Solutions for Fixed Ladder Fall Protection

Fall protection for fixed ladders is of special concern to OSHA. Why? In their words, "Falls from heights and on the same level (a working surface) are among the leading causes of serious work-related injuries and deaths." These injuries and deaths include fixed ladder falls.

In order to address this problem, OSHA has guidelines for fixed ladder fall protection. Importantly, they require a fall protection system on any ladder that extends beyond twenty-four feet. Additionally, ladder cages are no longer deemed as an acceptable means of fall protection. In fact, by November 18, 2036 cages must be replaced with an acceptable fall protection system.

Fixed Ladder Fall Protection Options

There are at least two ways to provide the needed fall protection on a fixed ladder. The first is to simply use a dual leg 100% tie-off lanyard. The second is to install a fixed ladder system. Note that in either case, because the ladder would now be serving as a fall arrest anchor point, one would have to verify that the ladder structure can handle the required loads to do so. Specifically, that both the ladder rungs and the way the ladder is attached to the structure meet anchorage point requirements.

Please also note that in both of the above methods, an appropriate harness is required. The harness needed is one that has a front/chest D-ring which is sometimes known has a climbing D-ring. The lanyard (in the first case) or the cable/trolley grab (in the second case) would attach to the harness's front D-ring.

Two Kinds of Fixed Ladder Systems

If you’ve chosen to go with a fixed ladder system, now what? There are two kinds—a rigid rail system and a cable system. 

Rigid Rail System—The rigid rail system consists of a rigid rail/track that is affixed to the ladder rungs. Such a system includes a trolley that freely moves up and down the track with the worker. The trolley is attached to the worker. This is typically done with a carabiner or a 3 foot shock absorbing lanyard. If the worker falls, the trolley locks up and arrests the fall.

A typical rigid rail system comes with mounting brackets and the desired length of rail. When ordering a rigid rail system, you will need to provide the ladder length, rung sizes, and rung shape to insure the correct fit.

Cable System—The cable system, like the  FrenchCreek VL-38, uses a cable instead of a ridged track. The cable is attached to brackets at either end of the ladder—a top bracket and bottom bracket. Tensioners, located in he bottom bracket, are used to take out any slack in the cable. On long runs, cable guides are attached to the ladder to add stability to the cable. The cable system uses a cable grab instead of a trolley to arrest falls. The cable grab attaches to the harness also using a carabiner or lanyard.

A typical cable system comes with the top & bottom bracket with tensioner, rung clamps for up to 1-1/8″ diameter rungs, 3/8″ galvanized wire-rope lifeline permanently terminated at one end, and the appropriate amount of cable guides based on system length.

Pros and Cons of Rail and Cable Systems

Rigid Rail Systems

Rigid Rail systems are more stable. This is important if used outdoors in windy conditions. The worker often feels safer on a rigid rail system. Rail systems are better suited for ladders inside tanks. Rail systems can be purchased in aluminum or stainless steel for corrosive environments. Rail systems are also better suited for multiple standoffs.

Rail systems, however, are more expensive. They also require more effort to order. Exact measurements are required on ladder length and the diameter of the ladder rungs. Even the ladder rung shape is needed. This is because the components of a rigid rail system have to be made to accommodate these variables.

Cable Systems

Cable systems offer more mobility along the ladder for the worker. The worker can shift a bit from side to side due to the flexibility of the cable. This could be helpful in some situations. Cable systems are arguably easier to install. Cable systems are less expensive. Cable systems are much easier to order and can be purchased in kits for varying lengths of ladders (the cable grab is sold separately).

The cable on cable systems, however, is more susceptible to wear and tear. This requires more diligent inspection and possible cable replacement from time to time. And, at this time, their also isn’t a stainless steel cable option for corrosive environments.