Designing a Fall Prevention System: Tips from Height Safety Engineers
Designing an effective fall prevention system is critical for ensuring worker safety, meeting legal obligations, and minimising operational risks. In Australia, fall-related incidents remain a leading cause of workplace injuries and fatalities. An engineered, standards-compliant fall prevention system drastically reduces these risks.
Here are key tips from experienced height safety engineers to guide the design process.
1. Start with a Comprehensive Risk Assessment
Every fall prevention system should begin with a site-specific risk assessment.
This involves:
- Identifying all areas where workers are exposed to fall risks
- Assessing the nature, duration, and frequency of tasks performed at height
- Considering environmental factors such as weather conditions and roof surfaces
A detailed risk assessment forms the foundation for selecting appropriate control measures and system components.
2. Follow the Hierarchy of Control
Designing a fall prevention system must align with the Hierarchy of Control, prioritising higher-order solutions:
- Eliminate the need to work at heights where possible
- Substitute the hazard with a safer method
- Engineer controls such as walkways, guardrails, and anchor points
- Administrate through safe work procedures and training
- Protect with personal protective equipment (PPE) as a last resort
Effective designs focus on elimination and engineering controls to maximise safety.
3. Integrate Passive Protection Wherever Possible
Passive protection systems, such as guardrails and walkways, require no user intervention and provide continuous fall prevention.
Examples include:
- Roof guardrail systems along edges
- Walkways with slip-resistant surfaces
- Permanent barriers around fragile roofing materials or skylights
Passive systems are preferable because they reduce reliance on worker behaviour and equipment use.
4. Select Certified, Standards-Compliant Equipment
All fall prevention equipment must comply with relevant Australian Standards, including:
- AS/NZS 1657 for walkways, ladders, and guardrails
- AS/NZS 1891 for fall arrest systems, harnesses, and anchor points
Using certified systems ensures your installation meets legal requirements and performance expectations. Always specify products tested to Australian conditions and industry standards.
5. Ensure Safe and Practical Access
Safe access to elevated work areas is a crucial part of any fall prevention system.
Best practices include:
- Designing direct and unobstructed paths to roof or elevated areas
- Using compliant ladders, stairways, and hatches
- Minimising the need for workers to traverse unprotected zones
Access systems should be positioned to avoid creating additional risks during entry or exit.
6. Plan for Maintenance and Inspection
A well-designed fall prevention system is maintainable over its lifespan.
Considerations include:
- Designing access points for easy inspection and servicing
- Using corrosion-resistant materials for external environments
- Establishing a maintenance schedule in line with manufacturer recommendations and Australian Standards
Designing for maintainability ensures the system remains safe and compliant long-term.
7. Incorporate Emergency Rescue Planning
Fall prevention systems must be complemented by rescue plans. Engineers should:
- Identify rescue anchor points where necessary
- Allow space for safe retrieval of workers in the event of a fall
- Coordinate rescue systems with fall arrest systems during the design phase
Rescue capability is a legal requirement under Australian WHS regulations and must not be an afterthought.
Final Thoughts
Designing a fall prevention system requires a methodical, engineering-led approach focused on eliminating hazards, maximising passive protection, and ensuring ongoing compliance.
By engaging certified height safety engineers and prioritising solutions that align with the Hierarchy of Control, businesses can create safer workplaces, reduce liability, and meet Australian WHS obligations.
