What ANSI Fall Protection Testing Proves

A worker connects his Self-Retracting Lifeline (SRL) to his safety harness before working along the edge of a warehouse roof. The SRL meets a safety standard. That should be enough to be safe, right?

Where will he anchor his SRL? Will its lifeline hold up if it runs over the roof’s edge during a fall? Is there enough room below him to stop the fall before he hits the surface below?

The American National Standards Institute (ANSI) approves standards that set tests for fall protection gear. Those tests show how an SRL performs under set conditions—but they cannot check this worker’s anchor, roof edge, or fall clearance.

Let’s look at what those tests prove and what you still need to check before work begins.

What ANSI Testing Establishes

The American Society of Safety Professionals (ASSP) works with ANSI to develop the Z359 Fall Protection Code. This code includes standards for gear such as SRLs, full-body harnesses, and anchors. Each product standard sets its own test rules. (Note: While technically “ANSI/ASSP,” it’s common to see the Z359 standards labeled simply as “ANSI” for convenience.)

For example, Z359.11 covers full-body harnesses, while Z359.14 covers SRLs. Regarding the latter, testers follow set steps to see how an SRL stops a fall. They measure the force of the stop and how far a test weight falls before it stops. They also test the strength of key parts. When an SRL passes the required tests, its manufacturer can show that the device meets the standard.

The Occupational Safety and Health Administration (OSHA) sets and enforces workplace safety rules. ANSI/ASSP standards serve as voluntary product standards, though a regulation or contract may require a specific one. Understanding the differences between ANSI vs. OSHA helps you see how those rules and standards work together.

What Testing Cannot Decide

Testers use set conditions so they can repeat a test and compare the results. But those results cannot tell you whether the worker can safely use that SRL on the warehouse roof.

The anchor’s height, the roof’s edge, and the space below all affect the setup. Past use may have worn the gear, too. You need to check those details before the worker starts.

Wear and Environmental Exposure

Sun, rain, grit, and rough surfaces can wear a lifeline on a warehouse roof. Welding sparks or chemicals can damage a safety harness’s webbing on other jobs. Testing shows how safety equipment performs under set conditions. It cannot tell you what has happened to that equipment since it left the factory.

Inspect equipment before each use. Follow the manufacturer’s instructions for what to check and when to take it out of service. If you find damage, stop using it.

Anchor Location and System Setup

Each piece of gear may meet its own standard, but the full system still must fit the work. A lower anchor can increase fall distance. An edge can put stress on a lifeline. Connectors must fit the parts they attach to.

Take SRLs as an example. An ANSI Class 1 SRL needs an anchor at or above the worker’s back D-ring. An ANSI Class 2 SRL can work with lower anchors and must pass tests for use near an edge. That does not mean it works with every anchor or edge. Check the manufacturer’s instructions, the available fall clearance, and how all the parts connect before work begins.

Worker Movement

Testers follow a set fall path. Workers move. On the warehouse roof, a worker may walk around vents, carry materials, or change anchors as the job moves forward.

If he walks too far to one side of his anchor, a fall could swing him into the building. His lifeline could also run across an edge. Plan where workers will move, check how those paths affect the fall, and review the setup whenever the work area changes.

Designing Beyond a Pass-Fail Result

A product standard sets tests for how gear must perform. It also sets rules for labels and instructions. Manufacturers need to think about how workers will use that gear each day.

On the warehouse roof, can a worker read the label in bright sun? Can he check his harness for wear? Can he handle a connector while wearing gloves? Clear labels and parts that workers can inspect help them use gear as intended.

Manufacturers can learn from workers, test gear in the settings it was made for, and improve their designs. They should also state the gear’s limits clearly, so workers know when they can use it.

Look Beyond the Label

A label can tell you which standard a piece of gear meets. It cannot tell you whether the full setup fits your jobsite.

Before workers start, check three things:

1. Do the manufacturer’s instructions allow this gear for the planned work and anchor location?
2. Do the parts fit together, and is there enough room to stop a fall?
3. Has someone inspected the gear and found it fit for use?
   

The worker on the warehouse roof needs those answers before he steps near the edge. Testing gives you a starting point. The instructions and a check of the jobsite help you put that gear to work within its limits.

Put those checks to work before you choose your gear. Explore ANSI-compliant fall protection equipment at FallTech to find options that fit your crew’s work and your job-site setup.