the value of fall hazard risk assessments

THE VALUE OF FALL HAZARD RISK ASSESSMENTS

April 11, 2023 Moderator: Speaker:KIM MESSER THOMAS E. KRAMER, P.E., C.S.P.

KMesser@LJBinc.com TKramer@LJBinc.com

2

LEARNING OBJECTIVES

Explain the basic elements of a fall hazard risk assessment

Discuss the benefits of performing an assessment

3

AGENDA

Background

Fall hazard risk assessment

Benefits of assessment

Case studies

Closing

4

TOTAL FALL FATALITIES

Source: BLS Census of Fatal Occupational Injuries

573 607652 623 634

659 698638

604

738

664

738 733

0

100

200

300

400

500

600

700

800

Fatalities

1995 1997 1999 2001 2003 2005 2007Year

5

TOTAL FALL FATALITIES

Source: BLS Census of Fatal Occupational Injuries

573 607652 623 634

659 698638

604

738

664

738 733

0

100

200

300

400

500

600

700

800

Fatalities

1995 1997 1999 2001 2003 2005 2007Year

+28%

6

WHY PERFORM AN ASSESSMENT?

Make the most effective investment in fall protection

Achieve compliance

7

FINANCIAL REASONS

Fall protection is cost intensive＞ Overhead systems

＞ PPE

＞ Other, low risk hazards

Abate most risk with given budget

Know when you are done

8

COMPLIANCE REASONS – OSHA

Proposed subpart D & I – OSHA 1910 ＞ Hazard surveys required under 1910.132

＞ Required for categories of falls listed under subpart D

I2P2 proposed regulation＞ Injury and Illness Prevention Program

＞ Focus on assessments, not how to abate hazards already

identified

9

COMPLIANCE REASONS – OTHER

ANSI Z359.2 standard＞ Required for all tasks exposing workers to fall hazard

＞ Surveys must include identification of possible abatements

Voluntary Protection Program (VPP)＞ Management Leadership and Employee Involvement

＞ Worksite Analysis

＞ Hazard Prevention and Control

＞ Safety and Health Training

10

GETTING TO KNOW YOUR RISK

Do nothing

Methods

11

GETTING TO KNOW YOUR RISK

Do nothing

Methods

1. Suggestion programs

2. Statistics

3. Job hazard analysis

4. Facility walk-through

5. Wall-to-wall fall hazard risk assessment

12

Suggestion programs

＞ Areas of keen interest

＞ Frequently accessed/hazardous areas

＞ Larger group

＞ Continuous improvement

METHODS

13

Statistics

＞ Bureau of Labor Statistics (bls.gov)

METHODS

14

FALL FATALITIES BY WORK ACTIVITY

0

20

40

60

80

100

120

140

160

180

200

1998 2000 2002 2004 2006 2008

Roofs

Ladders

Scaffolds

Non-movingvehiclesStrucSteel

Source: BLS Census of Fatal Occupational Injuries

15

Statistics

＞ Bureau of Labor Statistics (bls.gov)

＞ NIOSH FACE reports

Fatality Assessment and Control Evaluation

＞ Industry-wide incidents

＞ Organization-wide incidents

METHODS

16

Job hazard analysis

＞ Typically developed after hazard is identified

＞ No analysis of risk relative to other hazards

METHODS

17

Facility walk-through

＞ Competent or qualified person

＞ Identifies typical hazards

＞ Prioritize typical hazards

＞ Estimate abatement cost

＞ Specific to job function (internal)

＞ Objective set of eyes (external)

METHODS

19

Wall-to-wall fall hazard risk assessment

＞ Competent or qualified person

＞ Objective set of eyes

＞ Comprehensive vs. typical

＞ Management of data

＞ PREFERRED

METHODS

20

Suggestionprograms

Facilitywalk-through

StatisticsWall-to-wallfacility survey

METHODS

Job Safety Analysis

21

AGENDA

Background

Fall hazard risk assessment

Benefits of assessment

Case studies

Closing

22

BASIC ELEMENTS

1. Find out what and where the true issues are

2. Assess risk through priorities and abatement options

3. Select and implement the appropriate solution

23

BASIC ELEMENTS

1. Find out what and where the true issues are＞ Involve facility personnel

• Kick-off meeting

• Incentive programs

• Each unit

24

BASIC ELEMENTS

1. Find out what and where the true issues are＞ Conduct fall hazard survey

• Task descriptions and exposures

• Photograph hazards

• Hazard data

– Location

– Type of task

– Category

– Level or elevation

– Department

25

WHAT IS CONSIDERED A HAZARD?

Proposed 29 CFR 1910 Subpart D&I

§ 1910.28 Duty to have fall protection

§ 1910.29 Fall protection systems criteria and practices

Hazard surveys required under 1910.132 and the categories

of falls listed under subpart D

26

HAZARD LOCATIONS

§ 1910.28 Duty to have fall protection＞ (b) Protection from fall hazards

1. Unprotected sides and edges

2. Hoist areas

3. Holes

4. Dockboards (bridge plates)

5. Runways and similar walkways

6. Dangerous equipment

27

HAZARD LOCATIONS

§ 1910.28 Duty to have fall protection (cont.)7. Wall openings

8. Repair, service, and assembly pits (pits) less than 10 feet in

depth

9. Fixed ladders

10.Outdoor advertising (billboards)

11.Stairways

12.Scaffolds (including rope descent systems)

13.Walking-working surfaces not otherwise addressed

14.Protection for floor holes

28

HAZARD LOCATIONS

§ 1910.29 Fall protection systems criteria and practices＞ (b) Guardrail systems

＞ (c) Safety net systems

＞ (d) Designated areas

＞ (e) Covers

＞ (f) Handrail and stair rail systems

29

HAZARD LOCATIONS

§ 1910.29 Fall protection systems criteria and practices (cont.)＞ (g) Cages, wells, and platforms used with fixed ladders

＞ (h) Qualified Climbers

＞ (i) Ladder safety systems

＞ (j) Personal fall protection systems

＞ (k) Protection from falling objects

30

BASIC ELEMENTS

2. Assess risk through priorities and abatement options＞ Develop risk assessment

• Probability

– Number of workers exposed

– Frequency of exposure

– Duration of work

– Environmental conditions

• Severity

– Fall distance

– Obstructions in path of fall

31

Hazard Probability

Hazard

Severity

Frequently

(A)

Probably

(B)

Potential

(C)

Unlikely

(D)

Fatal - Cat. IV 1 1 2 3

TTD - Cat. III 1 2 3 4

Minor Injury - Cat. II 2 3 4 5

Violation Cat. I 3 4 5 5

RISK ASSESSMENT CODES

32

SIMPLE HAZARD SCORE SHEET

Rating Severity of Injury Probability of Fall

(Odds of occurring)

1 First Aid Very Low

(1/1,000,000)

3 Recordable Low

(1/10,000 – 1/1,000,000)

7 Disabling Injury Medium

(1/100 – 1/10,000)

10 Potentially Fatal High

(1 in 100)

33

BASIC ELEMENTS

2. Assess risk through priorities and abatement options＞ Evaluate abatement option

• Low-hanging fruit

– Aerial lifts

– Scaffold

– Swing gates

• Total cost of solution

• Cost vs. risk

• Hierarchy of control

34

HIERARCHY OF CONTROL

35

AGENDA

Background

Fall hazard risk assessment

Benefits of assessment

Case studies

Closing

36

WHERE IS YOUR GREATEST RISK?

37

Hazard Probability

Hazard

Severity

Frequently

(A)

Probably

(B)

Potential

(C)

Unlikely

(D)

Fatal - Cat. IV 1 1 2 3

TTD - Cat. III 1 2 3 4

Minor Injury - Cat. II 2 3 4 5

Violation Cat. I 3 4 5 5

RISK ASSESSMENT CODES

38

SIMPLE HAZARD SCORE SHEET

Rating Severity of Injury Probability of Fall

(Odds of occurring)

1 First Aid Very Low

(1/1,000,000)

3 Recordable Low

(1/10,000 – 1/1,000,000)

7 Disabling Injury Medium

(1/100 – 1/10,000)

10 Potentially Fatal High

(1 in 100)

39

WHERE IS YOUR GREATEST RISK?

1 2 3 … Hazard Rank …5206

Risk

40

BENEFITS OF ASSESSMENT

Validated program budget＞ Report cost-benefit metrics to management

Phased implementation plan

Development of procedures

Customized training

41

NOW THAT YOU KNOW YOUR RISK….

3. Select and implement the appropriate solution for the highest

risk hazards＞ Conceptual design

＞ Final design

＞ Construction/Implementation

＞ Additional training

42

CONCEPTUAL DESIGN

43

CONCEPTUAL DESIGN

44

CONCEPTUAL DESIGN

45

CONCEPTUAL DESIGN

46

CONCEPTUAL DESIGN

47

CONCEPTUAL DESIGNS

48

HAZARD CONTROL

49

AGENDA

Background

Fall hazard risk assessment

Benefits of assessment

Case studies

Closing

50

INSTITUTIONAL CAMPUS ASSESSMENT

Campus-wide risk assessment

51

INSTITUTIONAL CAMPUS ASSESSMENT

Campus-wide risk assessment＞ 100+ structures surveyed on 350-acre site

＞ Interiors and exteriors, including roofs and process equipment

＞ Nearly 2,500 hazards documented

＞ Organized data by maintenance type, by request

52

FINDINGS

Total hazards = 2,579 ＞ Handrail/guardrail = 969

＞ Maintenance access to equipment = 918

＞ Non-compliant ladders = 688

Hazard breakdown by maintenance type:＞ Institutional: 38%

＞ Process: 33%

＞ Facility: 29%

53

FINDINGS

Preferred Solution for Top 100 Hazards

Other11%

Guardrail18%

Fixed Platform24%

Aerial Lift27%

Scaffold20%

54

REFINERY ASSESSMENT

Facility-wide risk assessment

55

REFINERY ASSESSMENT

Facility-wide risk assessment＞ Objective set of eyes on the entire facility

＞ Client had ability to sort hazards from greatest risk to lowest risk

as well as by probable cost of the abatement

• Focus budget on high risk items

• Still able to pick off some low hanging fruit

＞ Able to combine abatements and address multiple hazards with

one solution

56

WHERE IS YOUR GREATEST RISK?

1 2 3 … Hazard Rank …5206

Risk

57

WHERE IS YOUR GREATEST RISK?

1 2 3 … Hazard Rank …5206

Risk

32% of risk in top 1% of hazards

77% of risk in top 10% of hazards

98% of risk in top 50% of hazards

58

WHERE IS YOUR GREATEST RISK?

Hazard Rank

RiskONLY 2% of the risk, but

25% of abatement cost

59

CLOSING

Ultimate goals＞ Reduce risk and increase safety for workers at heights

＞ Use your available budget to decrease as much risk as possible

60

THANK YOU FOR YOUR TIME

To learn more about fall protection from LJB Inc.

Blog＞ http://www.ljbfallprotectionblog.com

Podcasts – 60 Seconds for Safety＞ http://www.ljbinc.com/safetybydesign

YouTube video＞ http://www.youtube.com/watch?v=Dk7F8UJxnLU

THE VALUE OF FALL HAZARD RISK ASSESSMENTS

April 11, 2023 Moderator: Speaker:KIM MESSER THOMAS E. KRAMER, P.E., C.S.P.

KMesser@LJBinc.com TKramer@LJBinc.com