Fall Arrest Systems

A fall arrest system is a form of personal fall protection designed to stop a worker in free fall before they strike a lower level or structure.

The system typically consists of three core elements:

• A suitable anchorage
• A body-holding device, such as a full-body harness
• A connecting system, such as a lanyard, inertia reel or lifeline

Depending on the application, the system may also include energy absorbers, traveller devices, connectors and rescue equipment.

The purpose of fall arrest is not to prevent a worker from reaching the edge. Instead, it provides protection where a fall could still occur and must therefore be carefully engineered to control fall distance and arrest forces.

A complete fall arrest system can incorporate several different components depending on the application.

Full-Body Harnesses - A full-body harness distributes arrest forces across the body and provides the connection point between the user and the fall protection system.

Harnesses used for fall arrest should be correctly fitted, compatible with the rest of the system and appropriate for the task.

Anchor Points - Fixed anchor points provide secure attachment locations for localised work at height.

Their position and structural suitability are fundamental to the performance of the system.

Horizontal Lifeline Systems - Horizontal lifelines allow workers to move along a roof, platform or structure while remaining continuously connected.

They are commonly used on commercial and industrial rooftops.

Vertical Lifeline Systems - Vertical fall arrest systems provide protection while users climb fixed ladders, towers and other vertical access routes.

Self-Retracting Lifelines and Inertia Reels - Self-retracting devices automatically adjust the connecting line as the worker moves and lock rapidly when a fall is detected.

Energy-Absorbing Lanyards - Energy absorbers help reduce the forces transferred to the worker and structure during an arrested fall.

Connectors - Karabiners and other connectors secure individual components together and must be compatible with the system.

Rescue Equipment - A fall arrest strategy should include appropriate rescue equipment capable of recovering a suspended worker safely.

Different working environments require different forms of fall arrest protection.

Horizontal Fall Arrest Systems - Horizontal fall arrest systems provide continuous attachment across roofs and other long working areas.

They are particularly useful where workers need significant lateral movement.

Vertical Fall Arrest Systems - Vertical systems protect users while climbing ladders, towers, masts and similar structures.

Overhead Fall Arrest Systems - Overhead systems position the anchorage above the worker, helping minimise free-fall distance and swing-fall risk.

They are commonly used above:

• Vehicles
• Machinery
• Production lines
• Loading areas
• Aircraft
• Rail vehicles

Rigid Rail Fall Arrest Systems - Rigid rail systems use a fixed track rather than a flexible cable.

They can reduce deflection and provide smooth movement in demanding overhead environments.

Single Anchor Point Systems - Single anchors are suitable for localised tasks where the user's movement is limited to a defined area.

Temporary Fall Arrest Systems - Temporary systems may be suitable for construction, short-term maintenance or specialist access work where permanent infrastructure is not required.

Permanent Fall Arrest Systems - Permanent fall arrest systems are commonly installed on buildings requiring regular access for maintenance and inspection.

Roofs are one of the most common environments where fall arrest systems are required.

Commercial and industrial rooftops often contain exposed edges, fragile surfaces, rooflights, plant equipment and maintenance zones that cannot always be fully protected using guardrails.

Flat Roofs - Fall arrest systems can provide protection where workers need access close to exposed edges or openings.

Commercial Roofs - Office buildings, retail developments and public buildings often require safe access for routine inspections and maintenance.

Industrial Roofs - Factories, warehouses and manufacturing facilities may require extensive fall arrest systems to support plant maintenance and rooftop access.

Fragile Roof Areas - Fragile roofs require particularly careful planning because a worker may fall through the surface rather than simply over an edge.

Solar Panel Maintenance - Solar installations can create complex access routes and reduce the amount of clear roof space available for guardrails or other collective protection.

HVAC and Plant Access - Rooftop plant, air conditioning units and ventilation systems often require workers to move across exposed roof areas.

Rooflights and Skylights - Unprotected rooflights can create serious fall hazards and should form part of the overall roof safety assessment.

Provides Protection Where Fall Prevention Is Not Practical - Fall arrest allows workers to safely access areas that may not be reachable using restraint or collective protection alone.

Supports Greater Freedom of Movement - Horizontal, vertical and overhead systems can provide extensive mobility across large work areas.

Suitable for Complex Environments - Fall arrest can be engineered around plant, vehicles, structural obstacles and specialist maintenance requirements.

Permanent and Temporary Options - Systems are available for both long-term installations and short-duration projects.

Can Be Integrated with Existing Safety Systems - Fall arrest can form part of a wider strategy incorporating guardrails, walkways, restraint systems and safe access equipment.

Suitable for Roof, Vertical and Overhead Applications - Fall arrest systems are highly versatile and can be adapted to a wide range of industries and working environments.

Roof guardrails and fall arrest systems also perform different roles.

Roof Guardrails

Guardrails provide collective fall protection.

They:

• Protect everyone within the guarded area
• Do not require users to connect to PPE
• Prevent workers from reaching exposed roof edges
• Reduce reliance on individual behaviour

Fall Arrest Systems

Fall arrest systems provide personal protection.

They may be suitable where:

• Guardrails are not practical
• The working area is complex
• Users require access beyond protected zones
• Visual impact is a concern
• Specialist access tasks must be completed

The correct approach should always follow a site-specific risk assessment and the hierarchy of controls.

Fall arrest systems must be designed, installed and used within the wider framework of UK working-at-height requirements.

Work at Height Regulations 2005

The Regulations require duty holders to:

1. Avoid work at height where reasonably practicable.
2. Prevent falls where work at height cannot be avoided.
3. Minimise the distance and consequences of any potential fall where prevention is not possible.

Fall arrest sits within the third stage of this hierarchy.

BS EN 361

BS EN 361 contains requirements relating to full-body harnesses used in personal fall protection.

BS EN 355

BS EN 355 applies to energy absorbers used within relevant fall arrest systems.

BS EN 360

BS EN 360 covers retractable-type fall arresters.

BS EN 795

BS EN 795 relates to certain anchor devices used within personal fall protection systems.

BS 7883

BS 7883 provides guidance relevant to the design, installation, inspection and maintenance of anchor systems.

The exact standards applicable to a project depend on the components and system being specified.

Warehouses & Distribution Centres - Large roofs and loading operations often require fall protection for maintenance personnel.

Vehicle Maintenance Bays - Overhead fall arrest systems can protect workers operating on top of HGVs, tankers, buses and other vehicles.

Manufacturing Facilities - Industrial plant and machinery frequently require elevated maintenance access.

Commercial Buildings - Rooftop maintenance and inspection work can require permanent fall arrest infrastructure.

Data Centres - Critical rooftop systems need reliable access arrangements for engineers and maintenance teams.

Utilities - Water, power and telecommunications infrastructure often involves work on towers, structures and elevated plant.

Rail & Transport - Fall arrest systems can protect workers carrying out maintenance on trains, depots and transport infrastructure.

Aviation - Aircraft maintenance frequently requires overhead protection to reduce fall distance and improve worker movement.

Solar Installations - Solar panel servicing can require access across large and complex roof areas.

Construction & Infrastructure - Temporary and permanent fall arrest systems are widely used during construction, structural works and major maintenance programmes.

Safesite provides fall protection solutions for commercial, industrial and specialist working-at-height environments throughout the UK.

Our services include:

• Site surveys
• Risk assessments
• Fall arrest system design
• Structural and access assessment
• Horizontal lifeline systems
• Vertical fall protection
• Overhead fall arrest systems
• Rigid rail systems
• Anchor solutions
• Professional installation
• Inspection and maintenance
• Testing and recertification where applicable
• Rescue planning support
• Ongoing technical advice

We can also integrate fall arrest with restraint, guardrails, walkways and other working-at-height equipment to develop a complete safety strategy.