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Guardrails are an essential component of fall protection inside any industrial facility, for rooftop safety, as well as anywhere else a fall hazard exists. Wherever you use guardrails, they have to meet the standards set forth by OSHA in regard to size and strength. It's up to you, however, to choose the materials your guardrails are made of. Depending on the application, a metal guardrail, fiberglass guardrail, or another type of guardrail may be most appropriate. Once you understand the pros and cons of each type of material, the decision will be much easier to make.
In order to protect your employees and remain compliant with OSHA regulations the guardrails you install in your facility and as part of your roof fall protection systems have to meet certain criteria. Regardless of the material you choose for your guardrails they must meet the following specifications:
Guardrails must be 42 inches (1.07 m), plus or minus 3 inches (7.62 cm), above the walking-working surface. (Guardrails may exceed this height if they meet all the other requirements.)
Midrails, screens, mesh, intermediate vertical members, solid panels, or the equivalent must be installed between the walking-working surface and the top edge of the guardrail system if there isn't a wall or parapet at least 21 inches (0.53 meters) high.
Guardrails have to withstand a downward or outward force of at least 200 pounds (90.72 kg) within 2 inches (5.08 cm) of the top edge anywhere along the top rail without failing.
The top rail of guardrails must not be able to deflect to less than 39 inches (0.99 m) from the walking or working surface when the 200 pounds (90.72 kg) of pressure is applied.
Midrails, screens, mesh, and other vertical members have to be able to withstand 150 pounds (68.04 kg) of downward or outward force anywhere along the intermediate member.
Guardrails must be smooth to prevent workers clothing from being snagged and to prevent cuts, abrasions, and scrapes as employees come in contact with the railing.
The most common type of guardrail used in industrial settings is a steel guardrail. Since steel is a rigid, strong material, it generally meets the strength requirements for guardrails. And, of course, it can be manufactured to meet the size requirements for your facility while also meeting the OSHA requirements for height. Metal guardrails can be used both inside and outside your facility.
The biggest issue with metal guardrails is that steel is also an excellent conductor of electricity. In energy plants, and facilities with high-voltage machinery and equipment, a steel guardrail increases the risk of shock or electrocution. It's also extremely heavy, which means you may need to reinforce your concrete to handle the weight. In addition, steel must be properly maintained, which adds to the costs in the long run.
One of the most common alternatives to using a steel guardrail is fiberglass. Like steel, it can be manufactured to the appropriate height to meet OSHA regulations and is strong enough to withstand 200 pounds (90.72 kg) of force applied to it without failing. Due to its low conductivity and resistance to heat, it can be used where steel can't. Fiberglass guardrails can be used inside your facility around walkways and elevated work surfaces, outdoors, or to provide rooftop safety.
Fiberglass guardrails cost more upfront than the equivalent steel guard rails. However, lower shipping costs and the fact that you don't need to reinforce your facility to handle them make them more economical. Fiberglass guardrails can be manufactured in a variety of colors, such as warning yellow. However, over time, the color of the railing will fade if it's exposed to sunlight, but this doesn't affect performance.
While steel and fiberglass are the most common materials used for roof fall protection systems and fall protection inside a facility, they're not the only ones. Wood, wire rope, manila, and synthetic rope may also be used as top rails and midrails for rooftop safety and fall protection on walking/working surfaces.
Wood Guardrail Components
Although wood guardrail parts can provide adequate protection from falls and meet the guidelines for strength, they're not a perfect solution, especially outdoors. Wood absorbs moisture, is prone to cracking and breaking, requires a great deal of maintenance, and needs to be replaced frequently.
Manila and Synthetic Rope
Like every other material used in guardrails, manila and synthetic rope must meet the OSHA strength and height requirements. Like wood, rope is not a suitable material for long-term outdoor use as it is affected by UV light and the elements. It's important to inspect ropes frequently and replace them as needed to stay compliant.
Wire Rope
Rope made of wire is a stronger alternative to wood, manila rope, or synthetic rope. However, wire rope can become corroded if exposed to rain, snow, or other moisture. Wire rope can also pose a hazard to workers if it's not tightly wound. Regular maintenance and repairs are essential to maintain a wire rope.
The answer is “It depends.” Choosing fall protection devices and roof fall protection systems isn't as cut and dry as it seems. Base your decision on the application, your budget, and your specific needs. For instance, if you're looking for rooftop safety and metal guardrails are too heavy or too conductive for the application, fiberglass may be your best bet.
When it comes to choosing the right guardrails and roof fall protection systems, it's a wise idea to consult with an expert. You want to make sure that the material is appropriate for the application, that it's OSHA compliant, and that it won't break your budget. BlueWater is an industry leader, providing fall protection that meets all OSHA guidelines for a wide variety of industries. Our roof fall protection specialists can help you keep your workers safe with OSHA compliant fall protection devices, systems, and solutions you can count on. Click here to contact us today