money / Your Life (YMYL) responsibility. A fall from an aircraft fuselage can be catastrophic, yet any safety system must not obstruct the heavy movement of overhead cranes used for engine swaps and maintenance.
The primary challenge was the workspace itself. PSA needed a solution for their new hangar that allowed technicians to tie off at various configurations without losing the functional utility of their overhead cranes. Standard ceiling mounted systems would have created “dead zones” where the crane could not pass. Furthermore, because regional aircraft sit lower to the ground, the system needed to be rigid to minimize fall distance.
The Process & Solution: Adaptive Engineering and Value-Driven Design
This project highlights the Experience and Authoritativeness of the FLS team during a major mid-project scope pivot. When the original design no longer met the evolving needs of the hangar, FLS Sales and Engineering navigated a week of complex change management.
Our team identified an opportunity to repurpose over $19,000 in materials from the original design to optimize the new $174,000 investment. FLS engineers conducted a specialized structural analysis to ensure the existing crane infrastructure could safely handle the dynamic loads of multiple fall arrest events. To minimize hangar downtime, FLS deployed a double crew strategy, utilizing four experienced lead installers to complete the eight system installation in only two days onsite.
FLS delivered a hybrid rigid rail solution that moves with the work:
- Crane-Mounted FlexRail: Four 8 foot FlexRail systems were installed directly onto the existing Crane Gantry using LNA beam clamps. This ensures the fall protection moves with the crane and is always positioned exactly where the technician needs it for short term tasks.
- FlexBridge Systems: Two 40 foot FlexRail Bridges were attached to the crane runways. These bridges allow users to move in both X and Y axes, providing massive coverage areas for longer maintenance stints.
- Advanced User Gear: The system was outfitted with eight 30 foot Skyloc II SRLs and specialized nylon taglines for easy access, ensuring a complete turn key safety solution.
Summary: A Single-Source Solution for Aviation Safety
The PSA Airlines project demonstrates the FLS commitment to technical authority and fiscal responsibility. By integrating 100% fall protection into the existing crane machinery, we eliminated the risk of equipment collisions while maintaining full operational flow.
FLS provided full O&M manuals and manufacturer certifications, ensuring PSA’s “Safety First” culture is backed by PE stamped engineering and professional documentation. By leveraging internal engineering to solve for physical obstructions and budget shifts, we delivered a world class system that protects PSA’s most valuable assets—their people and their fleet.
Ready to enhance safety and efficiency at your facility? Contact Flexible Lifeline Systems for a comprehensive safety audit and let our team of experts help you find the perfect solution for your work at height.
