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While a manufacturing facility's internal workings rightly attract safety managers’ constant attention, they must devote attention to maintaining robust rooftop fall protection systems too. Hatch openings and guardrails are oft-overlooked rooftop fall protection measures that require diligent planning, and by accounting for rooftop fall safety needs from the beginning, expanding manufacturing facilities can reduce accidents and compliance violations indefinitely.
For any general industry or construction operation, facility expansion is an ideal time to assess compliance requirements and meet them over the longest possible term. It's important to note OSHA requirements for manufacturing facilities don't mandate specific pieces of equipment – but they do:
Set numerous equipment specifications for rooftop environments (e.g., guardrails, stairways, ladders, interior openings, and walking-working surfaces)
Apply at an extremely broad scale (especially with fall hazards)
Fall protection regulations not only extend to any walking-working surface over 4 ft (1.2 m), per OSHA 1910.28(b)(1)(i), but any walking-working surface that might subject workers to:
Increased slips and trips
Snow, ice, or other inclement weather
Dangerous machinery, such as rooftop HVAC equipment
Ingress/egress points, such as:
Internal ladderways
Stairs installed along the facility's facade
New facility build-outs can best accommodate future rooftop maintenance by considering how its fall protection systems must conform to the overall layout. For example:
Manufacturing facility fall safety on rooftops may require special attention for oddly shaped surfaces, ventilation ducts, or electrical equipment in working areas
Special access points, like hatches and skylights, normally carry the same safety requirements as any other interior opening or hole (e.g., OSHA 1926.501[b][4][i])
Hatch and stairway placement must not allow workers to egress into a safety hazard
OSHA 1910.28(b)(3)(v)(A) only requires guardrails around three of the four sides of a hatch opening – but for little more expense, an integrated access point railing/safety gate can secure the entire perimeter
Rooftop maintenance may require greater accessibility than fixed, penetrating guardrails allow
Modular, non-penetrating railing can easily be added at any stage of construction, and then fulfill future rooftop fall protection requirements
The architectural merits of a manufacturing facility may be more important closer toward, or within, city limits
Determining which equipment will meet the fullest range of OSHA requirements for manufacturing facilities requires special attention during the design phase. Even though the most adaptable flat roof fall protection systems can meet an extremely wide range of regulatory requirements at any stage, incorporating such devices into the original design can greatly increase safety and compliance.
To be sure, always consult your specific OSHA or CCOHS requirements for your locality. Also be aware of which operations relate to general industry vs construction at any phase of the build or future renovations.
As mentioned, the most versatile guardrails can meet both construction and general industry regulations. Comparatively, traditional fixed railing that penetrates the roof's surface neither accommodates fluid construction workflows, nor allows safety managers to adapt fall protection systems to changing needs.
Penetrating guardrails also damage the roof's surface, causing several issues:
Permanent damage to the roof's surface
Likelihood of voiding roofing material warranties
Increased labor during installation and reinstallation
The need to patch the roof whenever you want to reposition the railing
All these issues dissuade safety managers from moving rooftop guardrails, even if it could otherwise create huge workflow advantages. It also renders fixed railing practically useless for construction, except with immense planning that could be put to better use.
These drawbacks are completely avoidable with non-penetrating guardrails, using weighted baseplates proven under rigorous testing to meet the same OSHA guardrail requirements as fixed railings.
Even for industrial facilities, architectural design isn't just a matter of trading utility for looks. Good aesthetics inspire confidence in the new building's stakeholders and workforces. That's especially true if there is in fact no loss of function for the sake of form.
Folding roof safety railing presents the finest in modular rooftop fall protection, giving technicians the means of almost immediately deploying railing when safety requirements demand. A folding rail system also carries several advantages that can set your facility apart in your industry while impressing project investors. These advantages include:
Preserving sightlines along the roof's perimeter
Encouraging technicians to constantly evaluate when and which compliance requirements apply
Giving construction and maintenance crews the ability to temporarily remove guardrails and use PPE
The latter point carries far-reaching advantages for rooftop maintenance. Removable or folding guardrails allow technicians, relying on alternate fall safety measures, to more easily access and maintain:
Skylights
Hatch covers
Rooftop machinery
Ductwork and utility conduits
Parapets and other structures at roof edges
Flat roofing materials beyond normal working areas
Folding rails also enable hoisting and lifting operations at virtually any leading edge, so long as additional precautions are taken (e.g., personal fall arrest systems, per 1910.28[b][2][ii]).
Because OSHA only sets build specifications for fall protection systems, manufacturers are free to design manufacturing facility fall safety equipment with broad leeway in terms of value-adding features. Such features can enhance the safety of fall protection devices, due to both greater usability and utility.
Only the most innovative passive rooftop fall protection equipment can secure your interests throughout the manufacturing facility build and ongoing operations. This is much easier by forging a relationship with a leading fall protection manufacturer, familiar with the broadest range of technical and regulatory considerations.
BlueWater specializes in fall protection systems that preserve worker safety and the roof's integrity without compromise. Our support staff can dramatically reduce the guesswork involved in rooftop safety while accommodating even the most complex design requirements.
Meeting 100% of OSHA requirements for manufacturing facilities can be difficult, but only without the right equipment and technical knowledge. Contact BlueWater today and discuss your manufacturing facility fall safety requirements with our committed and experienced specialists.
