Many manufacturing companies use fall protection systems that pass OSHA standards to protect their workers on the job. However, despite developments in the fall protection industry that have created new systems that meet and exceed OSHA standards, many companies continue to use wire rope systems that can seem outdated. This article examines a variety of leading fall protection systems and their pros and cons.

When an individual is considering making an investment for their company in a fall protection system, there are many reasons why they consider wire rope systems. For one, wire rope systems are OSHA approved. In addition, wire rope systems have been in place for years and are typically effective at providing adequate protection for workers.

However, wire rope systems can not prevent a worker from falling at least several feet. On a wire rope system that is 40 feet in length, workers can fall as far as 8 feet before coming to a stop. For workers on a tanker truck or rail car, the chance of injury to the head or body during a fall of 8 feet with metal outcroppings, ladders, or even the ground is very high.

In addition to increased risk of safety, many companies have the misconception that wire rope systems are less expensive than other options. Because wire rope systems are the industry standard, why pay more? When a cost analysis of wire rope systems is completed, however, most companies will see that once you pay for the shock absorber and rope trolley, the cost of track systems are very similar.

Two tracks system that are a popular alternative to wire rope systems are called I-Beam Systems and Rigid Track Systems. I-Beam Systems are rigid and horizontal in design, making them safer than wire rope systems. However, their design makes worker movement more difficult and cumbersome. The installation of I-Beam Systems also demands more trusses and creates the need for large foundations, which can be more costly.

For companies in four-season climates, the elements can play a major role in the inefficiency of I-Beam Systems. Any climate that sees snow and ice can find their I-Beam Systems rendered completely useless because the trolley on an I-Beam cannot move through the elements. Companies that require a fall protection system in “dirty jobs” will also find I-Beam systems to require a lot of track cleaning in order to keep the trolley mobile, leading to an increase in worker downtime.

By comparison to wire rope systems and I-Beam systems, Rigid Track fall protection systems seem to be the best bet for promoting worker safety and efficiency. Rigid Track systems have an enclosed track that eliminate the potential hazard of the elements. From a cost perspective, Rigid Track systems are also competitively priced with wire rope systems and do not require the thousands of dollars in engineering inspection and reinforcement.

From a safety standpoint, Rigid Track fall protection systems seem to be the safest option for workers in a variety of industries. While wire rope systems allow workers to fall as much as 8 feet before providing “protection,” the rigid beam on a horizontal track system protects workers from a fall as soon as their hoist locks – there is no additional fall.

There are many options to consider for fall protection systems, but only one choice seems to be best for worker safety, worker efficiency, and cost benefits. Rigid Track systems are created using industry-leading engineering, and seem to provide the best fall protection on the market today. Consider horizontal fall protection for your workstations the next time you're in the market for improved fall protection.