Falling objects, like tools, materials, or debris, can expose workers to minor injuries like cuts and abrasions, but can also cause more serious injuries like puncture wounds or concussions. In some cases, especially if workers are not wearing hard hats, a dropped object can result in hospitalization or even a fatal injury.
Falling object hazards can exist anywhere work is performed above other people. Construction sites, scaffolds, elevated work platforms, ladders, warehouses, storage areas, and other workplaces can all create situations where tools or materials may fall to a lower level. Preventing these incidents requires controlling objects at the elevated work area and protecting people who could be exposed below.
OSHA Falling Object Protection Requirements
OSHA Standards very specifically state that workers must have protection from falling objects.
OSHA Construction Standard 1926.501(c) states that when an employee is exposed to falling objects, the employer must have each employee wear a hard hat and implement at least one of the following measures:
- Put up toeboards, screens, or a guardrail system to prevent falling objects.
- Build a canopy structure and keep potential falling objects far enough from the edge to prevent them from falling over the edge if accidentally displaced.
- Barricade the area where objects could fall, prohibit employees from entering the barricaded area, and keep potential falling objects far enough from the edge to prevent them from falling.
OSHA General Industry Standard 1910.28(c) similarly requires appropriate head protection when employees are exposed to falling objects and requires employers to provide additional protection through toeboards, screens, guardrail systems, canopy structures, or barricaded areas, as applicable.
Head Protection
Workers exposed to potential head injuries from falling or flying objects must wear appropriate head protection. In construction, OSHA Standard 1926.100 requires protective helmets when there is a possible danger of head injury from impact or falling or flying objects.
A hard hat or safety helmet can help protect the worker if an object falls, but head protection should not be the only method used to control falling object hazards. Preventing objects from falling in the first place and keeping people out of areas where objects could fall provide additional layers of protection.
Identify Falling Object Hazards
Before work begins, evaluate the work area for anything that could fall, roll, slide, tip, or be accidentally knocked to a lower level.
Consider tools being used at heights, materials stored near edges, equipment on scaffolds or elevated platforms, loose debris, overhead work, and materials being lifted or moved. Weather and environmental conditions should also be considered because wind can move lightweight materials, debris, or unsecured objects.
Workers below should also be considered when planning the work. If overhead work creates a falling object hazard, establish appropriate controls before allowing work to begin.
Prevent Tools and Materials from Falling
There are many different safety precautions that can be implemented that may help prevent falling object incidents. After a hazard evaluation, select controls appropriate for the work being performed.
Secure Tools and Equipment
Secure tools and materials when there is a possibility they could fall to a lower level. Where appropriate, tool tethering systems or tool lanyards can provide additional protection for tools used at heights.
Tool lanyards and other tethering equipment should be designed for the specific tool and used according to the manufacturer’s instructions. Improvised attachment points or makeshift tethers can create additional hazards.
Do not hang or drape tools, equipment, clothing, or other items over guardrails. Keep loose materials and equipment away from unprotected edges and openings where they could be accidentally displaced.
Control Small Personal Items
When working at heights, secure small personal items that could fall from pockets. Cell phones, pens, small tools, keys, and similar objects can become falling object hazards when dropped from an elevated work area.
Use pockets that zip, button, or otherwise close securely when carrying small items at heights.
Use Toeboards, Screens, and Guardrails
Toeboards can help prevent tools, materials, and debris from being kicked, pushed, or accidentally displaced from an elevated surface.
Inspect toeboards and other falling object protection regularly to make sure they remain properly installed and capable of providing protection.
When tools, equipment, or materials are piled higher than a toeboard, additional screening or paneling may be necessary. OSHA General Industry Standard 1910.29(k), for example, requires additional paneling or screening when materials are piled higher than the top edge of a toeboard.
Depending on the work and the hazards present, screens, debris nets, catch platforms, or other appropriate systems may also be used to help control falling objects.
Barricade Areas Below Overhead Work
Whenever possible, avoid working or walking directly below employees performing work at heights.
Establish barricades or controlled areas where falling objects could strike people below. Warning signs can also alert workers and others to overhead hazards, but signs alone do not physically prevent someone from entering a hazardous area.
When barricades are being used to meet OSHA falling object protection requirements, employees must be prohibited from entering the barricaded area.
Stay Clear of Suspended Loads
Workers should also stay clear of suspended loads and areas where materials are being lifted overhead. A suspended load can shift, swing, or fall if lifting equipment, rigging, or the load itself fails or moves unexpectedly.
Plan lifting operations so employees who are not necessary for the operation remain outside the area where they could be struck by a load or falling material.
Store and Stack Materials Securely
Improperly stacked or stored materials can create falling and collapsing object hazards even when no work is being performed overhead.
Stack materials so they are stable and secure against sliding, falling, or collapse. Consider the shape, weight, height, and stability of stored materials and avoid creating unstable stacks.
Good housekeeping also plays an important role. Remove unnecessary debris and loose materials from elevated work areas instead of allowing objects to accumulate where they could be kicked, blown, or pushed over an edge.
Discuss Falling Objects During Safety Meetings
Consider adding falling object hazards to regular safety meetings or toolbox talks. Use examples from the actual workplace to identify where tools, materials, debris, or equipment could fall and who could be exposed below.
Review the safety measures already in place and determine whether additional precautions are necessary to “stop the drop.” Discuss head protection, tool tethering, toeboards, screens, barricades, material storage, housekeeping, and restrictions on working beneath overhead operations.
Falling object prevention should focus on controlling the hazard before an object ever falls. Securing tools and materials, protecting edges, restricting access below overhead work, maintaining good housekeeping, and wearing appropriate head protection can work together to reduce the risk of serious falling object injuries.
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