ANGLO FATAL RISK GUIDELINE

Transcription

1 ANGLO FATAL RISK GUIDELINE WORKING AT HEIGHTS AA_AFRG_ doc APPROVED 18 December 2008 Page 1 of 88

2 CONTENTS PAGE 1 AIM 3 2 APPLICATION 3 3 DEFINITIONS 4 4 REASON FOR INCLUSION 11 5 REQUIREMENTS 12 6 PLANT AND EQUIPMENT REQUIREMENTS 12 7 SYSTEM AND PROCEDURAL REQUIREMENTS 55 8 PEOPLE REQUIREMENTS 77 APPENDIX A: REFERENCE DOCUMENTS 82 APPENDIX B: RECORD OF AMENDMENTS 82 APPENDIX C: WORKING AT HEIGHTS EQUIPMENT MAINTENANCE AND INSPECTION 83 AA_AFRG_ doc APPROVED 18 December 2008 Page 2 of 88

3 1 AIM To eliminate or minimise the risk of fatalities, injuries and incidents arising from working at heights. This guideline refers to the Group-wide implementation of the Anglo Fatal Risk Standard: Working at Heights and it is intended to be read in conjunction with the respective Standard. The guidelines contained in this document are considered as "highly recommended" and deviations are to be documented and justified. Full adherence to these guidelines will not be a factor in determining compliance with the Standards, since alternative methods can be available if justified on a risk basis. In case of conflict with requirements of any other Anglo document or guideline, the following hierarchy will apply: 1. Anglo Safety Way : ASW 2. Anglo Fatal Risk Standard : AFRS 3. Anglo Fatal Risk Guideline : AFRG It is important that when implementing Standards the organisation takes cognizance of, and comply with the relevant legal requirements in the country of application. 2 APPLICATION This Standard applies wherever there is potential for any person to fall 2 metres or more, or to gain access to within 2 metres of an open edge from where there is the potential to fall 2 metres or more, including working from various forms of portable and moveable elevated work platforms, cages, ladders, scaffolding and where objects could fall and cause injuries. Risk assessment may identify high potential fall hazards when working at heights of less than 2 metres, in which case this Standard shall be applied. (Note: if local legislation requires more stringent controls, then those controls shall be implemented.) This Standard does not apply to rope rescue situations and abseiling, which are regarded as specialist functions. This Standard applies to all Anglo American Group managed businesses and operations, including contractors and visitors when involved in controlled activities. The purpose of this Guideline is to provide guidance and clarity in respect of the requirements of the Anglo Fatal Risk Standard Working at Heights, which describes the minimum acceptable requirements for activities where a worker or objects can fall from heights. The purpose of this Guideline is to provide guidance and clarity in respect of the requirements of the Anglo Fatal Risk Standard Working at Heights, which describes the minimum acceptable requirements for activities where a worker or objects can fall from heights. AA_AFRG_ doc APPROVED 18 December 2008 Page 3 of 88

4 This guideline has been developed to provide more detail and clarification for the implementation of the requirements of the Standard. This should enable sites to be more aligned with each other on what the boundaries are with regards to meeting the requirements. This guideline is by no means exhaustive and will be updated periodically and supported by good practice sharing. It is not intended as a template for achieving compliance. 3 DEFINITIONS Barricading : a physical barrier that prevents inadvertent access to an area (e.g. handrails, access doors and gates or similar installations, whether temporary or permanent). Barrier tape does not qualify as barricading. Demarcation Fall arrest system Fall prevention : any method that indicates that an area is used for a specific purpose or that access is restricted (e.g. barrier tape, painted lines on floor surfaces, portable signs denoting drop zones or no access past a specific point). : the use of multiple, approved safety equipment components such as body harnesses, lanyards, deceleration devices, droplines, horizontal and/or vertical lifelines and anchorages, interconnected and rigged to arrest a free fall. : the design and use of a fall prevention system which ensures no exposure to an elevated fall hazard. This may require more than one fall prevention system or a combination of prevention or protection measures. Fall restraint : an approved device and any necessary components that function together to restrain a person in order to prevent that person from falling to a lower level. Fixed lanyard Inertia reel : : is a line used as part of a lanyard assembly to connect a harness to an anchorage point or a static line in situations where there is risk of a fall. (also known as a self-retracting lanyard or fall-arrest block) is a mechanical device that arrests a fall by locking onto a drop line and, at the same time, allows freedom of movement. Suspension trauma : is the effect that can occur when a person hangs for a prolonged period in fall-arrest equipment. The restriction of blood flow, especially from the legs, can cause serious cardiovascular problems within five minutes and become fatal shortly thereafter. AA_AFRG_ doc APPROVED 18 December 2008 Page 4 of 88

5 Controlled Activities or Controlled Sites Monitored Activities Uncontrolled Activities : are those where the Anglo American Group Company has the authority to determine how to manage the operation. It does not include monitored or uncontrolled activities. : are those where Anglo American can exercise some influence but cannot set Policies and/or comprehensive Control Standards and/or directly supervise and enforce their application (i.e. contractor and supplier transporting their goods and/or personnel to or from controlled sites ). : are those where Anglo American does not set or influence Policies or Control Standards and does not supervise safety performance. These include services provided by public Companies, activities performed at supplier or manufacturer shops, etc. Where there is uncertainty over whether the activity is controlled, monitored or uncontrolled, the matter should be referred to the Safety function for determination. Uncontrolled Activities : are those where Anglo American does not set or influence Policies or Control Standards and does not supervise safety performance. These include services provided by public Companies, activities performed at supplier or manufacturer shops, etc. Where there is uncertainty over whether the activity is controlled, monitored or uncontrolled, the matter should be referred to the Safety function for determination. Other definitions and abbreviations used in this Standard Note Administrative Control Anchor point Approved Safety Harness: : Definitions and terminology tend to vary from country to country. The definitions used here clarify terms used in this document. Where relevant, possible alternative terms are included with the definitions. : a system of work or safe work method that helps to reduce a worker s exposure to a fall hazard. Administrative controls are often used to support other fall prevention measures. : a secure point of attachment on a structure to which approved safeties harness, fall restraint device, fall arrest device, lanyard, lanyard assembly or lifeline may be secured. Note: This is also known as an anchorage or attachment point. : a full body harness of the parachute style with, as a minimum, a fall arrest attachment point at the top dorsal position and which was manufactured, has been maintained, and complies with relevant standards. Waist belt type harnesses do not qualify as approved safety harnesses. AA_AFRG_ doc APPROVED 18 December 2008 Page 5 of 88

6 Arrest Force Approved Safety Harness Body Containment Devices Competent Person Controlled Access Zones D-ring Connector : the force imposed upon the worker and the anchor point, the moment the fall arrest system stops the fall. : a full body harness of the parachute style with, as a minimum, a fall arrest attachment point at the top dorsal position and which was manufactured, has been maintained, and complies with relevant standards. Waist belt type harnesses do not qualify as approved safety harnesses. : designed to contain the body of a falling worker and to distribute forces resulting from an arrested fall to minimise the likelihood of injury. They consist of a full body harness together with associated components such as a lanyard and personal energy absorber. Harnesses can be used for restraint systems and work positioning systems according to relevant standards : a person who has acquired through training, qualification or experience (or combination of these) the knowledge and skills enabling that person to safely perform a specific task. A person needs to be assessed and found competent to perform a specified task or function. : areas where certain work may be done without the use of guardrails, personal fall arrest systems or safety nets. However, unlike a warning line, which is a barrier that cannot be crossed, a controlled access zone establishes a boundary that can be crossed, but only by a specifically designated worker. : a link used in a harness or a positioning belt as an attachment element or fall arrest attachment. It may also be used in lanyards, energy absorbers, lifelines, and anchor points as an integral Connector. D-rings can be used for work positioning and restraint. : is a hook that can be attached to anchor points. Connectors come in a variety of shapes, sizes and locking mechanisms. Only self closing, lockable connectors, requiring at least two distinct deliberate consecutive actions to open them are acceptable. Note : Karabiners, double or triple action hooks, and snap hooks are all specific types of Connector. Inertia reel : a mechanical device that arrests a fall by locking onto a drop line and, at the same time, allows freedom of movement. Note: This is also known as a fall arrest block. AA_AFRG_ doc APPROVED 18 December 2008 Page 6 of 88

7 There are three distinct types: Type 1 fall arrest device Note Type 2 fall arrest device Note Type 3 fall arrest device Fall Injury Prevention System Fall Arrest System Fall Restraint System : a fall arrest device that travels along a lifeline and, when loaded, locks to the line. The user is connected via a short lanyard to the activating lever, which locks the device in the event of a fall. A typical use of a Type 1 device is as a ladder fall arrest system, using a rigid rail or a flexible line attached to the ladder. : This includes rope grabs and rail grabs. : a mechanical fall arrest device from which a spring loaded lifeline pays out allowing full freedom of movement, and which locks onto a lifeline when loaded and releases when the load is removed. : This is also known as a fall arrest block or a self-retracting lifeline. : an inertia reel which incorporates a retrieval winch. : a system designed to arrest or prevent a worker s fall from one level to another whilst minimising the risk of injury during the fall. The fall injury prevention systems include fall restraint systems, fall arrest systems, catch platforms, scaffolding, safety nets and safety mesh. : the use of multiple, approved safety equipment components such as approved safety harnesses, lanyards, personal energy absorbers, droplines, horizontal and/or vertical lifelines and anchorages, interconnected and rigged to arrest a free fall. It is an assembly of equipment and components, including the necessary connectors, joined together and designed to slow and stop a worker during a fall, in order to prevent the worker from striking a lower level or an obstruction during a fall. The fall arrest system must then support the worker until a rescue can be affected. : an approved device and any necessary components that function together to restrain a person in order to prevent that person from falling to a lower level. It is a system designed to restrain a worker from reaching an exposed fall hazard. A fall restraint system includes personal fall protection equipment comprising an approved safety harness unless a documented risk analysis shows a waist belt to be adequate, acceptable anchor point systems, and trained worker and administrative procedures. AA_AFRG_ doc APPROVED 18 December 2008 Page 7 of 88

8 Fall Prevention Fall Protection: Fixed lanyard Free Fall Guardrails : the design and use of a fall prevention system which ensures no exposure to an elevated fall hazard. This may require more than one fall prevention system or a combination of prevention or protection measures. It is the elimination and minimization of potential fall hazards, lessening the chance of worker exposure to falls. Any same-level means used to reasonably prevent exposure to a fall hazard; examples of fall prevention are guardrails, walls, floors, and area isolation : actions and procedures required to effectively protect a worker from fall hazards : a line used as part of a lanyard assembly to connect a harness to an anchorage point or a static line in situations where there is risk of a fall. : any fall or part of a fall where the distance before the fall arrest system begins to take any loading is in excess of 600mm either vertically or on a slope on which it is not possible to walk without the assistance of a handrail or hand line. The maximum allowed free fall is 2 metres. : a fixed barrier around working areas or floor areas, consisting of a hand rail, a middle rail, and a Toeboard. Generally speaking, guardrails are a permanent or temporary portable structural system consisting of a hand rail, a middle rail and toeboard secured to vertical posts and is intended to stop a worker from inadvertently stepping off a working level and falling to a level below. The hand rail should be at a height of between 950 mm and 1100 mm above the walking surface. The middle rail should be midway between the hand rail and the walking surface. The guardrails must be of capable of resisting a static load of 900 Newton's (200 pound force) at any point along the rails. There are many different variations of guardrails, including woodslat, wire rope, steel frame, safety fencing, tube and clamp, perimeter netting and others. Any of these variations is acceptable, as long as the system meets the basic design characteristics as mentioned previously. Note : this may also be referred to as hand railing. Toe board : a floor level protective barrier that will prevent the fall of materials and equipment to lower levels. It shall project a minimum of 100mm above the floor level. It will also prevent a worker s foot slipping below the guardrails. Note : this may also be referred to as a kick plate. AA_AFRG_ doc APPROVED 18 December 2008 Page 8 of 88

9 Lanyard : a line usually used to connect an approved safety harness to an anchor point or lifeline in situations where there is a risk of a fall or when used in restraint mode to prevent a fall. Lanyards can be either adjustable or fixed length and can incorporate the use of a personal energy absorber. Single or dual lanyards are available, and are applicable to different working requirements. Note : a dual lanyard may also be referred to as a twin tail lanyard. Lifeline : a component consisting of a flexible line or a rail for connection to one or more anchor points. A vertical lifeline has an anchor point at one end and hangs vertically. A horizontal lifeline has an anchor point at both ends and stretches horizontally. Lifelines serve as a means for connecting other components of a personal fall arrest system to the anchor point. Note: : a vertical lifeline may also be referred to as a dropline. a horizontal lifeline may also be referred to as a static line. Limited Free Fall Maximum Arresting Force (MAF) Personal Energy Absorber Note Pole Strap Positioning Device System : a fall or the arrest of a fall where the fall distance before the fall arrest system begins to take any loading, does not exceed 600 mm either vertically or on a slope on which it is not possible to walk without the assistance of a handrail or handline. : the peak force exerted on the body or test weight when a fall protection system stops a fall. : an attachment designed to reduce the deceleration force imposed by a suddenly arrested fall. A Personal energy absorber is designed to be used with a full body harness and lanyard. The Personal energy absorber is usually built in to a lanyard, and the combination of the personal energy absorber and lanyard is called a lanyard assembly. It is typically two metres long overall. : this may also be referred to as a deceleration device or a personal shock absorber. : a strap securing a worker to a pole to enable work to be carried out. : a combination of equipment that permits the user to have both hands free while being supported on an elevating vertical surface. AA_AFRG_ doc APPROVED 18 December 2008 Page 9 of 88

10 Restrained Fall Restraint Line Restricted Access Work Area Rollout Rope Access Rope Grab Suspension Trauma Swing Fall SWL : a fall or the arrest of a fall where the worker falling is partially restrained by a device such as a pole strap, or is sliding down a slope on which it is normally possible to walk without the assistance of a handrail or handline. : the line-securing worker to a point of anchor point and is used to prevent a worker from reaching a point from which he or she could fall. : an area from which a fall is possible and where work is restricted to workers using fall restraints or fall arrest systems. : an action by which a connector unintentionally disengages from the component to which it is attached. : a rope access suspended system consisting of two lifelines independently anchored at the top to protect the authorized worker from falling. The ropes directly suspend the worker. The technique is used on buildings, bridges, and other structures for conducting inspection, cleaning and painting. : a deceleration device that travels on a lifeline and automatically, by friction, engages the lifeline and locks to arrest the fall of a worker. A rope grab usually employs the principal of inertial locking, cam/level locking, or both. : the effect that can occur when a person hangs for a prolonged period in fall-arrest equipment. The restriction of blood flow, especially from the legs, can cause serious cardiovascular problems within five minutes and become fatal shortly thereafter. : a pendulum-like motion that can result from moving horizontally away from, or toward, a fixed anchor point and falling. A swing fall will result from any fall where the lanyard or lifeline is not attached to an anchor point directly above the worker. Swing falls generate the same amount of force when falling the same distance vertically. Swing fall has the hazards in both the horizontal direction (swinging into obstructions) and vertical (falling onto obstructions or ground). : the safe working load that may be applied to an anchor point, or loaded on a working platform. Note : this may also be referred to as a working load limit (WLL). Total Fall Distance : the total distance a worker is likely to fall during both the free and restrained parts of a fall and includes the maximum dynamic extension of all supporting components. AA_AFRG_ doc APPROVED 18 December 2008 Page 10 of 88

11 Total Restraint Worker Working Surface : a situation where a fall is not possible. This is achieved through control of a worker s movement by means of a combination of a belt or harness, a line and a line anchor point which will physically prevent the worker from reaching a position at which there is a risk of a free or limited free fall. : any person working on an AA plc site, whether a permanent employee of AA plc, a contract worker for AA plc, or an employee or contract worker on the staff of a Contractor. : any surface, whether horizontal or vertical on which an worker walks or works, including, but not limited to, floors, roofs, ramps, bridges, runways, form work, and concrete reinforcing steel (but not including ladders, vehicles, or trailers), on which workers must be located in order to perform their job duties. Note : this may also be referred to as a walking surface. Work Positioning System : means any equipment, other than a temporary platform, which enables a worker to be positioned and safely supported at an elevating work location for the duration of that work. 4 REASON FOR INCLUSION Falls from heights have contributed to a significant proportion of our fatal and highpotential incidents. The causes of and factors contributing to these incidents have been: Lack of job planning and job assessment, including inspection of working areas; Failing to wear a harness; Wearing the wrong sort of harness; The use of a damaged harness; Wearing the harness incorrectly; Wearing a harness but not attaching the lanyard or fall restraint to an anchor point, or attaching it to an unsuitable anchor point; Unstable set-up of elevated work platforms; Degeneration of elevated platforms (e.g. corrosion); Inadequately-guarded or unbarricaded hole, edges, voids, excavations or walkways; Unsafe planking and scaffolding. AA_AFRG_ doc APPROVED 18 December 2008 Page 11 of 88

12 5 REQUIREMENTS Application of the Anglo Fatal Risk Standards is mandatory at all Anglo American managed businesses and operations. This mandatory nature is indicated by the use of the word shall within the Standards. In some places, the word should is used. This means that the primary intent remains, but specific circumstances may mean that implementation of the requirements is not reasonably practicable. Any deviation from the specifications set forth in these Standards should be formally approved following an exemption procedure. The exemption procedure comprises the following steps: 1. Documented and detailed description of the implementation difficulties. 2. Documented and detailed risk assessment of the situation under proposed alternative control measures. 3. Documented formal approval from the Divisional Head of Safety and the Divisional Chief Executive Officer that the level of risk as a result of the alternative control measures is understood, tolerable for the organisation and in line with the Anglo American Group vision of Zero Harm. This section is structured using exactly the same numbering sequence as the Anglo Fatal Risk Standard document. Each requirement is repeated inside a box, followed by a statement of intent. This is followed by discussion and clarification of that particular requirement with reference to other related requirements, Appendices, Communities of Practice, and other relevant documents. Appendices are used to reduce the size of this document, and allow more efficient continuous improvement. Detail has been added to some, but not all requirements, as some sections were deemed self explanatory. Links to associated reference material have been given at relevant places in this document. The main source of reference material and examples of leading practice can be found on the Anglo Fatal Risk Standard Quickplace. 6 PLANT AND EQUIPMENT REQUIREMENTS 1. Equipment design standards All equipment for working at heights shall comply with, and be used in accordance with, relevant approved design standards and manufacturer s specifications. Intent To ensure that all equipment used for working at heights is fit for purpose. Due to the many standards of design and differences in interpretation, it is very important that a recognised relevant and approved design standard is followed. All sites shall follow the specifications for safe use and maintenance indicated by the manufacturers of the equipment. All working at heights equipment shall be used, inspected and maintained according to manufacturers specifications to ensure proper functioning. All manuals and technical information must be readily available for consultation. AA_AFRG_ doc APPROVED 18 December 2008 Page 12 of 88

13 All working at heights equipment shall meet the relevant design standards applicable to each country, region or continent. In regions or countries where specific standards for working at heights are not present or specified, the local legislation or regulations shall be followed. The following International Standards should be considered as a good reference for use or consultation for Working at Heights: OSHA : Occupational Safety and Health Administration (USA) ANSI : American National Institute of Standards (USA) AS : Australian Standards (Australia) BSI : British Standards Institution (UK) CSA : Canadian Standards Association (Canada) SABS : South African Bureau of Standards (South Africa) Note: all standards published by the South African Bureau of Standards are available of thesource under the TechnoLink banner. 2. Anchor points Single person anchor points shall be capable of withstanding 15kN (approximately 3,372lbf). Where it is not practicable to install dedicated anchor points (i.e. ad hoc work) anchor points capable of withstanding 15kN shall be identified through a risk assessment process and shall be approved by a competent person prior to commencement of work. Intent To ensure that anchor points as critical points of attachment for safety lines or lanyards have the capability to support a worker or workers in the event of a fall. Anchors are the critical point when it comes to fall protection systems as all the harnesses, slings and ropes in the world won t help if the anchor point fails in the event of a fall. Selection and type of anchor point will depend on the nature and location of the task and the type of construction or supporting structure. Anchor points can either be engineered or improvised. An anchor point system is a combination of anchor point and anchor point connector(s). Anchor point connectors are usually designed and prefabricated by a manufacturer under the supervision of a qualified person and should meet the relevant standards. AA_AFRG_ doc APPROVED 18 December 2008 Page 13 of 88

14 Anchor points must have a minimum strength of at least 15kN. For two people connected to the same anchor point a minimum strength of at least 21kN is required. Note that in some countries, the strength of anchor points for a single worker is required to have a minimum strength of 22,2kN (i.e pounds), whereas other countries do not specify the strength. Some countries also allow a lower strength of 6kN for anchor points for fall restraint. The use of this lower strength is not advised, as it can lead to confusion as to what anchor point may be used for what purpose. The AA plc requirement of 15kN should be used in all countries, except where the higher strength applies. Note: Anchor point SWL values are generally given in units of kg (kilograms) or tonne. 15kN is 1,5tonnes, or 1500kg. Anchor point with a safe load of 1,5Tonne (15kN) AS/NZ Industrial fall arrest systems and devices ISO Personal fall arrest systems EN Protection against falls from a height. Anchor Devices Types of anchor points considered under the definition of the AFRS No.7 include: a) A device that has been purposefully manufactured and installed as an anchor point to support a personal fall protection system. b) A substantial structure, such a beam, column or similar substantial portion of the structure, selected as an anchor point where no dedicated anchor point is available. These anchor points generally require some supplemental rigging, such as a sling or bracket, to allow the anchor point connector of a personal fall protection system to connect to the anchor point. Various beam sizes that may be used as anchor points are shown in the Table below. For each beam size, the Table shows the maximum span on which it may be used as an anchor point, as well as the minimum number of bolts required to be used at each end of the beam. If the span exceeds that shown in the Table, or if the beams ends have fewer bolts than shown in the Table, or if the beam has been damaged in any way (such as by corrosion or impact) then the beam shall not be used as an anchor point. Steel angle sections, cold formed sections, cable trays, guard rail sections and the like shall not be used as anchor points. If any doubt exists, then a Structural engineer shall be consulted to specify adequate anchor points. AA_AFRG_ doc APPROVED 18 December 2008 Page 14 of 88

15 The actual strength of an anchor point is dependent on: The design of the anchor point. The orientation of the anchor point relative to the direction of loading. The condition of the anchor point. The connection of the anchor point to the supporting structure. The adequacy of the structure to resist the imposed loading. TABLE: BEAMS THAT MAY BE USED AS ANCHOR POINTS Section Size Maximum Span allowed Minimum no. of bolts allowed Beams 203x152 J 3 m 4/M16 bolts (I sections) 203x133 I 2/M20 bolts 203x152 J 4 m 254x146 I 203x152 J 5 m 356x171 I 406x178 I 6 m 6/M16 bolts 4/M20 bolts 457x191 I 7 m 4/M20 bolts 533x210 I 8 m Columns 203x203x52 H 3 m 4/M16 bolts (H sections) 203x203x71 H 4 m 2/M20 bolts 254x254x73 H 5 m 4/M20 bolts 254x254x89 H 6 m 254x254x107 H 7 m 305x305x97 H 8 m Channels 140x60 C 1,0 m 4/M16 bolts (C sections) 200x75C 2,0 m 2/M20 bolts 260x90 C 3,0 m 300x100 C 4,0 m AA_AFRG_ doc APPROVED 18 December 2008 Page 15 of 88

16 NB: Unless approved by a Structural Engineer, channels shall only be used as anchor points for vertical or near-vertical lanyard orientation. Channels shall not be used as anchor points where the lanyard has an angle of more than 30 from the vertical. Where channels are used as columns, they shall not be used as anchor points. The following requirements shall be complied with when any temporary anchor point is attached to existing steelwork: a) Where holes must be made for the attachment of brackets or eye-bolts, they shall be drilled and not burned. b) Anchor points shall not be attached to any beam supporting vibrating equipment (such as screens, large motors, crushers, scrubbers and the like) without the approval of a Structural engineer. c) All beams used as anchor points shall be supported at both ends. Cantilever beams shall not be used without the approval of a Structural Engineer. d) A temporary anchor point should be removed upon completion of the work for which it was intended. Anchor points may be attached to beams and columns using: a) Anchor straps Anchor Strap Connected to a Beam (Note that the strap must be protected from sharp edges, not as shown here). b) Eyebolts Only eyebolts having a Supplier s specified strength of not less than 15kN shall be used as anchor points. AA_AFRG_ doc APPROVED 18 December 2008 Page 16 of 88

17 An eyebolt used as a fixed anchor point (Note that the eyebolt must always be screwed right in as shown here) c) Brackets Brackets to be used as anchor attachment points may be made in accordance with the sketches below. All welding on these brackets shall be done by welders who are qualified in terms of AWS D1.1. The brackets shall comply with all details and notes shown on the sketches. Alternatively, a Structural Engineer shall be appointed to specify a design for the anchor point brackets Notes: 1. All plate 10 thick. 2. All plate Grade 250 MPa minimum 3. All bolt holes 18 diameter for M16 bolts 4. All bolts Class 4.8 minimum 5. All edges to be laser cut or machined and not burned Sketch of Bracket for Attachment to an I Beam 50 mm diameter hole Note that this sketch is not drawn to scale Sketch of a Bracket for Attachment to a Channel People working at height shall be aware that the anchor point shall be located in such a way to minimize swinging of the worker that can occur during a fall. If any obstruction exists in the path of the swing fall, the force generated by such a fall is the same as the force in a vertical fall. All sites must ensure that ladder rungs, handrail components and cable trays are not used as anchor points as their load limit will not withstand a fall. All sites shall ensure that all permanent anchor points are inspected by a competent person at intervals not exceeding six months. These inspections must assess whether the strength of the anchor point may have deteriorated due to corrosion, loosening of bolts, bending or other damage, and whether any changes to operational requirements or to plant layout may have rendered the anchor point ineffective (e.g. re-routing of pipes or cables may lead to anchor points being behind the pipes or cables, and thus not acceptable as an anchor point). AA_AFRG_ doc APPROVED 18 December 2008 Page 17 of 88

18 This anchor point is not acceptable, because in this scenario a fall would result in a swing fall. Guide for selection and safe use of anchor points a) Before use, anchor points shall be designed and approved by a registered professional engineer or another qualified person with appropriate education and experience, with experience in designing fall protection systems. If there is a need to devise an anchor point from existing structures such as beams, or eyebolts, a qualified person shall be used to evaluate these anchor points. b) A qualified person will be able to calculate the forces generated by arresting a fall, the total loading and the impact on the structural members the line is attached to. The qualified person can thus determine the optimal and safe location where and how to tie-off. c) The strength of a personal fall arrest system depends on its subsystems and components, as well as the points of anchor point and how strongly such a system is attached to the anchor point. Such attachment shall not significantly reduce the strength of the system, including the structural members such as beams, columns, or any rigid structure. d) All components and sub-components of the selected fall arrest system shall be compatible with each other. e) When tying off to a beam or column, do not attach the anchor point connection to a hole in the beam or column unless evaluated by a qualified person. The hole will weaken the beam or column structure. Do not drill a hole for tying off. This attachment will weaken the beam. f) Do not tie a knot in the anchor point connection. g) The anchor point shall be located in such a way to minimize swinging the worker (pendulum-like motion) that can occur during a fall. h) Select the point of anchor as high as possible above head height of the worker. This will ensure that the lanyard or lifeline remains as near vertical as possible, thus reducing the likelihood of a pendulum fall. i) Always specify the number of authorized users that are allowed to attach to a specific point of anchor. j) When planning and selecting an anchor point location, take into consideration the accessibility and ease of securing to it, and its proximity to an unguarded edge. AA_AFRG_ doc APPROVED 18 December 2008 Page 18 of 88

19 k) Fall arrest anchor points that will be in place for a period of longer than one month shall be signposted in accordance with the requirements of relevant standards. l) All anchor points shall be visually checked prior to use. m) Any anchor points identified as being damaged or insecure shall be removed, repaired or replaced as soon as possible. They shall not be used until they have been repaired. n) If an eyebolt is selected as a point of anchor, it should be rated along its axis. Eyebolt strength is greatly reduced if the force is applied at an angle to the eyebolt axis. Eye bolts shall not be used transverse to their axis. Eyebolts shall be screwed right up to the end of their threaded length when installed. o) Ladder rungs, handrail components and cable trays shall not be used as anchor points. p) When using a vehicle as an anchor, always attach to parts securely fixed to the vehicle, and which do not allow the lanyard or lifeline to slip off. Do not attach to towbars or roof racks. Use an anchor point between the four wheels as low as possible. Before commencing work, ensure that the gears of the vehicle are engaged and do not rely only on the brakes. This anchor point is not acceptable because the hand rail is not strong enough AA_AFRG_ doc APPROVED 18 December 2008 Page 19 of 88

20 KEY POINT SUMMARY DO: Ensure use of a proper anchor point. Visually inspect anchor point prior to use. Use an anchor point as high as possible overhead. DON T: Use ladder rungs, any guardrails component or cable trays as anchor points. Burn or drill holes in beams or columns for anchor points. TO BE DONE: List all locations where work is routinely done at heights. Ensure that all of these locations have clearly designated anchor points, approved by a competent person. Prepare a procedure for inspection of anchor points at intervals not exceeding six months. Prepare a procedure for reporting, and repairing or replacing, any anchor point found to be damaged or defective in any way. 3. Fall restraint systems Where personnel are required to work within 2metres of an opening where they could fall they shall use personal fall restraint equipment such as a fixed lanyard and harness as a minimum which will prevent them from falling over the edge. Intent To avoid injuries or fatalities preventing personnel from falling over an edge when working within 2metres of an opening. Prevention of a fall can be achieved by use of physical barriers or a fall restraint system which ensure that workers cannot reach a position where a fall could occur. Physical Barriers (such as guardrails) are the preferred type of fall prevention systems. If guardrails are not practicable, each worker can use a full body harness attached to a securely anchored lanyard or lifeline. Fall restraint systems consist of a fixed length or adjustable lanyard connected to an anchor point or a fall restraint lifeline. No energy absorber is needed, as being a correctly designed fall restraint system, there is no possibility of a fall. Fall restraint systems shall be rigged to allow the movement of workers only as far as the sides and edges of the working surfaces. So when an adjustable lanyard is used, the worker needs to ensure that the lanyard length cannot be extended to permit entry into an area where a fall is possible. Anchor points for fall restraint systems may not be strong enough to resist the impact loads applied in the event of a fall. Fall restraint equipment is far more desirable than a fall arrest system as it prevents a fall, thus preventing injury. AA_AFRG_ doc APPROVED 18 December 2008 Page 20 of 88

21 Typical uses of fall restraint systems include: a) Fall restraint of workers inspecting an open slope edge b) Workers cleaning tips in underground haulages c) Workers working on a low angle (not greater than 5 degrees) pitched roof or within 2 metres of an open edge or opening. d) Working with a pole strap around a pole. e) Working at the edge of a floor where guardrails has had to be removed to raise or lower equipment using a crawl beam. f) Any other location where workers are working within 2metres of an edge where the fall from the height could result in an injury. This fall restraint system consists of a full body harness attached to a securely anchored restraint lanyard. The lanyard prevents the worker from getting too close to an unguarded edge by limiting the distance the worker can travel Workers using fall restraint systems shall: a) Have been trained and assessed as competent in the use of such equipment. b) Perform a visual check on the full body harness prior to fitting it. If any faults are found the equipment shall be tagged Out of Service and arrangements made for a competent person to conduct a formal inspection. Ensure that the full body harness has been fully inspected and tagged within the previous 6 months. c) Perform a visual check on the lanyard for any cuts, abrasions or heat damage. If any faults are found the equipment shall be tagged Out of Service and arrangements made for a competent person to conduct a formal inspection. Ensure that the lanyard has been fully inspected and tagged within the previous 6 months. d) Perform a visual check on the anchor point that will be used. If it has corroded, has loose or missing bolts, has been bent or damaged, or if found unsuitable in any other way, it shall not be used as an anchor point. e) Connect to the anchor point prior to undertaking any work activity. AA_AFRG_ doc APPROVED 18 December 2008 Page 21 of 88

22 f) Ensure that the diameter of the D hook on the belt exceeds the throat depth of the attachment hook on the lanyard to prevent roll out. g) Only use a retractable lanyard where its maximum length does not allow approach to a position where a fall is possible. h) Ensure that all components of the fall restraint system are compatible. Inspection and testing All components of fall restraint systems shall be inspected, and if necessary tested, by the Manufacturers at defined regular intervals. The intervals at which equipment must be inspected and tested should not exceed six months, but this may vary depending on Manufacturer requirements and local legislation. Requirements for inspection and testing are described in more detail in Appendix C. KEY POINT SUMMARY DO: Visually inspect all components of the fall restraint system prior to use. Tag damaged or faulty equipment Out of Use. Ensure the correct length of lanyard to prevent falling. DON T: Approach an edge prior to proper connection of all components of the fall restraint system. Use any faulty equipment. TO BE DONE: Ensure that all workers are aware of when fall restraint is required, and what equipment must be used. Identify areas where routine work requires the use of fall restraint equipment, and install appropriate signage. Make an inventory of all fall restraint equipment, with inspection dates. Prepare a procedure for reporting, and removing from service, any fall restraint equipment found to be faulty or damaged. 4. Fall arrest systems Where there is potential to fall more than 2metres, personnel shall wear appropriate personal fall arrest equipment. In such circumstances, the use of a full body harness, including shock-absorbing lanyard or inertia reel is mandatory. The use of body belts for fall arrest is prohibited, except for specialised tasks such as pole-climbing belts worn by specially-trained linesmen. AA_AFRG_ doc APPROVED 18 December 2008 Page 22 of 88

23 Intent To avoid injuries or fatalities by protecting personnel working in a workplace where there is a risk of falling more than 2 metres. The use of a fall arrest system will safely slow and stop, and then support and hold the worker in the event of a fall. Vertical rope fall arrest system A fall arrest system must always include a full body harness and connecting means between the full body harness and an anchor point. Such connecting means may consist of a lanyard, lanyard assembly, personal energy absorber, Type 1 fall arrest device, lifeline, inertia reel, or suitable combinations of these. A fall arrest system will not prevent a fall from occurring in the first place, but it will stop a worker s fall after a short distance, preventing the worker from hitting the surface below, and minimizing the distance and severity of a fall. Due to the high probability of injury, fall arrest must only be selected as a fall protection system once all other systems have been considered and found impractical. An emergency rescue procedure is required for workers using fall arrest as a fall protection system. Fall arrest systems should be designed so that a worker equipped with a safety harness cannot free fall more than 2metres. Example of safe fall arrest system A fall arrest system shall be used instead of a restraint system if any of the following situations apply: a) The user can reach a position where a fall is possible. b) There is a danger of the user falling through the surface (e.g. roofing material). c) The slope of the working surface is over 15 degrees. d) There is any other reasonably likely misuse of the system that could lead to a free fall. AA_AFRG_ doc APPROVED 18 December 2008 Page 23 of 88

24 Anchor point structural steel able hold a static force of at least 15kN. Sling used around the anchor point. Connector used to join sling to lanyard hook Point of hook attachment is above D ring, ensuring max free fall is less than 2 metres. All the attachments are in line, thereby preventing a pendulum fall Good use of a fall arrest system Full body harness A fall arrest system requires a full body harness. A full body harness consists of straps passed over the shoulders, across the chest, and around the legs. In a fall, a full body harness protects more than a safety belt, because it distributes the force of impact over a greater area of the body. Safety belts have also been known to slip off the body in a fall. The full body harness must be the correct size and be adjusted securely. The harness instructions must be followed carefully to ensure the correct use of the harness. Various alternatives and improvements exist. a) Where a sternal (front) attachment point exists, this should be used in preference to the dorsal (back) point because: - It is usually easier for the worker to recover themselves with a sternal attachment - The pendulum effect may be able to be controlled better by the falling worker using this configuration. AA_AFRG_ doc APPROVED 18 December 2008 Page 24 of 88

25 Sternal Dorsal Sternal and dorsal connection points b) Some full body harnesses incorporate foot straps. These are straps that can be released in the event of a fall, and the worker s feet are inserted to support the body weight on the feet rather than on the leg straps. Leg straps restrict blood circulation in the groin area, so rescue must be affected quickly to avoid loss of consciousness. The use of foot straps releases this restriction in blood circulation, thus allowing a longer period for safe rescue. All full body harnesses used on AA plc sites should be fitted with foothold straps to avoid suspension trauma. Suspension Trauma Strap manufactured by DBI Sala, Spiderwebb and others helps prevent the effects of suspension trauma after a fall Lifelines A lifeline is a line made of either webbing or rope (wire or synthetic), which connects two anchors, either vertically or horizontally displaced. Attaching to the lifeline creates a moveable anchor point, permitting the user a degree of freedom in either restraint, work positioning or fall arrest modes. Only a certified and competent rigger with the authority to do so can install lifelines on sites. However, it is important to understand that it is a simple matter to overload a lifeline by over tensioning or placing too much load on it. Failure of a lifeline would have tragic consequences. When working with lifelines operators should always maintain a positive connection with the lifeline. On lifelines where there are AA_AFRG_ doc APPROVED 18 December 2008 Page 25 of 88

26 intermediate anchor points, the operators should have to use either two lanyards or a Y or dual lanyard. The lifeline to be used should be located as high as practicable. It is dangerous to work above the lifeline as the worker could fall more than 2,4metres. Vertical lifeline systems incorporate a device, which will move freely while ascending, but lockup if there is a fall. As this fall should be less than 600mm, sternal attachment (to the chest) to the full body harness is permitted. Lanyards The lanyard used to connect the harness to the lifeline fall arrest device shall incorporate a personal energy absorber. The maximum length of the lanyard, including the Personal energy absorber should generally not exceed 2,0m Where a work task can be completed without disconnecting the lanyard from an anchor point or lifeline, a single lanyard may be used. This will be the case, for example, when the work is carried out at one point or over a limited area, or when using a horizontal or vertical lifeline. Where the lanyard has to be disconnected for any reason, a dual lanyard shall be used. This will be the case, for example, when the lifeline is connected to intermediate anchor points and the worker must pass from one side to the other side, or when the worker must transfer from a workbox to an elevating work platform. Recommendations for safe use of Dual Lanyards The user of a dual lanyard shall only ever connect to this lanyard by the termination on the Personal energy absorber. When using a dual lanyard the worker shall ensure that at least one of the lanyards is connected to the structure at all times. AA_AFRG_ doc APPROVED 18 December 2008 Page 26 of 88

27 Care must be taken when climbing with a dual lanyard to not over climb the lanyard to the extent that the user of the lanyard would be exposed to a free fall greater than 2m. When climbing or working with a dual lanyard, it is acceptable to have both lanyards connected to the structure provided that the included angle between the two legs of the lanyard does not exceed 120degrees. When climbing or working with a dual lanyard do not hook the unused lanyard to your full body harness. This can create a situation where, in the event of a fall the parked lanyard would interfere with the operation of the Personal energy absorber, resulting in serious injury or death. Instead of hooking the unused lanyard to yourself: Connect the unused lanyard directly to another anchor point or lifeline. Connect both hooks to the same anchor point or lifeline but guard against roll out from the Connector. Connectors Obviously it is vitally important that the lanyard assembly and the full body harness are connected together, and remain so. Equally important is that the lanyard assembly is reliably connected to the anchor point. Often connection is made by a double-locking snap-hook. However some of the available connectors can be easily disconnected from the harness by twisting the gate of the hook against the harness D-ring, while applying gentle pressure on the safety latch, thereby causing "roll-out" of the snap-hook from the D-ring. Connectors must be self-locking to prevent accidental roll-out. Roll-out can occur when small D-rings, or other attachment hardware, cause the snap-hook gate to push open in a twisting action thus separating the two components. AA_AFRG_ doc APPROVED 18 December 2008 Page 27 of 88