People need to access industrial roofs on a regular basis. It might be to inspect the roof, install solar panels or maintain HVAC systems. Whatever the reason, if you’re a building owner, site manager, or FM, you have a duty to protect those working on your roof. Collective protection should always be the preferred choice, but these systems are not always suitable for industrial roofs. In these instances, horizontal lifeline systems offer a suitable alternative. But only when they are designed, installed, and used correctly.
When to use horizontal lifelines
Horizontal lifelines are required whenever workers need regular access to exposed areas of a roof where the risk of a fall cannot be eliminated.
Unlike other forms of fall protection, like temporary anchor points, lifelines provide continuous protection across wide roof spans, enabling safe movement along the structure.
These systems are especially valuable on sites where roof layouts change to accommodate equipment such as air conditioning units, extraction units, or PV solar arrays. A properly designed lifeline will ensure workers remain safely connected at all times as they move across open areas where there’s a fall risk.
Fall restraint vs fall arrest
A key consideration when specifying a lifeline is whether it will be used in fall restraint or fall arrest mode:
- Fall restraint prevents the worker from reaching an edge or hazard by limiting the length of their lanyard. This is the preferred option wherever possible, as it stops a fall from occurring in the first place.
- Fall arrest allows the worker to access edges or hazards but ensures that if a fall does happen, it is arrested quickly and safely. Fall arrest requires additional planning to account for clearance distances, the risk of a swing fall (also known as the pendulum effect), and rescue procedures.
Both approaches rely on correct system design and worker competency. The choice between restraint and arrest should be determined during the risk assessment and planning stage of any rooftop activity.
Benefits of lifeline systems
Horizontal lifelines provide several important advantages for industrial rooftop safety.
- Continuous connection: Workers remain attached throughout their task, even when moving across long roof spans.
- Flexibility: Systems can be designed to follow complex roof layouts, allowing access around plant & equipment, or skylights.
- Compatibility: Lifelines are compatible with a range of roof types, including trapezoidal metal sheets and fibre cement panels, provided the system is correctly engineered for the substrate.
- Efficiency: Safe access reduces downtime, allowing maintenance and installation tasks to be carried out with minimal disruption.
- Compliance: A correctly specified and certified system helps duty-holders meet their legal obligations under the Work at Height Regulations.
For duty-holders managing industrial facilities, lifelines strike a balance between safety, practicality, and cost. They offer a reliable method of ensuring safe access without the need for extensive scaffolding or temporary edge protection.
Training & recertification requirements
Installing a lifeline system is only the first step. The effectiveness of any fall protection system depends not just on its design, but on how it is used and maintained.
Employers must ensure that all workers accessing the system are trained in safe use, including:
- Understanding the difference between fall restraint and fall arrest.
- Correct fitting and use of harnesses, lanyards, and connectors are essential for safe operation.
- Awareness of potential hazards such as skylights and fragile surfaces.
- Rescue procedures if someone falls.
But installing a system and ensuring the competency of people using it is only part of your duty. You’re also legally obligated to have the systems regularly inspected and recertified at least once every 12 months, or more often if they are exposed to severe environmental conditions. Recertification verifies that anchor points, cables, and fixings are in good condition and capable of functioning as intended.
With the right systems and procedures in place, building owners, site managers, FMs, and employers can effectively manage the risks associated with working at height on their industrial roofs.
