New heights for fall protection

Comfort increases with today’s fall protection equipment

A fall arrest harness can’t save you if it’s not worn and a lanyard that’s not connected to an anchorage point will do nothing to protect you from the ill effects of gravity.

But a harness that pinches, binds and chafes and a lanyard that is more of a tripping hazard than a lifeline won’t do much for worker productivity – or morale.

That’s why fall protection companies are rolling out new products that improve comfort and maneuverability.

Comfort rules
“We want to make fall protection equipment so comfortable that workers will wear it. Safety managers report they have the equipment, but getting workers to wear it is another issue. Designed and sized properly, it can be worn continuously,” says Kim Meyer, soft goods product manager at DBI-SALA. “If the harness is easier to put on and more comfortable to wear, workers don’t mind wearing it all of the time. If there is no taking the harness on and off during the day, productivity increases,” she says.

Bob Apel, MSA product line manager, concurs. “It centers around comfort. It is at the forefront of every user’s thoughts. Subtle design changes in how harnesses are sewn and new connectors make a huge difference in the comfort level of the equipment,” he says.

“Comfort affects more than everyday wear. It is a critical factor if the worker takes a fall, says Eric Miller, senior marketing manager at AOSafety – Safewaze. “If a worker falls, does the fall protection system provide the victim some comfort until help arrives? Plus, is the equipment comfortable on the job? Is it lightweight and out of the way as it’s being used?”

New designs
New harnesses with interesting enhancements meet this challenge. New harness materials and styles greatly improve wearability.

“DBI-SALA’s ExoFit XP fall protection harness features new materials with even more comfortable padding and a breathable 3-D mesh. The pads are removable so they can be washed,” says Meyer.

MSA’s Apel says the shoulder straps on its TechnaCurv harness reduce neck chafing. “The torso straps of the harness curve around the neck, preventing webbing contact with the neck and increasing comfort. We have also incorporated variable-width webbing in the sub-pelvic strap of the harness. This provides 50 percent greater surface area over which to distribute a user’s weight during work positioning or suspension, which increases comfort. The visco-elastic shoulder padding is a memory foam covered with breathable, moisture-wicking material to improve comfort in warm work environments.”

The SecureFit’s mechanical buckle makes the TechnaCurv harnesses easier to put on and take off. “The buckle can be operated with one hand and adjusts easily for legs and chest straps,” Apel says.
Harness design continues to evolve to meet specific work needs. DBI-SALA, for example, has developed the ExoFit XP harness with a spring-loaded D-ring so it stands up, making lanyard connection easier as a one-person job.

Hardware upgrades
Lanyards, connecting devices and anchorage points are also getting engineering and design attention. “The bungee-style lanyard is very popular. Workers like using the Shockwave2 lanyards because they can leave them on, even if they are riding in a vehicle. The bungees are less bulky on the back,” says Meyer.

MSA’s Diamond lanyard has an internal shock absorber that runs the length of the lanyard. This reduces the lanyard’s weight, making it more comfortable. It also decreases the cost of the product. “The Expanyard version of the Diamond lanyard includes elastic material in its core and automatically expands and contracts between 4' and 6',” says Apel.

Self retracting lifelines
What’s gaining even more popularity are self-retracting lifelines. “Self-retractable lifelines work like a seatbelt and give freedom of movement. Some will lock at a 2' fall, then brake. This is gentler on the victim,” says Miller.

“The new retractable lifelines are smaller and lighter. For example, the Safewaze 3307 retractable lanyard weighs only 1.9 lbs. and fits in your hand,” says Miller.

Workers can now easily tie off to a beam or other support with tie-back lanyards that can be strapped over an anchorage point and tied back to itself. However, the experts warn workers should never do this with a conventional lanyard.

In case of an accident
Manufacturers are also looking for ways to make the fall protection equipment offer greater comfort in the event of a fall. Some rely on harness design changes, while others have added components that can help victims while they are awaiting rescue.

Safewaze and other manufacturers have developed small packs that mount discreetly on the back of the harness that can be opened after a fall to reveal a step-loop. The victim can step into the loop to take weight off of the thighs.

“Safewaze’s Rescue Step fits above the back D-ring. If the worker falls, the loop step provides relief and helps keep blood circulating in the legs,” says Miller.

Published in the May/June 2006 issue of Contractor Tools and Supplies magazine.

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