From warehouses and fulfillment centers to manufacturing plants and beyond, workers in almost any industrial setting depend on reliable roof fall protection systems to keep them safe while performing physically and mentally demanding activities. OSHA leading edge fall protection requirements are thus extremely comprehensive, which can make selecting the right industrial guardrails seem more difficult than it must be.
By contrast, modular railing systems can fulfill an incredibly wide range of roof fall protection requirements. While multifaceted, their primary function is leading edge protection, which is the focus of this article – but be advised that modular railing can fulfill innumerable other rooftop fall protection requirements as well.
For the longest time, the only potential advantage of permanent railing was its stronger connection with the roof's surface. Still, safety managers and building owners were eager to avoid the major deficits of systems designed to penetrate the roof's surface, which presents several inherent drawbacks:
Permanently damages the roof's surface
Often invalidates roofing material warranties
Restricts adaptation to changing work conditions and other roof fall protection equipment
The entire system could become compromised if a single mounting point fails
Such concerns raise two important questions: are these drawbacks worth the presumed advantage of permanent installations – and do permanent railings really have a strength advantage in the first place?
OSHA standards are the same for all industrial guardrails, regardless of how they engage with the walking working surface. Force rating standards are set to meet functional requirements (i.e., falling bodies), and OSHA isn't in the business of "approving" any given fall protection product.
Rather, leading edge fall protection standards require guardrails built and tested for certain force rating standards, at OSHA 1910.29(b) and 1926.502(b):
The top rail must withstand at least 200 lbs (890 N) of force, in a downward and outward direction, without deflecting to less than 39 in. (99 cm) above the walking-working surface
Midrails (and other intermediate members, like panels or screens) must withstand at least 150 lbs (667 N) of downward and outward directional force
The same sections outline many other design and build standards for dimensional, material, and surface finish requirements; but nowhere do OSHA guardrail requirements dictate how the railing must interface with the surface. What matters is only that rooftop railing fulfills its core function: protecting workers and preventing falls.
Previous attempts at transitioning to modular railing systems in the fall protection industry had mixed results. This was largely due to the use of horizontal counterbalancing rails, which created major tripping hazards right where they would do the most harm.
Even when positioned away from the working area, the horizontal members forced the entire railing system back further into the roof's perimeter. When the primary function of your railing is leading edge fall protection, compromising on placement due to technical limitations is a critical design flaw.
Today, it's possible to eliminate the drawbacks of traditional modular railing using weighted base plates. They still meet (and can even exceed) force rating standards, which apply along any point of the railing. This highlights another important design requirement for movable railing: the most effective modular railing should work as an interconnected system.
More specifically, when one point of the railing endures an impact, the adjacent railing helps absorb the force. Thus, it's not the weighted base plates alone that provide stability. The entire system works together to keep the weighted base plates, which interface with up to four vertical members, from moving.
Modular guardrails become even more secure with the addition of several other design features:
Industrial-strength rubber pads, which are ideal for smooth concrete or metal surfaces
Hot dipped galvanized steel or powder coated paint, which minimize corrosion and maximize product lifespan
Independent force rating tests by accredited engineering firms, including for direct impacts and wind loads
Outriggers (i.e., counterweighted returns positioned 90° to the railing) at the end of a run to maximize railing system's stability
As mentioned, modular guardrails eliminate the need to penetrate a roof's surface and permanently affix vertical members to the walking-working surface. This carries numerous design advantages over traditional railing:
Enables adjustment according to the nature of rooftop work or changing compliance needs (e.g., when general industry work transitions to construction)
Supports multiple rail or gate section lengths, often ranging from 3 to 10 ft (0.9–3 m)
D-shaped railing extensions that provide grab bar functionality at ladderways
Vertical posts held secure with zinc-plated and yellow chromate-dipped 1010 carbon steel pins
Positive lock mechanisms at the receiver posts, and which support universal directionality
Ability to adapt railing to oddly shaped structures – such as conduits or duct work, parapets, or step-ups/downs – using raised midrails or outriggers
Ultra-fast installation and modification using simple hand tools
Preserves the roof's integrity and any roofing material warranties
Wherever space permits weighted baseplates (about 4 sq ft, or 1.2 sq m), the types of modular guardrails discussed above are a superior choice. Yet what about space limitations that inhibit use of weighted base plates?
We've discussed just one type of modular railing system. In the most general sense, modularity is a design concept that relates to interchangeability of parts. For unique rooftop conditions, there are other modular railing designs that may prove more effective (or even necessary), including:
Interchangeable railing that can mount directly into the facade of a building or elevated platform
Machine guarding often requires balancing the dual need for protection and accessibility – and the best modular railing systems adapt equally well to safety gates or guardrails
Modular pipe fittings enable placement of vertical posts and rails in a multitude of configurations, such as when one section of railing runs alongside a wall or other obstruction
Selecting the most effective guardrail systems doesn't have to be as complicated as the safety standards they're meant to fulfill. While nothing replaces the need to thoroughly consult your OSHA or CCOHS regulations, modular designs are often the key to meeting the widest breadth of compliance requirements.
BlueWater has been a leader at the forefront of advanced roof fall protection equipment, including innovative modular designs. To optimize your rooftop's fall protection strategy at the leading edge and beyond, contact us today. One of our knowledgeable experts is waiting to help review your facility’s need for industrial guardrails and other safety solutions.
