Introduction to Work at Height
Any work where a person can fall from a level and get injured
Includes work on tanks, reactors, columns, pipelines, structures, roofs, and racks
High risk due to fall hazards, slippery surfaces, and narrow platforms
Extra danger from toxic gases, chemicals, and hot surfaces
Often done near running equipment and live processes
Rescue is difficult due to height and complex structures
Requires proper planning, permits, and safety systems
Needs trained workers and correct fall protection equipment
Definition & Scope of Work at Height (Chemical, Pharmaceutical & Petrochemical Industries)Definition
Work at height is any task performed at above 1.8 meter level where a person can fall and suffer injury
Includes working above ground, below ground, or near open edges
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Types of Work at Height Activities
Maintenance on tanks, reactors, columns, and vessels
Inspection of overhead pipelines and pipe racks
Instrument installation and calibration at elevated points
Painting, insulation, and cladding on tall structures
Scaffold erection and dismantling
Roof inspection, repair, and cleaning
Working on platforms, walkways, and catwalks
Accessing cable trays and lighting systems
Valve operation and sampling at height
Structural fabrication and modification
Chimney, stack, and flare line work
Loading and unloading from elevated bays
Emergency repairs at elevated locations
Common Causes of Falls with Mitigation Measures
1. Slippery surfaces due to oil, chemicals, water, or condensate: Immediate spill cleanup, anti-slip flooring, proper drainage, slip-resistant footwear
2. Unprotected edges on platforms, tanks, and structures: Guardrails, toe boards, safety nets
3. Improper or damaged scaffolding: Certified erection, regular inspection, load control
4. Unsafe use of ladders: Correct ladder selection, securing, training
5. Missing or weak guardrails: Install standard-compliant guardrails
6. Climbing on equipment, pipes, or valves: Provide proper access platforms and ladders
7. Strong wind on open structures and roofs: Weather monitoring, stop work in high winds
8. Corroded or weak gratings and supports: Regular inspection, timely replacement
9. Carrying tools or materials while climbing: Tool bags, hoists, rope systems
10. Improper anchorage points: Use 2 double anchorage points
11. Loss of balance due to PPE or restricted movement: Proper PPE sizing, task planning
12. Improper planking on scaffolds: Full planking, secure boards
13. Gaps between platforms and structures: Cover gaps, extend platforms
14. Not maintaining three-point contact on ladders: Training, supervision
15. Overloading of platforms: Load rating display, material control
16. Working near leaks/open process lines: Barricading, isolation, signage
17. Working near moving cranes or hoists: Exclusion zones, spotters
18. Loose clothing caught by structures: Proper PPE fitting, dress code
19. Walking backwards while guiding loads: Spotters, clear paths
20. Carrying oversized materials: Mechanical lifting, team handling
21. Uncovered floor openings: Covers, barricades, signage
22. Unmarked fragile roof sheets: Fragile roof signage, crawl boards
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Work at Height – Hierarchy of Controls
Elimination:
Remove the need to work at height by doing the job from ground level (prefabrication, ground assembly, remote inspection).
Substitution:
Replace high-risk access methods with safer ones (use MEWP instead of climbing structures, fixed platforms instead of ladders).
Engineering Controls:
Physically prevent falls using built-in safety systems (guardrails, toe boards, fixed ladders, walkways, safety nets, covers).
Administrative Controls:
Reduce risk through procedures and management (permit system, SOPs, JHA, training, supervision, work planning, weather checks).
PPE (Personal Protective Equipment):
Last line of defense (full body harness, lanyard, lifeline, helmet, anti-slip shoes).
Order of priority:
Eliminate → Substitute → Engineer → Admin → PPE
Higher-level controls must always be tried before relying on PPE.
Work at Height Permit to Work – Roles & Responsibilities
Permit Issuer (Area In-charge / Safety Officer)
Identifies height-related hazards and required controls
Ensures risk assessment and JHA are completed
Verifies guardrails, anchorage, access, and weather conditions
Confirms availability of rescue plan and equipment
Issues, displays, and closes the permit
Permit Receiver (Supervisor / Job In-charge)
Explains permit conditions to the work team
Ensures workers are trained and medically fit
Confirms correct PPE and fall protection systems are used
Maintains safe work practices during the job
Stops work if unsafe conditions arise
Authorized Operator Worker
Follows permit conditions strictly
Uses harness, lanyard, and anchorage properly
Inspects PPE before use
Maintains safe behavior and three-point contact
Reports hazards or unsafe conditions immediately
Standby Person / Spotter
Monitors workers from a safe location
Ensures barricading and restricted access
Keeps communication with workers
Raises alarm and initiates emergency response if needed
Safety Officer
Audits permit compliance on-site
Ensures correct control measures are implemented
Provides guidance on fall protection systems
Intervenes if unsafe acts or conditions are observed
Rescue Team
Remains ready during high-risk height work
Uses proper rescue equipment and methods
Performs safe and quick rescue
Provides first aid until medical help arrives
Ladder Safety Checklist – Work at Height
☐ Correct ladder type selected for the job
☐ Ladder free from cracks, bends, or damage
☐ Rungs clean, dry, and oil-free
☐ Side rails straight and intact
☐ Anti-slip feet/base pads in good condition
☐ Locking devices and spreaders working (step ladders)
☐ Proper ladder height selected
☐ Ladder placed on firm, level surface
☐ Base secured or tied to prevent movement
☐ Top secured where possible
☐ Correct angle maintained (4:1 for extension ladders)
☐ No makeshift supports used
☐ Ladder not placed on unstable objects
☐ Area below barricaded if required
☐ No live electrical lines nearby
☐ Adequate lighting available
☐ Weather conditions safe (no rain, strong wind)
☐ Proper anti-slip footwear worn
☐ Three-point contact maintained
☐ Face ladder while climbing
☐ No heavy tools carried by hand (use tool bag/hoist)
☐ No overreaching
☐ Belt buckle rule followed (between side rails)
☐ Only one person on ladder (unless designed for two)
☐ Not standing on top rung/step
☐ Harness used if required by risk assessment
☐ Ladder inspected before use
☐ Ladder stored properly after use
Scaffolding Safety Checklist – Work at Height
☐ Scaffold designed and erected by trained/competent persons
☐ Correct scaffold type selected for the job
☐ Base on firm, level ground
☐ Base plates and sole boards provided
☐ Standards vertical and stable
☐ Proper cross and diagonal bracing installed
☐ Platforms fully planked (no gaps)
☐ Planks in good condition (no cracks, warping)
☐ Planks properly supported and secured
☐ Guardrails, mid-rails, and toe boards installed
☐ Safe access provided (ladder/stair tower)
☐ Access ladder secured and in good condition
☐ No climbing on frames or braces
☐ Load rating displayed and not exceeded
☐ Materials evenly distributed
☐ No loose tools or materials on platforms
☐ Platforms clean and dry
☐ No oil, grease, or chemical spills
☐ Edge protection in place
☐ No open ends or missing rails
☐ Scaffold tied to structure where required
☐ No unauthorized modification
☐ All components present and secure
☐ Wheels locked (for mobile scaffolds)
☐ Outriggers used (for mobile scaffolds)
☐ Safe distance from live electrical lines
☐ Weather conditions safe (no strong wind/rain)
☐ Adequate lighting available
☐ Barricading and warning signs installed
☐ Daily inspection done before use
☐ Scaffold inspection tag displayed
☐ Damaged parts replaced immediately
☐ Harness used if required by risk assessment
☐ Rescue plan available
☐ Safe dismantling planned after job
Mobile Elevated Work Platform (MEWP) Safety Checklist – Work at Height
☐ Operator trained, certified, and authorized
☐ Correct MEWP type selected for the job
☐ Pre-use inspection completed
☐ No visible damage, leaks, or defects
☐ All controls functioning properly
☐ Emergency lowering system working
☐ Load capacity not exceeded
☐ Only required persons on platform
☐ Platform gate/chain closed and secured
☐ Guardrails intact and secure
☐ Harness worn if required (boom lifts)
☐ Lanyard connected to approved anchor point
☐ Platform floor clean and dry
☐ No oil, grease, or chemical spills
☐ Tools secured to prevent falling
☐ Ground surface firm and level
☐ Outriggers deployed if required
☐ Wheels and brakes working
☐ No potholes, pits, or weak surfaces below
☐ Safe distance from edges and openings
☐ Safe clearance from live electrical lines
☐ Overhead obstructions checked
☐ Travel path clear
☐ Speed controlled during movement
☐ No sudden or jerky movements
☐ Not operated in strong wind or rain
☐ Weather conditions checked
☐ Area below barricaded if required
☐ Warning signage installed
☐ No leaning or climbing on guardrails
☐ No ladders or boxes used on platform
☐ Load evenly distributed
☐ Communication maintained with ground person
☐ Spotter used in congested areas
☐ Power source stable and safe
☐ Charging/refueling done safely
☐ Parking brake applied when stationary
☐ Platform lowered before long travel
☐ No unauthorized modification
☐ Proper shutdown after use
☐ Key removed when not in use
☐ Rescue plan available and known
Roof Work Safety Checklist – Work at Height
☐ Roof structure inspected and found stable
☐ Fragile areas identified and clearly marked
☐ Weather conditions safe (no rain, strong wind, fog)
☐ Proper access provided (ladder, stair tower, MEWP)
☐ Access points secured and guarded
☐ Guardrails or edge protection installed
☐ Safety nets provided where required
☐ Lifelines or certified anchorage points available
☐ Full body harness worn
☐ Lanyard connected to approved anchor
☐ No walking on fragile sheets or skylights
☐ Crawl boards/walkways provided on fragile roofs
☐ Openings, skylights, and vents covered or barricaded
☐ Roof surface clean and dry
☐ No oil, dust, or loose material present
☐ Adequate lighting available
☐ No overreaching near edges
☐ Tools secured with lanyards
☐ Materials kept away from edges
☐ No throwing of materials from height
☐ Area below barricaded
☐ Warning signage installed
☐ Safe distance from live electrical lines maintained
☐ No work near hot vents or exhaust outlets
☐ Wind direction and speed checked
☐ No work during thunderstorms
☐ Anti-slip safety footwear worn
☐ No walking backwards near edges
☐ Proper handholds available
☐ Unauthorized access restricted
☐ Buddy system followed
☐ Continuous supervision provided
☐ Emergency rescue plan available
☐ First aid available nearby
☐ Communication maintained with ground team
☐ Safe exit route kept clear
Fragile Surface Safety Checklist – Work at Height
☐ Fragile surfaces identified and clearly marked
☐ Warning signage displayed at entry points
☐ No direct walking on fragile sheets or panels
☐ Crawl boards or walkways provided
☐ Guardrails or edge protection installed
☐ Safety nets installed where required
☐ Full body harness worn
☐ Lanyard connected to certified anchorage
☐ Lifelines provided where required
☐ Proper access to work area ensured
☐ Access points secured
☐ Roof openings and skylights covered
☐ Covers strong enough to support body weight
☐ Adequate lighting available
☐ Surface condition checked before stepping
☐ No cracks, breaks, or loose panels
☐ No overloading of fragile areas
☐ Only required tools and materials taken
☐ Tools secured with lanyards
☐ Materials stored away from fragile zones
☐ Area below barricaded
☐ Warning tape and signage installed below
☐ No throwing of materials from height
☐ Weather conditions safe (no rain, strong wind)
☐ Anti-slip footwear worn
☐ No running or sudden movements
☐ No working alone
☐ Continuous supervision provided
☐ Emergency rescue plan available
☐ Rescue equipment ready
☐ Communication maintained with ground team
☐ Unauthorized access restricted
☐ Safe exit route maintained
Edge Protection Systems Safety Checklist – Work at Height
☐ Edge protection installed before starting work
☐ Guardrails at correct standard height
☐ Mid-rails provided between top rail and platform
☐ Toe boards installed to prevent falling objects
☐ No large gaps in edge protection
☐ Guardrails firmly fixed and stable
☐ System strong enough to withstand load
☐ No sharp or protruding edges
☐ Temporary edges properly barricaded
☐ Open edges clearly marked
☐ Warning signage installed
☐ Edge protection visible from a distance
☐ No missing or broken sections
☐ End stops or returns provided at rail ends
☐ No climbing, sitting, or leaning on guardrails
☐ Guardrails not used as anchor points unless designed
☐ Protection system free from corrosion or damage
☐ Pre-use inspection completed
☐ Removed sections reinstated immediately
☐ No materials stored near edges
☐ Tools secured with lanyards
☐ Area below edges barricaded
☐ Unauthorized access restricted
☐ Adequate lighting along edges
☐ Safe access routes provided
☐ Weather conditions checked (wind, rain)
☐ Edge protection not overloaded
☐ Compatible with scaffold/roof/platform system
☐ Harness used if edge protection is incomplete
☐ Workers trained on edge safety
☐ Supervisor monitoring compliance
☐ Rescue plan available
Safety Nets Checklist – Work at Height
☐ Correct type of safety net selected for the job
☐ Net material certified and load-rated
☐ Installed by trained and authorized personnel
☐ Proper anchorage points identified and verified
☐ Nets securely fixed to strong structures
☐ No gaps between net sections
☐ Full fall zone covered
☐ Correct sag and tension maintained
☐ No loose or broken ties
☐ No cuts, tears, or worn-out sections
☐ No sharp edges near the net
☐ No hot work sparks falling directly on net
☐ Area below the net kept clear
☐ Warning signage installed
☐ No materials stored on nets
☐ Nets not used as walkways
☐ Regular visual inspection done
☐ Weekly detailed inspection recorded
☐ Damaged nets replaced immediately
☐ Weather conditions checked (wind, rain)
☐ Net not overloaded
☐ Access routes kept clear
☐ Rescue plan available
☐ Rescue equipment ready
☐ Workers trained on net use
☐ Supervisor monitoring compliance
Fall Prevention vs Fall Protection
Fall Prevention
Stops a person from reaching the edge or fall point so, No fall should happen
Used before considering fall protection
Examples: guardrails, edge protection, covers, walkways, barricades, proper access platforms
Best and safest method
No shock or injury involved
Fall Protection
Reduces injury after a fall happens it help to save life and reduce impact
Used when fall prevention is not possible
Examples: full body harness, lanyard, lifeline, safety nets, anchor points
Person may still fall but will be stopped safely
Requires rescue plan
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Guardrails & Barricading – Work at Height
Guardrails
Physical barriers fixed at edges to prevent falls
Used on platforms, roofs, scaffolds, and open sides
Must include top rail, mid-rail, and toe board
Strong enough to withstand body weight and impact
Should be continuous with no gaps
Visible and clearly marked
Best method of fall prevention
Requires regular inspection and maintenance
Barricading
Temporary or permanent barriers to restrict access
Used around open edges, holes, fragile areas, and drop zones
Prevents unauthorized or accidental entry
Made using tapes, cones, fencing, or rigid barriers
Must be clearly visible with warning signs
Area below height work must be barricaded
Helps in controlling people movement
Must not be easily removable or loose
Key Difference
Guardrails: Stop a person from falling
Barricading: Stop a person from entering a danger zone
Full Body Harness
A full body harness is a personal fall protection device worn on the body
It spreads fall impact across shoulders, thighs, chest, and pelvis
Prevents serious injury during a fall
Used when guardrails or platforms are not enough
Mandatory for roof work, scaffolds, MEWP, towers, and open edges
Must be connected to a certified anchorage point
Works with lanyard, shock absorber, or lifeline
Keeps the body upright after a fall
Reduces risk of suspension trauma
Must fit properly and be adjusted snugly
Requires regular inspection before use
Must be replaced if damaged or after a fall
Rescue plan is required when harness is used
Lanyards & Shock Absorbers
Lanyard is a connecting line between harness and anchorage point
Prevents a worker from falling freely
Used on scaffolds, roofs, platforms, MEWPs, and open edges
Must be strong, certified, and suitable for the job
Length should be selected to limit free fall distance
Shock Absorber reduces the force on the body during a fall
Opens or tears gradually to absorb energy
Prevents serious injury to spine and internal organs
Mandatory where free fall is possible
Lanyard with shock absorber is used for fall arrest
Must be connected only to approved anchorage points
Should not be tied around sharp or hot surfaces
Must be inspected before every use
Damaged or deployed shock absorbers must be replaced
Rescue plan is required when using fall arrest systems
Anchorage Points
Anchorage point is a strong, fixed point where lanyard or lifeline is connected
Horizontal & Vertical Lifelines
Horizontal Lifeline
A safety line fixed horizontally between two strong anchor points
Allows safe movement along edges, roofs, and long platforms
Worker stays connected while walking or working
Reduces risk of falling from open sides
Must be tensioned and installed correctly
Must be designed for number of users and fall load
Used on pipe racks, roofs, bridges, and long structures
Vertical Lifeline
A safety line fixed vertically from top to bottom
Used for climbing up and down tall structures
Connected with a rope grab or fall arrester
Automatically locks if a fall occurs
Used on ladders, towers, silos, and chimneys
Must be fixed to strong anchorage at top
Must be free from knots, cuts, or damage
Check points
Must be certified and load-rated
Must be connected to full body harness
Not to be tied on sharp or hot surfaces
Must be inspected before use
Rescue plan required when lifelines are used
Rescue Techniques
Rescue must be planned before starting height work
Quick rescue reduces risk of suspension trauma
Only trained rescue team should perform rescue
Self-rescue is preferred if safe and possible
Assisted rescue used when worker cannot self-rescue
Common Rescue Methods
Ladder Rescue: Using secured ladder to reach and assist the fallen worker
MEWP Rescue: Using boom lift or scissor lift to safely bring worker down
Rope Rescue: Controlled lowering or raising using ropes and descenders
Winch Rescue: Mechanical lifting or lowering system
Platform Rescue: Bringing worker onto a safe platform
Retractable Lifeline Rescue: Auto-lowering or lifting function
Key Rules
Never rush without safety
Rescuer must use full fall protection
Communication must be clear
First aid to be given immediately after rescue
Emergency services to be informed if required
Rescue Readiness
Rescue kit available at site
Trained rescue team present
Mock drills conducted regularly
Rescue plan displayed and known to all
Time is critical—rescue within minutes
First Aid for Fall Victims
Ensure area is safe before approaching the victim
Do not move the person unless there is immediate danger
Call emergency response team immediately
Keep the victim calm and still
Check consciousness and breathing
If not breathing, start CPR
Control bleeding using clean pressure dressing
Do not press on suspected fractures
Support injured limbs in the position found
Do not remove PPE or harness forcefully
If suspended in harness, relieve pressure safely
Lay victim flat once safely rescued
Keep body warm to prevent shock
Do not give food or water
Monitor vital signs until medical help arrives
Record incident details for medical team
Safety Harness Wearing Demo
Latest Incidents/Accidents
Here are some fall-from-height accidents in India (with source links):
1. 35-year-old labourer died after falling from third floor at construction site in Gurgaon – A worker fell while climbing the staircase and later died in hospital.
2. 32-year-old painter died after falling from fifth floor in Gurgaon – The worker fell from height while descending using a rope swing setup; lack of safety measures led to fatal injuries.
3. Nine migrant workers died after falling at a construction site in Minjur, Tamil Nadu – Workers fell while working on a power station extension project.
4. Industrial work-at-height falls contribute significantly to industrial fatalities in Karnataka – Nearly 25 % of worker deaths in manufacturing units in Karnataka are due to falls from heights, highlighting recurring fall hazards on industrial sites.
These incidents show that falls from height continue to be a major safety issue in construction and industrial environments across India.