Working at heights is hazardous, but throwing on whatever fall protection system is lying around isn't enough to protect workers; it must be appropriate for the situation. Horizontal lifeline systems are common in many industries, but knowing when and how to use them is crucial. This article delves into the components of a horizontal lifeline system, their application, and why it's often best to consult with a fall protection expert before making your final choice.

What is a Horizontal Lifeline System?

Companies often use Horizontal Lifeline Systems (HLL) for fall arrest and travel restraint when personnel tie-off anchor points are not easily accessible. Installers can place these systems at the base of a structure, overhead, or between. They secure a wire cable to a minimum of two anchor points and use those endpoints to tension and secure the lifeline. Additionally, they may add force-management components, as well as intermediate or corner supports between the endpoints.

An engineered system

In the event of a fall, the horizontal lifeline system deflects in the direction of the fall, and the force-management components deploy. It is critical that fall clearance beneath the walking-working surface is sufficient to prevent the worker from hitting lower levels. There are other factors that influence the amount of fall clearance required, including the span distance, energy absorbing components in the user’s lanyard, and setback distance of the anchor point from the fall hazard.    Therefore, accurate calculations by the Qualified Person are essential to ensure the system's ability to perform as designed and prevent serious injury or death.

Calculations must consider the forces exerted on the system during a fall arrest. For example, the span distance and sag angle influence the maximum arrest load, and a longer span may result in a higher impact force on an end or corner anchorage. This additional force matters because high impacts can result in system failures, property damage, and user injury or death. 

When anchored to the lifeline overhead, freefall distances and thus arresting force are much easier to manage. But when users must anchor to the lifeline below the dorsal d-ring on their harness, freefall distance and arresting force are increased greatly. For this reason, it is considered a best practice to only install lifelines in fall arrest applications overhead of the user. When lifelines run at ground-level or below the dorsal d-ring, the system should be designed for restraint and be used with connectors short enough to limit user travel and prevent a fall completely.

Inspection and maintenance

Regular inspection and maintenance of lifelines are crucial for ensuring the safety of its users. If any part of the system is compromised, the entire system is at risk. Those responsible for inspections vary depending on the safety role, and inspections should be done regularly, at least once a year, by a competent person. 

During inspections, it's important to look for damage or defects to any part of the equipment, the absence of markings or tags, and any element that could affect the usability of the equipment. If equipment fails an inspection, it should be removed from service immediately and marked as unusable or destroyed. Regular inspection and maintenance are crucial to ensuring that fall protection equipment will continue to work effectively.

Advantages of Horizontal Lifeline Systems

Due to the fall arrest and travel restraint capabilities of horizontal lifelines, they are an essential component of many fall protection systems. These systems provide reliable fall protection through the use of durable components like stainless steel wire and brackets that can withstand harsh weather conditions and external forces. 

They offer flexibility in mounting options, including floor-level, side-mounted, or overhead-mounted, allowing for customization to meet specific facility needs. Workers can move freely and benefit from uninterrupted safety with continuous protection provided by these systems. HLL systems are versatile, accommodating various work environments and multiple users by expanding the number of anchor points. 

Horizontal lifeline systems come in various types, each designed to cater to specific industries and usage. For instance, roof lifeline systems prevent falls when accessing, inspecting, or repairing roofs. These systems must consider factors like structure type and strength, roofing material, and anchor point location to select a system that can deflect or prevent falls without damaging the supporting structure or the roof itself. Pipe rack lifeline systems enable workers to access and repair elevated work areas safely. Crane rail lifeline systems provide 100% tie-off by attaching to a series of anchor points in surrounding structures. Overhead horizontal lifelines, suitable for areas where workers need to walk long distances and avoid re-attaching to various anchor points, are ideal for settings such as loading docks and rail yards. Manufacturers produce components for both temporary and permanently installed HLL systems. A Qualified Person will be able to select and install the appropriate system for any application, according to manufacturer’s instructions.

When is a horizontal lifeline appropriate

When deciding when to use a horizontal lifeline system, there are several factors to consider, such as the number of workers at height, the height of the workspace, and the type of work. 

One of the main advantages of horizontal lifelines is their ability to provide workers with safety and freedom of movement. This ability makes them ideal for maintenance, repair, or construction work where workers need to move around while attached to the system. In addition, they offer continuous protection, allowing workers to work safely without interruptions.

A horizontal lifeline system is also a practical solution when no other fall protection system is feasible or practical. For example, suppose other fall protection systems like safety nets or guardrails cannot be installed due to the nature of the worksite. In that case, a horizontal lifeline system can provide an effective solution.

These systems are also ideal for working at heights where a single anchor point is not enough to provide adequate protection. A horizontal lifeline system can offer multiple anchor points, and be engineered to allow several workers to be attached to the system simultaneously.

Ensuring working safety and OSHA compliance requires implementing a comprehensive fall prevention strategy that includes the proper mix of fall protection equipment and personnel training. However, choosing the appropriate fall protection solution and training workers on how to use it safely is a sometimes confusing but crucial component of protecting workers from the hazards of falls. 

Regulations

Unfortunately, making the wrong choice or calculation can be the difference between getting the job done or someone ending up in the hospital. This is why OSHA has specific requirements about the design, use and supervision of horizontal lifelines.

OSHA states the following as it pertains to horizontal lifelines in general industry:

OSHA 1910.140(c)(11) “The employer must ensure that each horizontal lifeline: Is designed, installed, and used under the supervision of a qualified person. Is part of a complete personal fall arrest system that maintains a safety factor of at least two.”

OSHA states the following as it pertains to horizontal lifelines in construction:

OSHA 1926.502(d)(8) Horizontal lifelines shall be designed, installed, and used, under the supervision of a qualified person, as part of a complete personal fall arrest system, which maintains a safety factor of at least two.

"Qualified" means one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated his ability to solve or resolve problems relating to the subject matter, the work, or the project.