Work at Height Safety in CRM-III — Fall Prevention, Scaffolds, Ladders & Rescue

1. Learning objectives

Identify fall hazards; select collective protection before personal fall protection; inspect access equipment; follow PTW and rescue arrangements.

2. What is work at height?

Any work where a person could fall a distance liable to cause injury, including near unprotected edges, openings, fragile surfaces, elevated platforms and ladders. Do not assume that work below a particular height is automatically safe. Follow the current BSL site-specific threshold and permit rules.

3. CRM-III exposure points

Overhead crane maintenance platforms; PL/TCM/HDGL/SPM equipment tops; elevated pipe racks; furnace and duct inspection; roof sheets and skylights; mezzanines; pits and floor openings; temporary scaffolds during shutdowns. Verify access routes and barriers for each job.

4. Hierarchy of controls

Avoid working at height where practicable (ground-level assembly). Prefer fixed platforms, guardrails, toe boards and properly installed scaffolds or MEWPs. Use travel restraint where appropriate; use fall arrest only with engineered anchorage, adequate clearance, compatible equipment and a prompt rescue plan. PPE is not a substitute for collective protection.

5. Permit and pre-job planning

Conduct task risk assessment/JSA and toolbox talk. Obtain the applicable PTW, confirm competence and supervision, inspect weather/lighting, assess overhead lines and moving machinery, barricade drop zones, establish communication and rescue capability. Isolate relevant equipment using approved LOTO where needed.

6. Scaffolds and working platforms

Use scaffolds erected, altered and inspected by authorized competent persons. Verify scaffold tag/status, firm footing, full decking, suitable access, guardrails, toe boards, load limits and safe clearance. Do not use incomplete, uninspected or modified scaffolds.

7. Ladder safety

Use ladders only when risk assessment establishes suitability for short-duration, low-risk tasks. Inspect rails, rungs, feet and locking mechanisms; set on firm level ground; secure against movement; maintain three points of contact while climbing; avoid overreaching and carrying bulky items by hand. Do not stand on prohibited top steps.

8. Harnesses, lanyards and anchorage

Inspect full-body harness webbing, stitching, labels, D-rings, buckles, lanyard, connectors and energy absorber before use. Select a rated, approved anchorage per engineered design and manufacturer instructions. Consider swing-fall and total fall-clearance distances; keep connections compatible. Remove damaged or fall-loaded equipment from service pending competent assessment.

9. Dropped-object prevention

Secure tools with suitable tethers where required; use toe boards, tool bags and exclusion zones; never toss materials from height. Barricade below and coordinate lifting and material transfer.

10. Weather, roofs and fragile surfaces

Stop or reassess work when wind, rain, lightning, heat or poor visibility make conditions unsafe. Treat roof sheets and skylights as potentially fragile unless verified otherwise. Provide engineered walkways, covers, edge protection and approved access systems.

11. Emergency response and rescue

Plan rescue before starting: trained team, suitable equipment, communication and prompt response. Raise the alarm and prevent additional falls; do not improvise rescue or enter an unsafe position. After fall arrest, arrange prompt retrieval and medical evaluation according to site emergency procedure.

12. Stop-work triggers

Missing guardrails or uncovered openings; unsafe ladder/scaffold; no approved anchorage; damaged harness; absent permit where required; unplanned simultaneous operations; uncontrolled dropped-object zone; unavailable rescue arrangements. Stop, secure the area and inform the responsible supervisor.

CRM-III area-wise risk and controls

Pre-work inspection checklist

• JSA/toolbox talk and PTW completed where required
• Suitable access equipment inspected and authorized
• Open edges and floor openings protected
• Fall protection compatible, inspected and anchored correctly
• Falling-object exclusion zone established
• Equipment isolation and simultaneous operations coordinated
• Weather and visibility suitable
• Rescue plan, equipment and trained responders available