DROPPED OBJECTS OVERVIEW
WHAT IS SAFETY AT HEIGHTS?
Fall protection for the worker has come a long way, but it's only part of the picture. There's another component of Safety at Heights that is only recently getting the attention it deserves—Objects at Heights.
RISK AWARENESS
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LUCK IS BAD POLICY. DROPS WILL HAPPEN.
The most serious nuclear threat in the history of the U.S. came not from the Soviets, but from a single nine-pound wrench socket. Dropped by an airman performing maintenance on a Titan II missile at a launch complex in Damascus, Arkansas, the socket fell 70 feet, ripping a hole in a fuel tank and leading to an explosion that forced a 9-megaton warhead out of the ground. Thankfully, safety features prevented any loss of radioactive spillage or detonation, but the explosion killed one and injured about twenty more. The 1980 Damascus Titan missile explosion is a drastic example of what can result from operating like everything is going to work perfectly every time. In this case, it almost wiped an entire state off the map.
| Audio | Visual |
|---|---|
| Nuclear Technician: I was fairly new to working out on the missile sites. | Nuclear technician puts on hazard suite. |
| Nuclear Technician: Right above us was a 9-megaton thermonuclear warhead | View of nuclear warhead in silo |
| Nuclear Technician: It was a monster waiting to go off. | View of nuclear warhead in silo |
| Nuclear Technician: You think about working on a weapon of mass destruction ... | Technician working near nuclear missile in top of silo. |
| Nuclear Technician: You're counting on everything to work perfect all the time | Technician working near nuclear missile in top of silo. |
| Nuclear Technician: And things just don't work perfect all the time. | Technician drops a large bolt, which plummets to the bottom of the silo. The bolt ricochets into the nuclear missile causing damage and a gas like substance begins spraying out of the nuclear missile. |
By the time astronaut Heidemarie Stefanyshyn-Piper realized her tool bag was improperly tied down, it was too late. "Oh, great,"" she muttered as the tool bag drifted slowly away from her post outside the international space station. Luckily, nobody was hurt, and nothing was damaged—with the exception of her ego and NASA's budget. The embarrassed astronaut subsequently described the $100,000 incident as "very disheartening", adding, "There's still the psychological thing of knowing that we made a mistake and having to live through that. It was hardest coming back in and having to face everybody else."
| Audio | Visual |
|---|---|
| News anchor: A spacewalk today by shuttle Endeavor astronauts working outside the International Space Station. | Space shuttle Endeavor orbits above the Earth while connected to the International Space Station (ISS) with an astronaut working on the exterior of the ISS. |
| News anchor: It all went pretty well until one of the astronauts lost a tool bag. | Helmet camera view of an astronaut searching for tools in their gear bag. |
| News anchor: The bag and its contents: grease gun, scrappers, tethers, some clean wipes ... | The astronaut fumbles their bag, it begins to drift away toward planet Earth. |
| News anchor: Are now among the thousands of items in Earth's orbit. | The astronaut tries several times to grasp the bag. |
| News anchor: We're told they pose no danger. | The tool bag quickly moves out of reach and continues to float away toward planet Earth. |
| News anchor: But if you're out taking a walk tonight and you find some grease guns or clean wipes, you're urged to call NASA. | Full view of the ISS as it orbits planet Earth. |
| News anchor: They'd love to get it back. | Helmet cam view of astronaut's gloved hands as they use a power-drill to work on the exterior of the ISS. |
It was the summer of 2016 when a four-pound bolt fell 100 feet and struck a wind turbine worker, knocking him unconscious and leaving him with a severe head wound. ”Lucky” may not be the first word to come to your mind in this situation, but considering the size of the bolt and the height at which it fell, the 26-year-old worker was fortunate to pull through and live to work another day. "Wind Energy workers are exposed to many hazards that can result in fatalities and serious injuries such as falls, struck by, electrical shocks and crushing injuries. While wind energy is a growing industry, the hazards are not unique and OSHA has many standards that cover these working conditions," said Judy Freeman, OSHA's Area Director in Wichita, following the mishap.
| Audio | Visual |
|---|---|
| NO AUDIO | A person drops a tool bag full of nuts and bolts from a 2-story building onto three water melons. |
| Sound of metal bolts striking watermelons. | Down facing view from 2-story building, as nuts and bolts strike the water melons below. |
| NO AUDIO | Close up view from the ground of the damage done to the water melons after being struck by the nuts and bolts. |
THE RISING COST OF FALLING OBJECTS
Severe injury and fatality from dropped objects—even something as small as a wrench socket—are all too common, resulting in thousands of injuries, hundreds of deaths, hundreds of millions in total costs and who knows how many close calls every year.
54,030 Injuries
Falling objects or equipment resulted in 6% of all workplace injuries.
241 Fatalities
Representing 40% of all “struck by” incidents and 4.5% of all workplace fatalities.
*BLS, 2019
$294,020,000
241 fatalities x $1.22M, the average cost per fatal accident.
*NSC, 2019
THE STANDARD
ANSI/ISEA 121-2018: A HIGHER STANDARD IN AT-HEIGHTS SAFETY
Recognizing the pressing need for formal guidelines within the category of Objects at Heights, leading safety equipment manufacturers like Ergodyne joined forces with the International Safety Equipment Association (ISEA) to develop a standard for tethering and transporting tools and equipment. ANSI/ISEA 121-2018 is the first standard for this type of equipment.
WHAT 121 COVERS
Similar to ANSI Z359 for fall protection, ANSI/ISEA 121-2018 is recognized as industry best practice. Though not directly enforceable by OSHA, the standard can be referred to under the General Duty Clause to interpret a better way for protecting workers against falling objects. The current standard focuses on four classes of preventative solutions actively used by workers to mitigate dropped objects.
The new dropped objects measure does not address things like passive preventative solutions (netting, toe boards, etc.) or best practices in the field, like telling workers where they should connect a tool lanyard on their harnesses. See Areas of Focus section for more details.
THE FOUR AREAS OF FOCUS
Anchor Attachments
Retrofit attachment points installed onto fixed anchor locations like a structure or the worker themselves to anchor tool tethers.
Tool Attachments
Retrofit attachment points installed onto tools and equipment, allowing them to be tethered.
Tool Tethers
Lanyards that connect tools to an anchor point.
Containers
Bags and buckets that are used to transport tools and equipment to and from at-heights work zones.
A COMPLETE TETHERING SYSTEM 101
GET THE BASICS OF OBJECTS AT HEIGHTS SAFETY
Much like the category of Workers at Heights has the ABC's of fall protection, we've innovated the 3T's of dropped objects prevention in the category of Objects at Heights: Trapped, Tethered, and Topped.
Click the indicators below to see the 3T's of dropped objects prevention in action along with the product solutions to support them.
TRAPPED
CREATING CONNECTION POINTS ON TOOLS
Trapping refers to retrofitting a connection point onto a tool or primary anchor for a safer attachment point. Most tools do not come with a secure attachment point built into the tool. In these situations, a secure attachment point must be created.
TETHERED
RETENTION BETWEEN TOOLS/GEAR AND ANCHOR POINTS
Tethering is the retention of the tools and equipment to the anchor points that hold them. This is often achieved through use of a tool lanyard. These lanyards should have the proper connections on each end for the tools and anchors being used. They should also be made with a shock-absorbing design whenever possible.
TOPPED
SECURE CLOSURE ON CONTAINERS FOR TOOLS AND EQUIPMENT
Tool pouches, bags and hoist buckets/bags should have a secure closure or "top" that can cover contents and prevent them from spilling if tipped. All containers may have tethering points available to attach tool lanyards but, if a container does not have a secure closure, it must have these tethering points available.
ADDITIONAL TRAINING RESOURCES
DROP KNOWLEDGE, NOT TOOLS
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Arsenal® 5973, 5974 & 5976 Hoist Buckets Feature Zippered Tops For ANSI 121 Approved Drop Prevention
How to Safely Tether Hand Tools and Other Small Tools with Other Small Tools with Squids® Tool Slips
FAQ
MAMA SAID THERE'S NO SUCH THING AS A DUMB ONE. REACH OUT TO TRAINING@ERGODYNE.COM WITH QUESTIONS OF YOUR OWN.
Any object, large or small, that falls from its previous position (excluding people), e.g. tools, PPE, equipment and structures.
STATIC
Any object that falls from a stationary position under its own weight, such as a handle snapping off a hoisted contractor's bucket.
DYNAMIC
Any object that falls as a result of a secondary force, like a worker dropping a tool or accidentally kicking an item off a ledge.
Whenever tools and equipment are brought to even modest heights, there's a risk for dropped and falling objects.
| INDUSTRY | EMPLOYS |
|---|---|
| Utilities | 554.1K |
| Telecommunications | 766.2K |
| Construction | 7,164K |
| Wind energy | 381K |
| Oil and gas | 671.6K |
| Mining | 186.9K |
| Electricians/service techs | 942.4K |
| Transportation | 5,289K |
| INDUSTRY | EMPLOYS |
|---|---|
| Nuclear | 45.8K |
| Manufacturing | 12,630K |
| Food Processing | 1,631.1K |
| Transportation (aviation) | 438.5K |
| Underwater MRO | 202.7K |
| Oil & gas | 671.6K |
| Mining | 186.9K |
| Construction | 7,164K |
Two categories: Those caused by elements and those that are worker/equipment-generated.
ELEMENTS
- Weather
- Vibration
- Corrosion
- Deterioration
- Body effects like cold, numb hands
WORKER/EQUIPMENT
- Tripping or colliding
- Poor housekeeping
- Not following procedures
- Miscalculations/poor design
- Missed/inadequate inspections
- Homemade tools and equipment
The key is prevention in the form of active engineering controls that prevent items from falling in the first place. If there is no drop, there is no chance of being struck by a falling object. Other prevention mitigation solutions are expensive and tedious to install and remove, so tethering and container equipment are the best practice for these risks. You can see the challenges with other solutions:
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PPE: Hard hats, steel toe boots and other PPE minimize injury on specific body locations, but do not prevent a “struck-by”. If an object strikes someone on the shoulder rather than the head, it won't help. If the object is very heavy or tapered/sharp, it can defeat a hard hat. More needs to be done.
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Admin Controls: Creating barriers with caution tape or other means pushes workers and bystanders away from the at-risk location. However, it's no secret that a small deflection can propel an object outside an established perimeter causing injury or damage anyway. Again, preventing the drop from above is key.
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Passive Engineering Controls: Netting and toe boards are expensive to install and remove, and can give a false sense of security. Items can still fall beyond these systems. In addition, toe boards promote poor housekeeping by encouraging individuals to leave tools and equipment on the platform. Actively tying off equipment is your best bet.
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