As the economy reopens and industries expand, the demand for storage tanks has boomed. Many industries rely on these storage tanks including the food and beverage industry, cosmetics industry, plastic manufacturing, the steel sector, paper industry, and the power and energy sector, just to name a few. And storage tank manufacturing companies need to step up to capitalize on the increased demand. But your moves need to be calculated, the manufacturing and installation process has to be safety-driven, and every storage tank must meet the OSHA fall protection requirements.
Storage Tank Manufacturing Fall Risk Assessment
Constructing, moving, and servicing large industrial storage tanks can be dangerous. Sleek metal walls, rounded edges, and height make storage tanks particularly challenging to work with and increase the risk of falls. You’re well aware of your responsibility under the OSHA fall protection regulations to provide a safe worksite for your employees. That begins with an assessment of your facility’s risk factors. Focus on:
Ladders
It’s important that employees have safe access to the top of storage tanks and elevated working and walking surfaces. At every stage, from the storage tank manufacturing to installation and day-to-day operations, ladders are vital to providing access. OSHA’s ladder fall protection guidelines require:
- Providing protection on fixed ladders that are 24 feet or higher above the level below with a ladder safety system that consists of a carrier, safety sleeve, lanyard, connectors, and body harness or,
- Assigning workers with personal fall protection devices that include anchorage, connectors, a body belt, harness, lanyard, deceleration device, lifeline, or any suitable combinations of these.
- Employees must also be trained on how to safely climb and descend ladders by holding railings and only carrying loads that are safe under the circumstances.
Elevated Work/Walking Surfaces
The use of elevated work structures is common place during the storage tank manufacturing process, but they can host a variety of fall hazards. OSHA fall protection regulations require you to provide fall protection for employees anytime they’re working at a height of 4′ or more above a lower level. You’ll need to make sure to provide one or more of the following fall protection devices on the elevated work platforms, scaffolding, and mezzanines around storage tanks to be compliant with OSHA’s guidelines.
- Protect exposed edges with a permanent guardrail system or a modular safety rail system that’s 42″ tall (plus or minus 3″) and able to withstand 200 lbs of force. Keep in mind that access points need to be protected by a metal swing gate or other type of safety gate.
- Safety nets are particularly challenging and costly to install and maintain, but they might be necessary in some cases. They must be installed as close to the underside of the working/walking surface as possible. Nets have to be able to withstand a 400-lb weight applied from above without fail. The mesh openings cannot be more than 36″ sq or more than 6″ on any side.
- Employees could also be assigned OSHA approved PPE that includes a harness, lanyard, self-retracting lifelines, and vertical lifelines. Regardless of the type of PPE you use, it must be regularly inspected, well-fitted, and used properly to provide maximum fall protection.
Stairs & Stairways
Accessing the mezzanine or platform located above a storage tank, is imperative, and this will often mean employees are regularly climbing and descending stairs. Precautions have to be taken to minimize fall risks for employees in these situations. Besides maintaining a clutter-free stairway environment, other OSHA requirements include:
- Protecting stairway openings with a fixed guardrail system or modular safety rail surrounding the exposed sides. Again, guardrails have to be 42″ (+ or – 3″) tall and be able to withstand a 200-lb force from either an upward or downward position.
- Providing safe access to the stairway while also limiting exposure to the opening when the stairway isn’t in use. This is best accomplished with a metal swing gate at the stairway entrance. The metal swing gate must meet the same height and strength requirements as the guardrail.
- Preventing falls on stairs begins with lighting, warning markers, and proper maintenance. In addition, flights of stairs with at least 3 treads and 4 risers must be equipped with fall protection equipment like handrails and a stair rail system.
Loading Docks
One of the busiest areas of any storage tank manufacturing facility, or any industrial facility really, is the loading dock area. Employee safety and fall protection are a priority with so many trucks backing in and pulling out, materials, equipment, and supplies coming in and going out. OSHA requires the following loading dock safety measures:
- As with other areas of your facility, you’ll need to provide fall protection. The most common solution is a 42″ (+ or – 3″) safety railing around a loading dock that’s 4′ or more above the lower level. You might also consider installing a metal swing gate or other safety gate to protect the area further.
- Employees should be assigned a personal fall arrest system that includes anchorage, connectors, a body harness or belt, lanyard, lifeline, or deceleration device or any suitable combination of these items.
- Limiting the distance an employee can fall with a travel restraint system may also be a good idea. This type of fall protection utilizes an anchor point, connectors, a lanyard or lifeline, and a body harness to keep workers from falling to the level below.
Areas Around Machinery
Manufacturing large storage tanks requires heavy equipment and machinery. These are also some of the biggest dangers in any manufacturing facility, and it’s important to keep the area secured. Whether you’re trying to keep unauthorized personnel from entering the area or restricting movement within your facility, a modular safety rail or other guardrail system is essential.
- Enclosing areas around machinery with guardrails is a great way to protect people and equipment. They need to follow the same OSHA guidelines for guardrails outlined above.
- It’s important to provide access to the restricted area without compromising safety. This is easily accomplished with a safety gate or metal swing gate that meets the same OSHA rules as the guardrail. A self-closing gate may be more appropriate for heavy traffic areas.
Partner with a Storage Tank Fall Safety Expert
At Fabenco, we understand how important it is to keep your employees safe while they work on building storage tanks for your customers. Contact us today to find out how we can help with solutions that meet your specific needs to improve your facility’s safety, so you stay compliant and productive.
