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Managing Risk of Falls at Workplaces

Falls from Height - Major Hazard​

Falls from height are the leading cause of death and serious injury in construction.

Common Fall Scenarios:

  • Falling from roofs, edges of floors/slabs
  • Through fragile surfaces (skylight, roof sheets)
  • From ladders, scaffolding, elevated work platforms
  • Into excavations or voids
  • From structures during erection/demolition

[!warning] High Consequence Falls from even low heights (< 2 meters) can cause serious injury or death, especially if landing on hard surfaces or striking objects.

When is Work at Height High-Risk Construction Work?​

Work involving risk of fall > 2 meters requires Safe Work Method Statement.

Examples:

  • Roof work on houses (typically 3-4m from ground)
  • Working on slabs/floors of multi-storey buildings
  • Scaffolding erection/use
  • Working from ladders >2m

Who Has Duties?​

PCBUs​

Must:

  • Eliminate risks of falls (where reasonably practicable)
  • If not practicable to eliminate, minimize risks
  • Provide fall protection systems
  • Ensure workers trained in fall protection use
  • Prepare SWMS for work >2m fall risk

Designers​

Must design structures to:

  • Eliminate or minimize fall risks during construction, use, maintenance, demolition
  • Include permanent anchorage points for maintenance access
  • Provide safe access for ongoing maintenance

Workers​

Must:

  • Follow safe work procedures and SWMS
  • Use fall protection equipment as instructed
  • Report damaged or defective equipment
  • Not remove or bypass safety systems

Hierarchy of Control for Falls​

Level 1: Elimination​

Most Effective: Remove the need to work at height.

Methods:

  • Pre-fabricate at ground level, lift into position
  • Design roof trusses on ground, crane to roof
  • Use tilt-up construction (walls erected from ground)
  • Remote inspection (drones, cameras) instead of physical access

Example: Pre-fabricate roof sections complete with battens and flashing on ground. Crane to roof as complete units, eliminating most work at heights.

Level 2: Minimize Risk - Passive Fall Prevention​

If elimination not practicable, prevent falls using passive systems (physical barriers).

Guardrails/Edge Protection:

  • Top rail at 900-1100mm
  • Mid-rail
  • Toe board (minimum 100mm)
  • Strong enough to withstand leaning/impact
  • No gaps > 250mm

Advantages:

  • Protects everyone in area (not just those wearing harnesses)
  • No special training required
  • Does not rely on worker behavior
  • Most reliable control

Applications:

  • Slab edges during construction
  • Roof edges
  • Scaffold platforms
  • Mezzanine floors
  • Stair openings

Guardrails on mezzanine floor Figure: Mezzanine floor barrier

Guardrails on top of tanker Figure: Guardrails installed on plant for safe access

Perimeter Safety Screens:

  • Mesh attached to structure perimeter
  • Catches falling workers and materials
  • Used on multi-storey construction

Safety Mesh/Netting:

  • Under fragile roof materials
  • Below overhead work (catches falling workers/materials)
  • Must be installed by competent person

Covers Over Penetrations:

  • Secure covers for floor openings, shafts
  • Must support weight of person walking on it
  • Clearly marked ("HOLE - DO NOT REMOVE COVER")

[!tip] Edge Protection is Preferred Guardrails and edge protection are more reliable than fall arrest systems. Use wherever reasonably practicable.

Level 2: Minimize Risk - Work Positioning and Restraint​

Fall Restraint Systems: Physically prevents worker from reaching fall edge.

Components:

  • Anchorage point (rated, tested, certified)
  • Full-body harness
  • Lanyard (adjustable, limits travel to prevent reaching edge)

Advantage:

  • Prevents fall (worker cannot reach edge)
  • No fall arrest forces

Limitation:

  • Work area restricted
  • May not be practicable for large areas

Restraint technique options Figure: Restraint technique - prevents reaching the fall edge

Example: Worker on roof with harness connected to ridge anchor. Lanyard length prevents reaching eaves.

Level 3: Minimize Risk - Fall Arrest Systems​

When Used: Where higher-level controls not reasonably practicable.

[!warning] Fall Arrest is Last Resort Fall arrest stops a fall but does not prevent it. Significant injury risk from fall itself, suspension trauma, and arrest forces.

Components:

1. Anchorage Point:

  • Must withstand 15kN (static) or 12kN (if engineered)
  • Certified and inspected
  • Located to minimize free-fall distance and swing

2. Full-Body Harness:

  • AS/NZS 1891.1 compliant
  • Correctly fitted to individual
  • Dorsal (back) attachment point for fall arrest

3. Connecting Device:

  • Shock-absorbing lanyard: Reduces arrest forces
  • Self-retracting lifeline (SRL): Arrests falls quickly, minimal free-fall
  • Must be compatible with harness and anchorage

4. Rescue Plan:

  • Method to rescue fallen worker within 6 minutes
  • Suspension trauma can be fatal
  • Rescue equipment and trained personnel

Critical Requirements:

  • Maximum free-fall distance 2 meters (preferably <1m)
  • Minimum clearance below (calculate fall distance + lanyard extension + worker height + safety margin)
  • Regular inspection (before each use)
  • Training in correct use
  • Compatible equipment (not mixing brands without verification)

Total fall distance calculation Figure: Calculating total fall distance vs clearance required

Example Calculation:

  • Worker height: 1.8m
  • Free-fall: 1m
  • Lanyard extension during arrest: 1.2m
  • Safety margin: 1m
  • Minimum clearance required: 5m below anchor point

Level 3: Administrative Controls and PPE​

Used in conjunction with fall protection systems, not alone:

  • Training in fall protection use
  • SWMS for work at heights
  • Permits for roof access
  • Competent supervision
  • Weather restrictions (wind, rain, ice)
  • PPE (hard hats, safety boots)

Specific Fall Risks and Controls​

Roof Work​

Fragile Roofs: Materials that won't support person's weight (old corrugated iron, skylight, fiber-cement).

Controls:

  • Install walkways/crawl boards (distribute weight)
  • Safety mesh under fragile areas
  • Edge protection at roof perimeter
  • Fall arrest if mesh/rails not practicable
  • Never rely on roof material alone

Pitched Roofs:

  • Scaffolding with edge protection for installation/maintenance
  • Roof brackets and planks (not <30 degrees pitch)
  • Fall arrest for steep pitches
  • Consider weather (rain, ice makes surfaces slippery)

Ladders​

Ladders are for Access, Not Workplaces: Use ladders only for:

  • Short duration, low-risk work
  • Access to/from another level

Requirements:

  • Industrial-rated (not domestic)
  • Inspected before use (check rungs, stiles, feet)
  • Secured (tied off top and bottom, or footed by second person)
  • Correct angle (1:4 ratio - 1m out for every 4m up)
  • Extend 1m above landing platform
  • Three-point contact (two hands, one foot or two feet, one hand)
  • Face ladder when ascending/descending
  • Don't carry loads (use tool belt or hoist materials)

When Not to Use Ladders:

  • Prolonged work (use scaffold/platform)
  • Heavy or awkward loads
  • Work requiring two hands
  • Work above 2 meters (where scaffold practicable)

Scaffolding​

Advantages:

  • Large work platform
  • Edge protection built-in
  • Stable base for materials
  • Suitable for prolonged work

Requirements:

  • Erected by licensed scaffolder
  • Designed for loads (workers + materials)
  • Inspected before use and regularly
  • Tagged (green = safe, red = unsafe - DO NOT USE)
  • Tied to structure (prevents collapse/movement)
  • Edge protection (toe boards, mid-rails, top rails)
  • Safe access (internal ladder, stairs)
  • Level, stable base (base plates, mud sills)

Perimeter scaffold with fully decked working platform Figure: Perimeter scaffold with guardrails, mid-rails, and toe-boards

Inspection:

  • Before each shift
  • After weather events (strong wind, rain)
  • After any modifications
  • By competent person

Users Must:

  • Check tag before using
  • Not modify scaffold
  • Not overload
  • Not remove edge protection
  • Report damage immediately

Elevated Work Platforms (EWP)​

Types:

  • Scissor lifts (vertical)
  • Boom lifts (articulated/telescopic)

Boom-type elevating work platform Figure: Boom-type elevating work platform

Safety Requirements:

  • Licensed operator for boom-type (boom length of 11 metres or more)
  • Pre-start inspection
  • Guardrails on platform (intact, no gaps)
  • Harness required for boom-type (anchor to platform, not structure)
  • Level, stable ground
  • Use outriggers if fitted
  • Avoid overhead hazards (powerlines, structures)
  • Lower platform when traveling

Fall Protection:

  • Scissor lifts: Guardrails (harness generally not required)
  • Boom lifts: Guardrails + harness anchored to platform

Excavations​

Risk: Falling into excavations (same as falling from height).

Controls:

  • Edge protection (barriers, guardrails) around excavation perimeter
  • Covers over narrow trenches (must support traffic loads if applicable)
  • Warning signs
  • Adequate lighting
  • Safe access/egress (ladders every 15m)

See Excavation Work for detailed guidance.

Rescue Procedures​

Suspension Trauma: Hanging motionless in harness after fall can cause blood to pool in legs, leading to unconsciousness and death within 6-15 minutes.

Rescue Plan Must Include:

  • Method to reach and rescue fallen worker
  • Equipment (rescue lines, descent devices, EWP, crane)
  • Trained rescue personnel
  • Communication method (phone, radio)
  • Contact emergency services (000)
  • First aid and medical treatment
  • Target rescue time: <6 minutes

While Awaiting Rescue:

  • Conscious worker should move legs (pumping action to maintain blood flow)
  • If suspension relief straps available, deploy and stand in them

Practical Construction Example​

Scenario: Installing roof sheeting on single-storey warehouse (eaves 5m from ground)

Hazard Identification​

  • Fall from roof edge (5m fall = fatal)
  • Fragile roof lights (not yet installed)
  • Weather (wind, rain)

Risk Assessment​

  • Extreme risk: Fall from 5m onto concrete = likely death or serious injury

Controls Implemented​

Engineering (Level 2):

  • Perimeter edge protection installed before roof work starts (guardrails on all edges)
  • Safety mesh installed under areas where roof lights will be fitted
  • Scaffolding with edge protection on one side for material delivery and safe access

Administrative:

  • SWMS prepared and reviewed with workers
  • Only competent roofers permitted on roof
  • Work stopped if wind >30 km/h or rain
  • Exclusion zone on ground (5m from building perimeter)

PPE:

  • Hard hats (falling objects from edge)
  • Safety boots, gloves
  • Fall arrest harness (backup - edge protection is primary control)

Result​

Roof installed safely. Edge protection prevented any falls. Mesh provided backup protection at roof light penetrations.