SPANCO Rigid Lifelines - Six Man Gantry Fall Protection System

An aircraft training and simulator facility located in the southern United States, handles outsourced manufacturing of F22 Raptor aircraft mock-ups for pilot training/simulation for the United States Government. The manufacturing process involves the building of the F22 mock-ups in three sections, the aft, the arm, and the landing gear. These sections can weigh up to 20,000lbs. Each section is treated as an individual work station and may be as high as 6 to 9 feet off the ground. Sections that include the top of the air craft are sloped and have a pitch similar to that of the roof on a house.

When first setting up the manufacturing process, plant safety manager John Smith immediately recognized the serious fall hazards associated with the work stations. Multiple workers were going to need to get on top of these sections at the same time to put skin on aircraft. They would be carrying tools, need to climb ladders, and navigate the steep pitch on a daily basis. John was also well aware that OSHA mandates that over 4 ft., a fall restraint was needed.

John needed a system that was portable, non intrusive, and could accommodate 5,000 lbs. of weight for up to 6 people. Workers also needed to have the ability to cross paths. John first explored the solutions that a traditional wire rope system might provide, but the thought of trying to have 6 workers tied on a system seemed like a nightmare. A traditional wire rope system was also unable to offer the portability that John needed. A traditional wire rope system had a ‘limited footprint,’ due to the need to move the section to the cable, and even considering moving a 20,000 lbs. section of an aircraft to the fall protection seemed foolish and inefficient. John also was dissuaded by the fact that traditional wire rope systems suffer from the serious flaw of initial sag, and freefall distance. Meaning that in the event of a fall, a wire rope system may prevent a total fall, but there could be significant bodily injury.

It was during John’s search for a fall protection solution that SPANCO sales rep Bud Lohr offered a presentation on SPANCO Rigid Lifelines Fall Protection Systems. John brought in his entire safety committee to hear this presentation. During the presentation, Bud highlighted the SPANCO Rigid Lifelines Gantry Fall Protection System. As he talked, John and his counterparts started to see the value that a SPANCO Rigid Lifelines Gantry Fall Protection System could offer their situation. The system seemed to perfectly fit John’s fall protection needs. The SPANCO Rigid Lifelines Gantry Fall Protection System offered portability as it could be rolled from workstation to workstation, and be locked in place when needed. It also allowed for up to six workers to hook up to a dual track system simultaneously, allowing them to work while protected, and easily pass each other as needed. Soon after the presentation, John called Bud to inquire about having a SPANCO dealer stop in to talk about a system.

John’s company invested in a SPANCO Rigid Lifelines Gantry Fall Protection System in October of 2007. Workers wheel the system up to section they are working on, lock the wheels, then climb a ladder and latch onto the systems with a lanyard. The workers can then start their work, knowing they are secure. Since the purchase, the SPANCO Rigid Lifelines Gantry Fall Protection System has aided in a couple of actual fall incidents. In each incident the individual fell from the aircraft section and was restrained by the SPANCO Rigid Lifelines Gantry Fall Protection System. In every case, no worker suffered from any bodily injury. It is also convenient for John because unlike a traditional wire rope system, a SPANCO rigid track system does not have to be tagged and taken out of commission for inspection, it can continue being used, providing better workplace efficiency. Since the system has been put into place John said there have been zero complaints. In his words, “when employees don’t like a new process at work, they complain, with the new SPANCO Rigid Lifelines Fall Protection Gantry, our worker’s have never complained once.”

• SPANCO Rigid Lifelines - Six Man Gantry Fall Protection System

SPANCO Rigid Lifelines - Fold-Away Fall Protection System Provides a Custom Solution

OSHA’s 2006 Census of Fatal Occupational Injuries Summary relayed an alarming 5% increase in occupational fatalities related to falls. This translated into the third highest number of fall related deaths since the inception of the OSHA Census in the early 1990s. Despite these recent numbers, public and privately owned companies continue to put their employees at risk by asking them to work at dangerous heights, or on or over dangerous machinery without proper fall protection.

SPANCO, Inc. has recognized the serious safety deficiencies existing in today’s industry and has strived to be a leader in Rigid Lifeline Fall Protection by listening to end-users and custom engineering personal fall protection systems to accommodate unique industry needs while keeping the security of the employee and the reassurance of the employer at the forefront of their mission.

This year saw the addition of a new SPANCO Rigid Lifelines fall protection solution, the SPANCO Rigid Lifelines Fold-Away Fall Protection System. Engineering of this system started when end-users came to SPANCO and expressed interest in a fall protection system that did not require permanent installation, one that had some mobility. Many end-users complained that a permanent structure would interfere with their work processes by being in the way of large overhead cranes. Traditional wire rope systems were also not an option due to low clearance and other design deficiency like greater free fall distance. SPANCO management and engineers sat down and evaluated these end-user requests and as a result, the Fold-Away Fall Protection System is now being offered to end-users, and success stories are already apparent.

A few months ago, a process engineer and plant safety manager for a small powered transformer facility in the south identified a serious safety deficiency in their production process. Inside their facility, transformers were being manufactured through a series of production stations. During the production process, large transformer shells measuring anywhere from 10’ to 18’ in height, were transported via rail or crane to the individual stations. Once at the stations, workers needed climb on top of the shells in order to insert coils, gauges, and other transformer components. This process of climbing on top of the shells was extremely dangerous due to the height of the transformers. After evaluating their need, the process engineer and safety manager contacted ITAC, a member of the SPANCO distribution network. It was explained that the company needed a system that could provide low clearance fall protection to their workers while they climbed on top of the transformer shells, but that the system could not interfere with the overhead crane that was used to move the shells from station to station.

After listening to the situation and doing an onsite evaluation, Industrial Turn Around Corporation (ITAC) fall protection engineer Bruce Simms immediately recognized that the new SPANCO Rigid Lifelines Fold-Away Fall Protection systems was a perfect fit. Simms brought the project to SPANCO vice president George Nolan. Nolan collaborated with SPANCO engineering to design a custom fold-away system that interfaced with the company’s current warehouse columns and conduit. The resulting system was comprised of 2 forty foot spans of continuous dual steel track that was underhung on steel jibs that measured 15 feet off of the warehouse house column when the system was fully extended. When folded in against the columns, the system protruded only one foot off of the columns, providing room for the overhead crane to work as usual. The system can be manually moved and locked into place at varying degrees. Another great feature of the system is the dual track that allows for two workers to work on top of the transformers and walk along opposite sides and pass each other without needing to disconnect from the trolley. SPANCO track also provides a 310lb capacity and in this case, a 310lb capacity for each individual track.

After a few months of use the company’s safety manager is thrilled with the integration of the system. In fact orders are currently being placed for another similar system in another part of the plant.

In today’s industries, plant engineers or safety managers may not realize the potential custom fall protection solutions that are available to their industry or company. When a production hazard has been identified in your workflow, you may want to explore customized fall protection solutions that a company like SPANCO can provide. Don’t be afraid to think outside the box, SPANCO engineers have customized fall protection systems for use with gantry cranes, free standing jib cranes, and lightweight enclosed track bridge crane applications where a dual axis allows for a worker to operate from front to back, and left to right. Every end-user application is unique and that is why fall protection solutions must be custom, not canned compliance. SPANCO understands the importance of listening to the end-user and engineering products that meet their unique application needs.

• SPANCO Rigid Lifelines - Fold-Away Fall Protection System Provides a Custom Solution

SPANCO Rigid Lifelines - Fall Protection System Provides Security to Truck Drivers

A major manufacturer of chocolate confections receives 2-4 shipments of liquid chocolate on a weekly basis. The liquid chocolate is transported to their manufacturing facility in 6500-gallon tanker trucks. Trucks dock at a station to the rear of the facility and a pumping hose is attached to the back of the tanker. The driver of the truck is then responsible to climb on top of the tanker trailer and manually ensure that all chocolate is successfully pumped into the facility. This process includes walking back and forth on top of the tanker while using a large rubber hand held tool to help push the chocolate to the back of the tank.

While observing this process, the plant safety manager recognized the serious safety concern that was present for the truck driver. The driver was being exposed to a potentionally life-threatening situation due to the risk of falling while simply trying to complete his job. This was compounded due to deliveries being made year round, where a tanker trailer covered with ice becomes almost impossible to navigate.

In looking for a solution, the manufacturer contacted a SPANCO distributor who immediately recognized the value in having a SPANCO Rigid Lifelines Freestanding Fall Protection System installed along the side of their docking station. After explaining the benefits of a SPANCO Rigid Lifelines Fall Protection System, a custom system was installed. The system track is 37 feet in length with 22-foot high uprights. A trolley moves along the track and allows for a cable and harness attachment. The new system allows for truck drivers to put on a harness and then ascend and navigate to the top of their tanker truck safely. In the event that a driver would fall from the top of his trailer while unloading, the SPANCO fall protection system will now help to avoid serious injury or death.

With the inclusion of a SPANCO fall protection system, the manufacturer can now take pride in providing truck drivers with a more secure work environment. This is a benefit to the company due to liability being a potential significant expense. Remember, equipment is cheaper than the accident.

• SPANCO Rigid Lifelines - Fall Protection System Provides Security to Truck Drivers