It’s one of the most overlooked yet deadly dangers in the workplace: the risk of dropped objects. About every 10 minutes in the United States, a worker is struck by an object that fell from above. Cell phones, buckets, tape measurers, and hammers are just a few of the items that may cause damage if dropped from a jobsite at height.

Among the myriad hazards that corrosion control and protective coatings workers face daily, preventing dropped objects must be a top priority. The stakes are too high to ignore: In 2022 alone, falling objects accounted for 238 deaths and 57,000 injuries in the United States.

The International Safety Equipment Association (ISEA) has taken significant steps to mitigate this hazard with the release of its newly revised American National Standard for Dropped Object Prevention Solutions (ANSI/ISEA 121-2023). The Risks and Costs of Dropped Objects

The term “dropped objects” refers to any non-human object that falls unexpectedly from a height, whether it’s a small screw or a large piece of equipment. A worker operating at heights might need to bring along anywhere from 1 to 20 various tools, materials, or pieces of equipment. Unfortunately, there’s no one-size-fits-all solution for carrying these items at heights, given the diverse shapes and forms involved.

Numerous factors can cause a worker at heights to accidentally drop something. Natural elements, including wind, rain, and snow, have an impact, as do the motions or vibrations of structures. These conditions can significantly affect the worker’s grip, particularly in wet or slippery situations.

Additionally, human errors contribute to the risk. Making misjudgments, handling of tools or equipment improperly, disregarding procedures (intentionally or unintentionally), and using homemade tools or attachments all play a part. Moreover, some falling objects may simply be unsecured debris or parts of equipment.

The hazards associated with dropped objects are numerous and severe. The risks are not only limited to physical harm to workers but also extend to substantial financial costs due to damaged tools, equipment, and other property.

While preventing human falls is critical, protection from falling objects is equally vital. The danger posed by unsecured objects is significant — not only to human safety but also to machinery, building surfaces, and other equipment. For instance, a dropped wrench from a significant height can cause severe damage, such as bursting a pipe, leading to major flooding.

Nate Bohmbach, senior director of Product Management at Ergodyne, a manufacturer of a variety of personal protective equipment (PPE), and chair of ISEA’s Dropped Objects Product Group, noted the importance of this standard. He said that “far more industries face risks from falling objects than they do from human falls.” Therefore, it is imperative to secure all objects to prevent them from detaching and causing harm or damage below. The first step in that is to bring awareness to the issue.

The consequences of dropped objects may include:

● Serious Injuries or Fatalities: Dropped objects can result in severe injuries or death to workers and bystanders. In addition to the tragic human impact, series injuries and fatalities cost companies well over $300 million per year.

● Damage to Tools and Property: Dropped tools can damage other equipment, structures, and the environment.

● Operational Downtime: Retrieving dropped items, and repairing or replacing any machinery or equipment they might have struck, can result in significant downtime. This undermines productivity and adds substantial hidden costs to the contractor and/or asset owner.

● Financial Impacts: The costs of damage can add up quickly and could include higher insurance premiums, accident settlements, and expensive lawsuits. It may also cause contractors to miss additional work with other clients due to a prioritization of fixing those damages.

Compliance and Best Practices

Protection from dropped objects is not merely a safety recommendation but a compliance requirement. The U.S. Occupational Safety and Health Administration (OSHA) mandates that employers address hazards related to falling or dropped objects under its General Industry and Construction standards.

Understanding and implementing proper tethering systems is crucial. It is essential to avoid makeshift solutions, such as duct tape or twine, and instead use equipment that meets the revised ANSI/ISEA 121-2023 standard. This ensures a global best practice for dropped object prevention. It may be an additional investment at the beginning, but it just may help save the company and client money in the end.

The New ANSI/ISEA 121-2023 Standard

ANSI/ISEA 121-2023 is the international benchmark for preventing dropped objects. This standard, unique in its scope and application, sets forth minimum design, performance, testing, and labeling requirements for solutions aimed at reducing dropped object incidents in industrial and occupational settings. In fact, this is the world’s only standard for dropped objects prevention.

To combat the risk of dropped objects, coatings workers need the right tools and training. PPE such as hard hats and safety eyewear are essential in general and in relation to dropped objects, but they are not the only line of defense. Proactive measures must be taken to prevent objects from falling in the first place.

The ANSI/ISEA 121-2023 standard provides comprehensive guidance for employers to minimize the risk of dropped object incidents. It focuses on active solutions, which are proactive measures workers can take to prevent falling objects, as opposed to passive solutions or PPE, which do not prevent objects from falling.

The four active controls outlined in the standard include:

1. Anchor Attachments: These are designed to be installed on structures, equipment, or workers to provide appropriate connection points for tethering.

2. Tool Attachments: These provide appropriate connection points for tethering tools or equipment.

3. Tool Tethers: Lanyards or materials are designed to connect tools to approved anchor points.

4. Containers: Buckets, pouches, and bags are designed to transport tools and equipment to and from heights.

Best Practices for Preventing Dropped Objects

To effectively prevent dropped objects, coatings contractors should follow these best practices:

• Remember the three T’s of dropped objects:

o Trapping: Modify tools to create secure attachment points without impeding their functionality.

o Tethering: Connect tools to sturdy anchors with lanyards, ensuring they remain within reach and do not fall. o Topping: Use containers with secure closures for transporting tools and materials to prevent accidental drops. • Stay In the Know: Ongoing training and adherence to updated safety standards are vital to prevent dropped objects. Regular safety training sessions on the latest safety standards ensure that workers are prepared and equipped to address potential hazards.

• Work Smarter: Preventing dropped objects is not just about having a sure grip on tools. It involves using physical barriers, such as toe boards, and attaching tools to workers or structures to prevent them from falling.

• Conduct Regular Inspections: Regular inspections of tools, equipment, and work areas can help identify potential hazards and prevent dropped objects. Ensure that all tools and equipment are properly secured and in good working condition.

• Use Proper Tethering Systems: Tethering systems that meet the ANSI/ISEA 121-2023 standard should be used to secure tools and equipment. Avoid makeshift solutions, such as duct tape or twine, which can fail and can result in dropped objects.

• Create a Safety Culture: Promote a safety culture within the organization by encouraging workers to report potential hazards and near-misses. Implementing a safety reporting system can help identify and address issues before they result in dropped objects.

• Use Proper Containers: Containers with secure closures should be used to transport tools and materials to prevent accidental drops. Ensure that containers are properly labeled and regularly inspected for damage.

TL:DR

Preventing dropped objects is essential to the workplace safety of anyone working in coatings and corrosion control. As safety professionals say, “If there’s safety up high, no objects should fly.”

The ANSI/ISEA 121-2023 standard, which is available via ISEA’s website, offers a comprehensive framework for mitigating these risks through active solutions that focus on securing tools and materials at heights. By understanding and implementing these guidelines, coatings contractors can significantly reduce the incidence of dropped objects, thereby protecting workers, equipment, and property down below.

Safety isn’t just about wearing the proper PPE. It’s also important to follow the right guidelines and standards and to mitigate risks on site.

Editor’s note: This article first appeared in the September 2024 print issue of CoatingsPro Magazine. Reprinted with permission.