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Safety is always top priority in food processing plants, and that includes fall safety throughout every area of the facility. As someone responsible for safety of your workers, you know this extends to rooftops, as well. What are the fall risks you need to be particularly vigilant about? Have you done an analysis of what those potential hazards are?
Typically, food processing plant rooftops are flat (with a slope of between 1 and 10 degrees), so the primary fall risk may be someone stepping over edges rather than sliding on the grade of a peaked roof. This means passive fall safety solutions such as a guardrail systems will be the foundation of your rooftop fall protection. However, food processing plants also often have some unique rooftop features that may require fall protection for areas beyond just the leading edge.
In this article, we’ll take a look at the most common hazards on food processing facility rooftop environments and the top rated safety railings and other equipment that provide the best solutions.
As previously stated, the major fall risk for any worker on your plant's roof is a leading edge. This means an unprotected edge that changes location as new roofing is constructed or repairs are made. Leading edges present a big risk of falls for workers of all kinds, including maintenance and construction personnel.
What kind of safety device should you buy to protect leading edges? Portable, nonpenetrating systems are generally the best guardrail option available. These guardrails can be securely put in place without damaging/penetrating the roof, and they are easily repositioned as work progresses and the leading edge moves or is removed entirely. Portable top rated safety railings will meet the OSHA requirements for guardrail systems, which include specifications about height, weight-bearing ability, and more:
"The top edge height of top rails, or equivalent guardrail system members, are 42 inches (107 cm), plus or minus 3 inches (8 cm), above the walking-working surface. The top edge height may exceed 45 inches (114 cm)..."
Guardrails also have to “withstanding, without failure, a force of at least 200 pounds (890 N) applied in a downward or outward direction within 2 inches (5 cm) of the top edge, at any point along the top rail” without failing.
A common unique feature most food processing plants have is a range of HVAC and ventilation system’s housed on their rooftops. These systems can limit available walking space and pose potentially dangerous tripping hazards. And often they require regular maintenance and cleaning to keep them running at optimal efficiency, adding extra need for protecting those employees who work on them.
Providing effective fall protection around these systems is key to keep any food processing facility’s rooftop safe. Depending on the position of your HVAC units and the surrounding roof environment, three good potential solutions exist: a guardrail system, a safety net, or a personal fall arrest system.
Guardrail systems are the best default option, providing reliable, OSHA-compliant protection around HVAC and ventilation units. However, due to these units’ sizes, occasionally there may not be sufficient room to position a guardrail between the unit and the roof edge. Specialized non-penetrating parapet railing extensions can be especially useful for creating rooftop fall protection around a unit that is close to a leading edge.
Where guardrails are not feasible (or as a supplementary measure), safety nets are another viable option. OSHA regulations in section 1596.502(c) detail the guidelines and requirements for safety net systems. You should familiarize yourself with these as you consider your options. Among other factors, safety nets require proper attachment to the side of your building as well as regular inspection, cleaning, and replacement of some of its components. You may need to hire an engineer or other specialists to install and maintain your safety net system.
Personal fall arrests (also known as positioning systems) will be needed for personnel working in rooftop environments at your food processing facility where railings and other passive protection are not available or insufficient. These harnesses, lanyards, lifelines, and other specialized equipment work as active fall protection systems to protect maintenance or construction workers.
Another common fall hazard for food processing facilities are roof access ladders. OSHA recently revised its rules for ladders, stating:
“Fall protection must be provided whenever the length of climb on a fixed ladder equals or exceeds 24 feet. Also, even if less than 24 feet, under cages, wells, ladder safety devices, or self-retracting lifelines must be provided where the top of the fixed ladder is greater than 24 feet above lower levels.”
Often either a building mount ladder is the only ways for employees to access these roofs, and each can be a potential risk for falls. Not only is there the risk for any employee using the ladder, but there is also a fall risk for any employee working near the open where the ladder provides access. To protect employees around these hazards, the best guardrail option should be specifically designed for building mount ladders.
Rather than use a ladder to gain access to your roof, you may have a roof hatch installed in your food processing facility. These can also pose a falling hazard and require specific kinds of rooftop fall protection around their opening.
The primary falling hazard for this type of access point comes when leaving the hatch open. Rather than close the hatch for safety, workers sometimes leave the hatch open because they fear someone will close it behind them. A fear like this is understandable, but your primary responsibility is to address the fall hazard it creates.
Without a protective guard around the opening, someone could also easily fall through. In this case, specialized guardrails are available to go around the hatch opening. Various types are available, ranging from grab bars to fixed-position safety rails.
Skylights create a similar fall risk to open hatches, and OSHA requires that they be protected to the same degree. Portable railing systems should be used around them when you have a maintenance crew working on your roof for cleaning or repairs.
Now that you know the unique hazards of your food processing plant’s roof, what are the top rated safety railings and other fall protection devices you should use to keep them safe? If you're unsure of where to start, there is an easy answer:
Your best solution is to consult an expert rooftop fall protection and safety products team with experience in the food processing industry to help you select the best guardrail solutions for your facility’s needs. BlueWater is an experienced fall protection partner and a leader in the field, providing guidance and equipment to help you achieve rooftop safety and OSHA compliance. Our safety experts are standing by, ready to assist you with finding the best fall protection solutions for food processing facilities.