Document
U.S. DEPARTMENT OF TRANSPORTATION ORDER FEDERAL AVIATION ADMINISTRATION IR 3900.72A Aircraft Certification Service Effective Date: 03/03/2023 SUBJ: Aircraft Certification Service (AIR) Fall Protection Program (FPP) The Aircraft Certification Service (AIR) Fall Protection Program (FPP) is an element of the AIR Occupational Safety and Health (OSH) Program and establishes the minimum requirements for fall protection of AIR employees. This program outlines the requirements that must be met to achieve an effective FPP.
If desired by office management, this program may be enhanced to address local workplace conditions. Office-specific programs developed at the branch level are allowed as long as they are equal to or more stringent than this FPP.
The requirements detailed in this document are based upon Federal Aviation Administration (FAA) Order 3900.19, Federal Aviation Administration (FAA) Occupational Safety and Health (OSH) Policy, Chapter 4; Fall Protection applicable portions of Occupational Safety and Health Administration (OSHA) 29 CFR 1910, 29 CFR 1926; and industry consensus standards. AIR management and employees must implement the requirements found herein.
Falls from elevated working surfaces (at or greater than 4 feet above the next lower level) present a significant risk of death or serious injury to workers. Falls from aircraft working surfaces, work platforms, ladder stands, and aerial devices are potential sources of serious injuries and fatalities. Falls are unplanned events. Individuals who believe that they will be able to "catch" themselves, and prevent the fall, are generally mistaken.
Digitally signed by LISA
LI SA-ANN L
ANN L MANSFIELD Date: 2023.03.03
MANSFIELD
12:17:15-05'00' Lisa Mansfield Director, Enterprise Operations Division Aviation Safety Aircraft Certification Service Distribution: Electronic Initiated By:AIR-900 03 / 03 / 2023 IR 3900.72A Table of Contents Paragraph Page Chapter 1. General Information ............................................................................................... 1-1 1. Purpose of This Order. ................................................................................................ 1-1 2. Audience ...................................................................................................................... 1-1 3. Where Can I Find This Order ...................................................................................... 1-1 4. What this Order Cancels .............................................................................................. 1-1 Chapter 2. Roles and Responsibilities ...................................................................................... 2-1 Executive Director, Aircraft Certification Service (AIR-1) . ....................................... 2-1 1.
Director, Enterprise Operations Division {AIR-900). ................................................. 2-1 2.
3. AIR Managers. ............................................................................................................ 2-1 4. AIR Fall Protection Program-Program Manager (FPP-PM) ....................................... 2-2 5. Local AIR OSH POCs ................................................................................................. 2-2 6. AIR Employees. .......................................................................................................... 2-3 Chapter 3. Fall Protection Program Requirements ................................................................ 3-1 1. Unsatisfactory Condition Report (UCR) ..................................................................... 3-1 2. Aviation Safety (AVS) OSH Policy Statement. .......................................................... 3-1 3. Scope of FAA at External Industry Workplaces . ........................................................ 3-1 4. Identification of Potential Fall Hazards ....................................................................... 3-1 5. Hazard Control Measures ............................................................................................ 3-2 Fall Prevention and Protection. ................................................................................... 3-2 6.
External Industry Workplace Orientation and Training .............................................. 3-3 7.
8. Inspection of Personal Fall Arrest Equipment, Devices and Systems. ....................... 3-4 9. Fall Prevention Systems. ............................................................................................. 3-5 10. AIR Training Requirements. ....................................................................................... 3-6 11. Acquisition of Fall Protection Equipment. .................................................................. 3-7 12. Program Evaluations. .................................................................................................. 3-8 Chapter 4. Administrative Information ................................................................................... 4-1 1. Distribution .................................................................................................................. 4-1 2. Authority to Change This Order .................................................................................. 4-1 3. Suggestions for Improvements .................................................................................... 4-1 4. Records Management. ................................................................................................. 4-1 03 / 03 / 2023 IR 3900.72A Table of Contents Paragraph Page Appendix A. Fall Protection Definitions ................................................................................. A-1 Appendix B. Fall Protection Information ................................................................................ B-1 Appendix C. Additional Guidelines for Personal Fall Arrest Systems (PFAS) .................. C-1 Appendix D. Applicable Standards and Regulations ............................................................ D-1 Appendix E. Directive Feedback Information ........................................................................ E-1 03 / 03 / 2023 IR 3900.72A Chapter 1. General Information 1. Purpose of This Order. The purpose of this order is to provide requirements and guidelines to protect AIR personnel from falls while performing work related duties on or near unprotected elevated working surfaces that are at or greater than 4 feet above the next lowest level. This order is applicable to industrial-type work locations and aircraft accident investigation sites.
Additionally, this order assists in the identification and evaluation of fall hazards to which employees may be exposed and to provide specific training as required by the Occupational Safety and Health Administration (OSHA) Fall Protection Standards. It is beyond the scope of this document to address slip/trip/fall hazards in office environments. Appendix A, Fall Protection Definitions, defines many of the terms used in this order.
2. Audience. This program applies to all AIR personnel, supervisors, and managers involved in aircraft surveillance activities to include aircraft accident investigations and other work-related duties on or near elevated working surfaces that are at or greater than 4 feet above the next lowest level.
3. Where Can I Find This Order. You can find this order on the FAA employee website at Orders and Notices, on the FAA public website at Orders and Notices and in the Dynamic Regulatory System (DRS).
4. What this Order Cancels. IR 3900.72, Aircraft Certification Service (AIR) Fall Protection Program (FPP), dated April 9, 2018 is cancelled.
1-1 03 / 03 / 2023 IR 3900.72A Chapter 2. Roles and Responsibilities 1. Executive Director, Aircraft Certification Service (AIR-1). AIR-1 must ensure resources are available to effectively implement and maintain the FPP throughout the AIR organization.
2. Director, Enterprise Operations Division (AIR-900). Director, Enterprise Operations Division must: a. Oversee the overall implementation and maintenance of the FPP in the AIR organization.
b. Designate an AIR FPP-Program Manager (FPP-PM) to oversee the program and to provide the necessary technical support to AIR Divisions as needed.
c. Ensure employee participation in the FPP.
d. Ensure AIR OSH POCs located in different regions received initial AIR provided fall protection training that meets the basic requirements of a competent person.
e. Evaluate the completeness and quality of the FPP elements through FPP effectiveness reviews.
3. AIR Managers. AIR managers must: a. Implement the requirements of this program based on applicability.
b. Have the authority to determine whether there is a need for the acquisition of FAA-issued fall protection equipment and if so, contact the AIR OSH Program Office prior to any purchases.
With the understanding that a large majority of AIR inspectors who perform work activities on elevated work surfaces at or greater than 4 feet above the next lowest level will use the external industry workplaces' fall protection equipment.
c. Coordinate with a Local AIR Office OSH POC if program is applicable to the office.
Their duties would include, but are not limited to: assisting as needed in the procurement, training, accountability, and maintenance of fall safety equipment acquired by the office, if needed.
d. Identify employees whose duties may require them to work on elevated platforms at or greater than four feet from the next lowest level and/or use fall protection equipment. Ensuring that these employees receive initial AIR-provided fall protection training prior to performing any work-related activities that may involve the use of fall protection equipment. Fall protection training provided by former employers, with the exception of Flight Standards Service (FS); or external industry workplace provided fall protection training does not qualify an individual to utilize fall protection equipment.
e. Perform an annual self-evaluation of the office FPP, if applicable, to ensure that users of fall protection equipment have received initial AIR or PS-provided fall protection training: and users are properly using, storing, inspecting and maintaining fall protection equipment, if 2-1 03 / 03 / 2023 IR 3900.72A provided by AIR. The evaluation must be in writing and maintained at the local branch office.
A copy of the office FPP evaluation must be provided to the AIR OSH Program Office within 30 calendar days of its completion.
f.
Request assistance from the AIR OSH Program Office or FPP-PM when needed.
g. Report any falls or near misses in accordance with accident reporting requirements in FAA Order 3900.19, and report via FAA Form 3900-6.
4. AIR Fall Protection Program-Program Manager (FPP-PM). The AIR FPP-PM out of the AIR OSH Program Office must: a. Be responsible for the establishment of the AIR-wide FPP and have responsibility for ensuring this FPP is current with FAA, OSHA, and other applicable standards and re lations as gu noted in appendix C.
b. Coordinate with organizational OSH professionals who provide oversight and subject matter expertise for FPP activities.
c. Support the implementation of fall protection requirements by AIR offices and evaluating the responsible offices regarding implementation of this program.
d. Serve as the point-of-contact (POC) regarding technical aspects of the AIR FPP and provide consultation to any AIR division regarding issues relating to fall protection and implementation of the FPP requirements.
e. Determine fiscal planning and cost estimation for FPP implementation and maintenance.
f. Serve as the technical POC for the FPP and assist local AIR OSH POCs with implementation support, if deemed applicable.
g. Be trained to the competent person level and maintain certification in accordance with American National Standards Institute (ANSI) requirements.
h. Perform annual program evaluation of the FPP to ensure effectiveness and make changes to program requirements, if needed based on evaluation findings.
i. Conduct safety hazard analyses (SHAs) at external industry workplaces to determine the ration of fall protection systems, such as fall arrest, climbing protection, and rescue, and confi gu post findings on the MyFAA AIR OSH website. Also assess aircraft accident safety hazard analysis (SHA) conducted by FS for any fall protection recommendations.
j. Assess fall protection related training to ensure it meets the requirements and intent of this FPP.
5. Local AIR OSH POCs. The Local AIR OSH POCs, based on program applicability within an office, must: 2-2 03 / 03 / 2023 IR 3900.72A a. Assist manager/supervisor with ensuring office compliance with this program order.
b. Receive initial AIR or FS provided fall protection training that meets the basic requirements of a competent person and become familiar with the mandatory requirements contained in this order.
c. With assistance from the AIR FPP-PM, based on input from employees and managers to help determine whether or not the office will provide the fall protection equipment, if they will use the external industry workplace's equipment, or if there will be a combination of the two options.
d. Contact the AIR OSH Program Office prior to the purchase of any fall protection equipment.
e. Inspect and maintain office-provided fall protection equipment (if applicable), including the inspection along with equipment user(s) prior to issuing and upon its return for damage or defects, and ensure it is properly stored along with appropriate recordkeeping and documentation.
6. AIR Employees. AIR employees must: a. Become familiar with and comply with the requirements contained in this FPP order to include appendices B and C if their job may expose them to fall hazards from elevated working surfaces at or greater than 4 feet above the next lowest level, requiring the use of fall protection equipment.
b. Not use fall protection equipment until they have received initial AIR or FS provided fall protection training.
c. Use fall protection systems in accordance with training received.
d. Not subject themselves to fall hazards on or near unprotected elevated working spaces that are at or greater than 4 feet above the next lowest level, use defective fall protection equipment, or perform any function that they feel may expose them to potential injury.
e. Perform the prior-to-use inspection on any fall protection equipment for damage or defects and follow the guidance contained in this FPP and provided in the training.
f. Be familiar with external industry workplace specific rescue/retrieval plans and fall protection communication methods.
2-3 03 / 03 / 2023 IR 3900.72A Chapter 3. Fall Protection Program Requirements 1. Unsatisfactory Condition Report (UCR).
a. Background. No employee is expected to perform work activities that subject them to an unsafe or unhealthful work condition. If an employee is potentially exposed to an unsafe or unhealthful condition or a fall hazard, they must not perform the task until the hazard is remediated. If it cannot be corrected or there are no alternative measures that can be taken to address the hazard, the employee must not complete the activity.
b. UCR Reporting. Preferably, the hazardous condition should be discussed with the supervisor to abate the unsafe condition. However, any employee or employee representative who believes that an unsafe or unhealthful working condition exists must have the right to make a report of the unsafe or unhealthful working condition to an appropriate agency safety and health official and request an inspection of the workplace.
c. Filing an UCR. Although an employee may convey the unsatisfactory condition verbally to their supervisor, it is recommended that an employee file a UCR. See the current edition of FAA Order 1800.6, Unsatisfactory Condition Report, for further instructions.
2. Aviation Safety (AVS) OSH Policy Statement. Per the AVS OSH Policy Statement, "Employees who determine their duties cannot be performed due to unsafe work activities or working environments must disengage from the activity or work environment and immediately notify their frontline supervisor."
3. Scope of FAA at External Industry Workplaces. The FPP addresses AIR employees working in external industry workplaces (e.g., manufacturers, suppliers) where the FAA does not have the authority to abate hazardous conditions. The external industry workplace has the responsibility to identify elevated working surfaces (at or greater than 4 feet above the next lowest level) and apply the appropriate control measures. However, the FAA is ultimately responsible for the safety and health of its employees. AIR employees must be trained to recognize elevated working surfaces and be able to determine whether adequate safeguards have been installed or if a Personal Fall Arrest System (PFAS) is required. If AVS employees recognize a condition that presents a dangerous fall hazard in the absence of fall protection equipment, they may refuse to access the height until the external industry workplace provides a safer and more suitable means for working at that elevation or an alternative solution is achieved (e.g., photographs or video).
4. Identification of Potential Fall Hazards. AIR employees in the course of surveillance activities may be required to observe work being performed on or from elevated work areas.
Many of these work areas present the potential for falls. In some cases, engineered fall protection, such as a standard guardrail system, is not possible or the employer under surveillance has inadvertently created a potential fall hazard. Examples include: a. Improperly erected scaffolding, work stands and ladder stands that are not appropriate for the application; 3-1 03 / 03 / 2023 IR 3900.72A b. Wing and tail surfaces; c. The surface of the fuselage crown; d. Use of aerial lift and scissor lift devices during manufacturing of aircraft; e. Open aircraft service doors and bays; unsecured temporary flooring during aircraft manufacturing; f. Floor holes and openings in temporary flooring and scaffolding; g. Movable bridge or dock plates for access to the interior of aircraft used when the work stand does not get close enough to the aircraft; and h. Potential elevated surfaces or high terrain areas at aircraft accident sites.
5. Hazard Control Measures.
a. Hierarchy of Controls for Fall Hazards. The hierarchy or the preferred order of control measures for fall hazards is first and foremost to eliminate the exposure to the hazardous condition. However, due to the nature of an AIR employee's role, this is not always possible; especially at an external industry workplace and aircraft accident investigation work site. If it is not possible, the employee must employ other methods to mediate the fall hazard. Employees and their supervisor must carefully exercise professional judgment when determining the need to survey a work activity that presents a significant risk of a fall.
b. Addressing the Fall Hazard. The preferred hazard control methods for addressing fall hazards are: (1) Elimination. Removing the hazard from a workplace or allowing the work to be done from the ground if this is an acceptable/approved practice (e.g. telescoping tools or use of drones) for aircraft surveillance activities. This is the most effective control measure.
(2) Engineering Controls. If the hazard cannot be eliminated, using an engineering control is the next-preferred measure to control the risk. An example is the installation of a standard guardrail system and barriers on the elevated work platform.
(3) Personal Protective Systems and Equipment (PPE). These must be used after other control measures are determined not to be practical. Other methods of performing the work that requires PPE may include observing work activities from an aerial lift device or utilizing a PFAS. The employee always has the right to discontinue the task if they feel the task cannot be accomplished safely.
6. Fall Prevention and Protection.
a. Fall Prevention. Fall prevention measures involve, for example, the installation of guardrail systems on ladder stands and platforms, guarding of wall openings using standard guardrail systems, and properly covering floor holes and openings when not in use. These 3-2 03 / 03 / 2023 IR 3900.72A measures consist of permanent, passive systems that do not require training to use effectively, but do require planning on the part of the external industry workplace.
b. Fall Protection.
(1) When fall prevention measures are not feasible due to location, or are not practical for the work situation under observation, personal fall protection must be considered. Whenever training and/or PPE is required, it is fall protection not fall prevention.
(2) The overall objective of fall protection is to minimize the potential for injury because of a fall. Items required for personal fall protection include, but are not limited to, a fall arrest body harness (Class 3), shock-absorbing lanyards, rope grabs, vertical and horizontal lifelines, retractable lifelines, and appropriate anchorage.
(3) Use of a "body belt" or "lineman's belt" as part of a fall protection system is strictly prohibited and must never be used by any AIR personnel.
( 4) Personnel lifting devices such as scissor lifts, boom trucks, or other aerial lift devices, may be available at many work locations. These devices offer a means of access to elevated work locations. When aerial devices (except scissor lifts) are used, personal fall protection (i.e., body harness and lanyard) must be used. Personal fall protection (i.e., body harness and lanyard) is required in a scissor lift only if the platform will be extended. However, fall protection must be worn if required by operator.
( 5) AIR employees must not operate aerial lifts, scissor lifts, or other personnel lifting devices, unless an emergency arises in which the operator is unable to lower/operate the lift.
7. External Industry Workplace Orientation and Training.
a. AIR Personnel Training. Prior to working on elevated working surfaces that are at or greater than 4 feet above the next lowest level, applicable AIR personnel must receive initial fall protection training provided by either AIR or FS by a Fall Protection Competent Person. The training will include the requirements contained in this document, the proper utilization and inspection of a full-body harness, use and inspection of fall arrest systems, and inspection techniques to ensure that an effective engineered fall prevention system, such as a standard guardrail system, is in place.
b. Assessing the Need for Equipment. It is the responsibility of each office manager or their designee to assess the need for AIR-issued fall protection equipment versus using the external industry workplace's equipment or a combination of the two options. If AIR-issued fall protection equipment is needed, notify the AIR OSH Program Office.
c. Management Notification. Because of the design specifications of many fall protection systems, the external industry workplace will likely require the AIR employee to use their fall protection equipment (i.e. body harness and lanyard). This is the most common scenario.
However, the AIR employee must notify their immediate supervisor and apprise them of the external industry workplace's fall protection requirements before proceeding further. The 3-3 03 / 03 / 2023 IR 3900.72A manager/supervisor should contact the AIR OSH Program Office for assistance with obtaining training for the employee, if they are not already trained.
d. Prior Fall Protection Training. Each branch office manager or their designee must ensure that before personal fall protection equipment is utilized, the AIR employee has received initial AIR or FS provided fall protection training that includes these program requirements.
Additionally, the AIR employee must receive the external industry workplace's training, if they require it. For this program, initial AIR employee general safety and health training, fall protection training provided by former employers, or external industry workplace-provided fall protection training are not sufficient to qualify an AIR employee to utilize fall protection equipment.
e. Safe Work Requirements. The AIR employee is required to follow the safe work requirements established by the external industry workplace unless a requirement is deemed to create a potential hazard.
f. Retraining and Refresher Training. If actions or conditions show inadequacies in the employee's knowledge or the systems they use change or become obsolete, the employee must be retrained. All AIR-provided fall protection training must be refreshed every 2 years if the employee is actively using fall protection systems. The AIR OSH Program Office will coordinate the refresher training.
8. Inspection of Personal Fall Arrest Equipment, Devices and Systems.
a. Fall Arrest System Inspection. If it is necessary for an AIR employee to utilize personal fall protection for the observation of a work activity, the employee must perform an inspection of the fall arrest system. In most cases, the fall arrest system was designed, installed and under the control of the external industry workplace. Therefore, basic questions must be asked of the external industry workplace and a visual inspection of the components of the fall arrest system must be made. Never assume that simply because employees of the external industry workplace are using the system that the system is safe for use.
b. Additional Guidance. Appendices A, Fall Protection Definitions, and B, Fall Protection Information, provide additional requirements and guidance on inspection.
c. Before Using ANY PFAS. The following criteria should be followed before using any PFAS: (1) Ascertain if the fall arrest system and the anchorage was designed by a registered professional engineer or a fall protection qualified person. If documentation is not available, do not use the system. Determine if the system is under the supervision of a qualified person.
(2) Inspect the connectors, snaphooks and D-Rings for corrosion or deformities. If any apparent visible damage is observed, do not use it.
(a) Snaphooks must be the locking type with a self-closing, self-locking keeper, which remains closed and locked until unlocked and pressed open for connection or disconnection. It will require two actions to open. This is the only type allowed for use by 3-4 03 / 03 / 2023 IR 3900.72A OSHA. Snaphooks that comply with the newer consensus standards will have a gate that can withstand 3,600 pounds.
(b) Snaphooks may not be engaged directly to webbing, rope, or wire rope, to each other, or to a D-Ring to which another snaphook or other connector is attached, unless it was specifically designed to do so.
(c) Snaphooks must not be attached to any object which is incompatibly shaped or dimensioned in relation to the snaphook, such that unintentional disengagement (also called rollout) could occur by the connected object being able to depress the snaphook keeper and release itself.
(3) Ensure that horizontal lifelines have been designed and maintained with a minimum safety factor of 2 and note whether it is designed for multiple users, which should be shown on the engineering documentation.
(4) Physically examine the body harness and the safety lanyard for cuts, snags or other defects in the webbing in accordance with the AIR or FS-sponsored training; check for chemical contamination from oils or grease; note any de-stitching or evidence that the equipment was subjected to impact loading (used to arrest a previous fall). If any of these conditions are observed, do not use them.
(5) Ensure that all ropes and straps (webbing) used in lanyards, lifelines, and strength components of body harnesses are labeled with the manufacturer's name and certification(s).
(6) All U.S. fall protection equipment must be tested to American National Standards Institute (ANSI)/American Society of Safety Professionals (ASSP) Z359 Fall Protection and Arrest Standards (listed on labels). Before using an international facility's fall protection equipment, the AIR employee should consult AIR FPP-PM for foreign equipment equivalencies.
(7) Never use fall protection devices such as harnesses and lanyards for material handling or hoisting. If the equipment has been seen in this arrangement, do not use the external industry workplace's equipment until their systems can be evaluated.
(8) If an FAA-owned harness or lanyard fails the prior-to-use or annual inspection, the AIR employee or their manager will send it to the AIR OSH office.
9. Fall Prevention Systems.
a. Standard Guardrails. The majority of elevated surveillance activities conducted by AIR employees are performed on systems that provide protected walking and working surfaces such as scaffolding, work platforms, and aerial lifts. These systems need to be equipped with standard guardrails on all open sides and with a closure apparatus for ladder and stairway openings or other points of access.
b. Scaffolding Decks. Scaffolding decks must be fully planked with no gaps or openings.
Temporary flooring must be secured from movement when live weight is applied. If temporary 3-5 03 / 03 / 2023 IR 3900.72A floor coverings are not secured, exit the area and ask the external industry workplace to secure them from movement.
c. Manually Propelled Ladder Stands, Stairways, and Scaffolding. OSHA requires a minimum of two brakes to be engaged for portable stands and platforms. If a ladder stand, rolling stairway, or scaffolding rolls when you step onto it or flexes laterally, verify at least two brakes (caster locks) are engaged. Some stands have more than four brakes/casters. If this is the case, it is recommended that at least half of the casters be locked. Additionally, all ladder stands and scaffolds shall be capable of supporting at least four times the design working load.
d. Floor Openings and Holes. OSHA requires floor openings or holes on platforms, walkways or in floors to be guarded with a standard guardrail or covered with a cover capable of supporting the maximum potential load to which they may be subjected. Covers must be secured against displacement. In many certification/surveillance or repair situations, such hazards may not be mitigated in accordance with OSHA. The AIR employee must assess the area and determine whether or not they can enter and perform their work safely. Where necessary, the AIR employee should have the external industry workplace secure covers, install guards, or otherwise mitigate hazards prior to commencing activities that would put them at risk.
e. Lifts. If the need to utilize a personnel lifting or hoisting device arises, the AIR employee riding in or working from boom lifts must secure their fall protection lanyard to the device's engineered anchorage point at all times. Never secure the lanyard to a guardrail unless the guardrail system was designed for that purpose. Ensure that the lifting device is placed on a solid level surface so that the probability of overturning is reduced. If it is equipped with outriggers, they must be extended properly. Ensure that the capacity of the lifting device will not be exceeded (capacity rating must be posted on the lift) and that it has a minimum design carriage rating for two individuals and equipment. In no case must an AIR employee independently operate the lifting device, unless an emergency arises in which the operator is unable to lower/operate the lift.
f. Fall Clearance for Horizontal Lifelines. Care should be exercised when using horizontal lifelines located at or near the walking-working surface. This type of installation may result in a free fall distance greater than six feet. Therefore, extreme caution must be exercised when tying-off and using this type installation.
10. AIR Training Requirements. The use of personal fall protection systems necessitates proper training, which includes identifying fall hazards and an understanding of how to use the equipment, proper inspection, its capabilities, and its limitations.
a. Training Requirements. Training in the use and evaluation of fall protection systems and devices must be provided to all AIR employees who may be potentially exposed to fall hazards related to elevated working surfaces that are at or greater than 4 feet above the next lowest level. At a minimum the training must include: (1) The contents of the AIR fall protection standards and regulations.
(2) The nature of potential fall hazards AIR employees are likely to encounter during work activities.
3-6 03 / 03 / 2023 IR 3900.72A (3) The correct procedure for donning full-body safety harnesses and using fall protection lanyards and lifelines, including retractable lifelines.
( 4) Proper handling, storing, maintaining, and inspecting of fall protection equipment.
(5) The proper use and the limitations of the systems they may encounter.
(6) The AIR employee's role regarding the use of fall protection.
b. Initial and Refresher Training. Initial training must be provided at the time of initial assignment to tasks requiring the potential use of fall protection PPE. Refresher training is required every 2 years for AIR employees who have been using or are likely to use fall protection systems that required donning a harness. If actions or conditions show inadequacies in the employee's knowledge or the systems they use change or become obsolete, the employee must be retrained.
c. Training Classes. The AIR FPP-PM will assist in facilitating classes to ensure that AIR FPP students must be knowledgeable in the subject matter. The branch offices will be notified of the classes via the AIR Workforce Development Branch in coordination with the AIR OSH Program Office.
d. Documentation. All training must be properly documented in the FAA's official electronic training information system. Documentation of training must include a written certification record that contains the name or other identifier of the employee, the date of training, and the name of the qualified trainer who performed the training.
e. Additional Information. Appendix B, Fall Protection Information, and Appendix C, Additional Guidelines for Personal Fall Arrest Systems (PFAS), provide additional information for fall protection training.
11. Acquisition of Fall Protection Equipment.
a. Purchasing Fall Protection Equipment. Normally an AIR employee will be using external industry workplace-provided fall protection equipment, but there will be rare situations where the local branch office may need to purchase fall protection equipment. This will require AIR FPPM review and approval.
b. Fall Protection Equipment Assessment. It is the responsibility of branch office management, with consultation from the AIR OSH Program Office to determine the need for and acquisition of fall protection equipment for their employees.
c. Approved Equipment. AIR branch offices have to ensure fall protection equipment is approved not only by local management, but also by AIR FPP-PM prior to purchase. Funding for this type of personal protective equipment (PPE) will be handled at the branch office level.
d. Full-Body Harness and Other Protection Devices. Full-body harnesses that were tested in accordance with ANSI/ASSP Z359 must be the only harnesses used in the United States. For international testing requirements, consult with the AIR FPP-PM for equivalencies.
3-7 03 / 03 / 2023 IR 3900.72A The use of a body belt, also known as a lineman's belt, is prohibited for fall protection. Fall protection lanyards used by AIR personnel must have shock absorbers integrally integrated into the lanyard. The lanyards must not exceed 6 feet in length.
e. Full-Body Harness and Lanyard Limitations. Full-body harnesses and lanyards have limitations regarding overall weight/working capacity. This includes the weight of the worker, tools, clothes, etc...
(1) The ANSI standard outlines requirements for the harnesses and lanyards and states that their general off-the-shelf capacity must be 130 - 310 pounds.
(2) However, if the person and equipment weigh less than 130, or more than 310 pounds, specially designed harnesses and lanyards are available. Since ANSI has released testing requirements for harnesses/lanyards that can have higher capacity ratings, most major manufacturers have manufactured harnesses/lanyards with ratings of 420 pounds. The labels and manufacturer's instructions will indicate the capacity ratings.
(3) If the person's overall weight is outside the general working range of 130 to 310 pounds, they must: (a) Not use the external industry workplace's harnesses/lanyards unless its capacity has been verified.
(b) Verify with the external industry workplace that the system to which the harness and lanyard will be connected to (e.g., horizontal lifeline or self-retracting lifeline (SRL)) has been engineered to safely arrest the fall for those weighing less than 130 or more than 310 pound forces.
12. Program Evaluations.
a. Level and Frequency of Evaluation. The effectiveness of the FPP must be evaluated at the Individual and the Program level.
(1) Individual Level. The evaluation at the individual level must take place annually to evaluate the effectiveness of the FPP and to determine if there are any changes to equipment needs.
(2) Program Level. The program level evaluation must occur annually by responsible branch office management with assistance provided by the AIR FPP-PM. The fall protection program elements must be reviewed annually for quality and effectiveness.
b. Evaluation Tools. Program evaluation-related questions will be distributed annually as a job aid for completing the individual level evaluations.
c. Documentation. The findings of the program evaluation must be documented and must include recommendations for program corrections, modifications and additions. This documentation must be kept for 5 years.
3-8 03 / 03 / 2023 IR 3900. 72A Chapter 4. Administrative Information 1. Distribution. This order is distributed to AIR headquarters (HQ) management, all AIR branch offices, branches, facilities, and AIR employees involved with work in elevated areas.
2. Authority to Change This Order. The issuance, revision, or cancellation of the material in this order is the responsibility of the AIR Enterprise Operations Division (AIR-900).
3. Suggestions for Improvements. Please forward all comments on deficiencies, clarifications, or improvements regarding the contents of this order to: The AIR Directives Management Officer to AIR OMO Mailbox Your suggestions are welcome. FAA Form 1320-19, Directive Feedback Information, is located in appendix E to this order for your convenience.
4. Records Management. Refer to FAA Order 0000.1, FAA Standard Subject Classification System; FAA Order 1350.14, Records Management; or your office Records Management Officer (RMO)/Directives Management Officer (OMO) for guidance regarding retention or disposition of records.
4-1 03/03/2023 IR 3900. 72A Appendix A Appendix A Fall Protection Definitions 1. Aerial Lift. Any vehicle-mounted device, telescoping or articulating, or both, which is used to position personnel. This does not include scissor lifts.
2. Anchorage. A secure point of attachment for lifelines, lanyards or deceleration devices.
3. Body Harness. Straps which may be secured about the employee in a manner that will distribute the fall arrest forces over the thighs, pelvis, waist, chest and shoulders and which can be attached to other components of a Personal Fall Arrest System (PFAS).
4. Competent Person. An individual knowledgeable of fall protection equipment who is capable of identifying existing and potential fall hazards, and who is knowledgeable of applicable rules, standards, and regulations regarding the erection, use, inspection, and maintenance of fall protection equipment and systems.
5. Connector. A device used to couple (connect) parts of the PFAS and positioning device systems together.
6. Deceleration Device. Any mechanism, such as a rope grab, shock-absorbing lanyard, or automatic self-retracting lifeline (SRL)/lanyard, which dissipates a substantial amount of energy during a fall arrest, or otherwise limits the energy imposed on an employee during fall arrest.
7. Deceleration Distance. The additional vertical distance a falling employee travels, excluding lifeline elongation and free fall distance, before stopping, from the point at which the deceleration device begins to operate. It is measured as the distance between the location of an employee's body harness attachment point at the moment of activation (at the onset of fall arrest forces) of the deceleration device during a fall, and the location of that attachment point after the employee comes to a full stop.
8. Floor Hole. A gap 2 inches (5.1 cm) or more in its least dimension in a floor, roof, or other walking-working surfaces.
9. Floor Opening. An opening measuring 12 inches or more in its least dimension, in any floor, platform, pavement, or yard through which persons may fall; such as a hatchway, stair or ladder opening, pit, or large manhole.
10. Free Fall. The act of falling before a PFAS begins to arrest the fall.
11. Free Fall Distance. The vertical displacement of the fall arrest attachment point on the employee's body harness between onset of the fall and just before the system begins to apply force to arrest the fall.
12. Guardrail System. See Standard Guardrail definition.
A-1 03/03/2023 IR 3900. 72A Appendix A 13. Ladder Stand. A mobile, fixed size, self-supporting ladder consisting of a wide flat tread ladder in the form of stairs. The assembly should include handrails.
14. Lanyard. A line of rope, wire rope, or synthetic webbing which generally with a connector at each end, for connecting the body harness to a deceleration device, lifeline, or anchorage.
15. Lifeline. A component consisting of a flexible line for connection to an anchorage at one end to hang vertically (vertical lifeline), or for connection to anchorages at both ends to stretch horizontally (horizontal lifeline), and which serves as a means for connecting other components of a PFAS to the anchorage.
16. Lower Levels. Those areas or surfaces onto which an employee can fall. Such areas or surfaces include, but are not limited to ground levels, floors, platforms, ramps, runways, cargo holds or portions thereof.
17. Personal Fall Arrest System (PFAS). A system used to arrest an employee in a fall from a working level. It consists of an anchorage, connectors, and body harness and may include a lanyard, deceleration device, lifeline, or suitable combinations of these.
18. Rope Grab. A deceleration device which travels on a lifeline and automatically, by friction, engages the lifeline and locks so as to arrest the fall of an employee. A rope grab usually employs the principle of inertial locking, cam/level locking, or both.
19. Self-Retracting Lifeline/Lanyard (SRL). A deceleration device containing a drum-wound line which can be slowly extracted from, or retracted onto, the drum under slight tension during normal employee movement, and which, after the onset of a fall, automatically locks the drum and arrests the fall. Most have a deceleration device built into the inner mechanisms. Some SRLs have a decent device integrated into the unit that will lower the fallen worker at a moderate rate of speed after the fall has been arrested.
20. Scissor Lift. A type of lift that travels only straight up and down and does not articulate outward or have an extensible boom. Scissor lifts are classified as mobile scaffolding.
21. Snaphook. A connector is comprised of a hook-shaped member with a normally closed keeper, or similar arrangement, which may be opened to permit the hook to receive an object and, when released, automatically closes to retain the object. The locking type with a self closing, self-locking keeper which remains closed and locked until unlocked and pressed open for connection or disconnection is the only type allowed for use by OSHA regulations. The latest ANSI standard requires the gate of snaphooks to withstand 3600pound forces.
22. Standard Guardrail. A standard railing consisting of a top rail, intermediate rail, and posts, and which has a vertical height of 42inches (plus or minus 3-inches) from the upper surface of the top rail to floor, platform, runway, or ramp level. The top rail shall be smooth-surfaced throughout the length of the railing. The intermediate rail shall be approximately halfway between the top rail and the floor, platform, runway, or ramp.
A-2 03/03/2023 IR 3900. 72A Appendix A 23. Unprotected Sides and Edges. Any side or edge (except at entrances to points of access) of a walking-working surface (e.g., open doorway, floor, roof, ramp, or runway) where there is no wall or compliant guardrail system.
24. Unsatisfactory Condition Report (UCR). Provides all agency employees with direct means for advising management of an existing unsatisfactory condition per FAA Order 1800.6, Unsatisfactory Condition Report. Although the condition may be an isolated occurrence, the collection and tracking of reports via the Safety Management Information System (SMIS) may assist in the identification of trends or patterns that require a broader corrective action than may be apparent from a single occurrence.
25. Walking-Working Surface. Any surface, whether horizontal or vertical on which an employee walks or works, including, but not limited to, wing and tail surfaces, fuselage crown, floors, roofs, ramps, bridges, runways, and work platforms.
26. Wall Opening A gap or voids 30 inches or higher and 18 inches or wider, in a wall or partition, through which employees can fall to a lower level.
27. Work Area. The portion of a walking-working surface where job duties are performed.
A-3 03 / 03 / 2023 IR 3900. 72A Appendix B Appendix B. Fall Protection Information 1. Fall Protection Categories. All fall protection products fit into four functional categories: a. Fall Arrest. A fall arrest system is required if any risk exists that a worker may fall from an elevated position, as a general rule, the fall arrest system should be used anytime a working height of 4 feet or more is reached. A fall arrest system will only come into service should a fall occur. A full-body harness distributes the forces throughout the body, and the shock-absorbing lanyard decreases the fall arresting forces.
b. Positioning. This system holds the worker in place while keeping their hands free to work. Whenever the worker leans back, the system is activated. The personal positioning system is not allowed to be used as the arrest system. This is commonly used by tower climbers.
c. Suspension. Suspension equipment can be a system that lowers and supports the worker while allowing a hands-free work environment (e.g. window washing). Additionally, suspension equipment can be a fall arrest system that arrests the fall and suspends the worker until rescue arnves.
d. Retrieval/Rescue. Preplanning for retrieval or rescue in the event of a fall should be taken into consideration when developing a proactive fall management program. The external industry workplace must have a rescue program and any AIR employees using their systems must review this program prior to first use and periodically thereafter.
2. Fall Protection Systems. Listed below are different types of fall protection equipment and their recommended usage.
Type Description
I II I
Full body harnesses that meet ANSI/ASSP 2359 are designed for industrial Full Body applications, and possible suspension, and they are tested to the highest industry Harness standard. This is the only device approved for use by AIR personnel.
Positioning Web or cable versions. The cable is designed for corrosive or excess heat Lanyards environments and must be used in conjunction with shock absorbing devices.
When climbing a ladder, rail systems can be used on any fixed ladder as well as Rail Systems curved surfaces as a reliable method of fall prevention.
A deceleration device which travels on a lifeline used to safely ascend or descend Rope Grabs ladders or sloped surfaces and automatically, by friction, engages the lifeline and locks so as to arrest the fall of an employee.
Rope Lanyard Usually used for restraint purposes.
Self-Retracting Gives fall protection and mobility to the user when working at height or in areas Lifeline (SRL) where there is a danger of falling.
When used, the fall arresting force on the user's body will be greatly reduced if a fall Shock Absorbers occurs. Shock absorbers can elongate 3.5 to 4 or more feet when activated.
Ideal for arrest and restraint purposes when a shock absorber is incorporated into Web Lanyard the system.
8-1 03/03/2023 IR 3900. 72A Appendix B 3. Inspection and Maintenance. Harnesses should be inspected frequently to maintain their service life and high performance, harnesses should be inspected frequently. Visual inspection before each use and an annual inspection by a competent person are required. If any of the conditions listed below are found, the equipment should be replaced before being used.
a. Harness Inspection.
( 1) Webbing and Rings. Inspect webbing for wear points, abrasions, and damaged threads, or tom, severed, or damaged stitching or sewing. Also, check webbing for excessive sun damage (fading), or other deformities. Bend the webbing in an inverted "U." Watch for frayed edges, broken fibers, pulled stitches, or chemical damage. Webbing should be flexible and not brittle when you run it between your fingers. Webbing must not have paint on it. Check rings or snaphooks for pits and rust pits. Check for labels and tags that are not intact or able to be read.
(2) Buckles and D-Rings. Attachments of buckles and D-Rings should be given special attention. Note any unusual wear, frayed or cut fibers, or distortion of the buckles. Rivets should be tight and nonremovable with fingers. The body side rivet base and outside rivets should be flat against the material. Bent rivets will fail under stress. Inspect frayed or broken strands. Broken webbing strands generally appear as tufts on the webbing surface. Any broken, cut, or burnt stitches will be readily seen.
(3) Buckles. Buckle tongues should be free of distortion in shape and motion. They should overlap the buckle frame and move freely back and forth in their socket. Rollers should tum freely on the frame. Check for distortion or sharp edges. The outer bar or center bars must be straight. Pay special attention to comers and attachment points of the center bar.
(4) Grommets. For tongue and buckle leg straps, the round grommets where the tongue fits should be round and not oblong. If they are elongated, this is evidence that the harness may have been impacted by a fall. Compare with other grommets for shape.
b. Lanyard Inspection. When inspecting lanyards, begin at one end and work to the opposite end. Slowly rotate the lanyard so that the entire circumference is checked.
(1) Hardware.
(a) Snaps. Inspect closely for hook and eye distortion, cracks, corrosion, or pitted surfaces. The keeper or latch should seat into the nose without binding and should not be distorted or obstructed. The keeper spring should exert sufficient force to firmly close the keeper. The keeper or latch must be kept from opening once the keeper closes.
(b) Thimbles. The thimble (protective plastic sleeve) must be firmly seated in the eye of the splice, and the splice should have no loose or cut strands. The edges of the thimble should be free of sharp edges, distortion, or cracks.
(2) Lanyards.
(a) Steel Lanyards. While rotating a steel lanyard, watch for cuts, frayed areas, or unusual wear patterns. Steel lanyards for fall protection must have an integrated shock-absorber.
8-2 0 3 /0 3 / 2 0 23 IR 3900. 72A Appendix B (b) Web Lanyard. While bending webbing, observe each side of the webbed lanyard. This will reveal any cuts or breaks. Due to the limited elasticity of the web lanyard, fall protection without the use of a shock absorber is not recommended.
( c) Rope Lanyard. Rotation of the rope lanyard while inspecting from end to end will bring to light any fuzzy, worn, broken or cut fibers. Weakened areas from extreme loads will appear as a noticeable change in original diameter. The rope diameter should be uniform throughout, following a short break-in period.
c. Shock-Absorbing Packs. The outer portion of the shock-absorbing pack should be examined for bum holes and tears. Stitching on areas where the pack is sewn to the D-Ring, belt or lanyard should be examined for loose strands and deterioration. The label with manufacture date and information, must be legible.
d. Visual Indication of Damage to Webbing and Rope Lanyards.
(1) Heat. Heat causes nylon to become brittle and has a shriveled brownish appearance.
(2) Chemical. Chemicals cause a change in color usually a brownish smear or smudge.
(3) Transverse Cracks. Transverse cracks appear when the webbing is bent over tightly, which causes a loss of elasticity.
(4) Ultraviolet Rays. Do not store webbing and rope lanyards in direct sunlight, because ultraviolet rays can reduce the strength of some material.
(5) Molten Metal or Flame. Webbing and rope strands may be fused together by molten metal or flame. Watch for hard, shiny spots or a hard and brittle feel. The webbing will not support combustion, nylon will.
(6) Paint and Solvents. Paint will penetrate and dry, restricting movements of fibers.
Drying agents and solvents in some paints will appear as chemical damage.
4. Cleaning of Equipment. Basic care for fall protection equipment will prolong the life of the equipment and contribute toward the performance of its vital safety function. Proper storage and maintenance after use are as important as cleaning the equipment of dirt, corrosives, or contaminants. The storage area should be clean, dry and free of corrosive elements.
a. Nylon and Polyester. Wipe off all surface dirt with a sponge dampened in plain water.
Squeeze the sponge dry. Dip the sponge in a mild solution of water and commercial soap or detergent. Work up a thick lather with a vigorous back and forth motion. Then wipe the webbing dry with a clean cloth. Hang freely to dry but away from excessive heat.
b. Drying. Harness, lanyards and other equipment should be air dried without sunlight.
8-3 03/03/2023 IR 3900. 72A Appendix C Appendix C. Additional Guidelines for Personal Fall Arrest Systems (PFAS) 1. Selection and Use. The kind of PFAS selected should match the particular work situation, and any possible free fall distance should be kept to a minimum. Consideration should be given to the particular work environment. For example, the presence of acids, dirt, moisture, oil, grease, paint solvents or other corrosive or solvents, and their effect on the system, should be evaluated. Hot or cold environments may also harm the system. The external industry workplace should have means available to promptly rescue an individual should a fall occur.
Where lanyards, connectors, and lifelines are subject to damage by work operations such as welding, chemical cleaning, painting, or abrasive blasting, etc., the component should be protected, or other securing systems should be used. The external industry workplace should monitor the effectiveness of its fall protection system and have documentation of these monitoring activities available for review, if requested. Furthermore, the host employer should have means available to promptly rescue an individual should a fall occur.
2. Testin . The fall protection equipment used by AIR personnel must meet American g National Standards Institute (ANSI) / American Society of Safety Professionals (ASSP) 2359 testing standards; this will be listed on the equipment's labels.
3. Com onent Com atibilit . Ideally, a PFAS is designed, tested, and supplied as a complete p p y system. However, it is common practice for lanyards, connectors, lifelines, deceleration devices, and body harnesses to be interchanged since some components wear out before others. The AIR employee should realize that not all components are interchangeable. For instance, a lanyard should not be connected between a harness and a deceleration device of the self-retracting lifeline, since this can result in additional free fall for which the system was not designed. Any substitution or change to a PFAS should be fully evaluated by a competent person.
4. Em lo ee Trainin . AIR employees who perform work activities from elevated work p g y surfaces require training in the evaluation, use, and limitations of PFAS. This should include the following: a. Application limits; proper anchoring and tie-off techniques.
b. Estimation of free fall distance, including determination of deceleration distance, and total fall distance to prevent striking a lower level.
c. Methods of use; and inspection and storage of the system.
d. Careless or improper use of the equipment can result in serious injury or death.
e. AIR employees should become familiar with the material in this appendix, as well as manufacturer's recommendations, before a system is used.
f. Reduction in strength caused by certain tie-offs (such as using knots, or tying around sharp edges) and maximum permitted free fall distance.
C-1 03/03/2023 IR 3900. 72A Appendix C g. The importance of inspection prior to use, the limitations of the equipment, and unique conditions at the worksite which may be important in determining the type of system to use.
5. Instruction. The external industry workplace should have obtained comprehensive instructions from the supplier/vendor and manufacturer as to the system's proper use and application. The external industry workplace may require the AIR employee to receive training in the use of their fall protection equipment/system. This training may include: a. Caution statements on critical use limitations and application limits; b. Proper hook-up, anchoring and tie-off techniques, including the proper D-Ring or other attachment points to use on the harness for fall arrest; c. Proper climbing techniques; d. Methods of inspection, use, cleaning, and storage; and e. Site-specific procedures.
6. Rescue. The external industry workplace must ensure that an AIR employee can be promptly rescued or can rescue themselves should a fall occur. The availability of rescue personnel, ladders or other rescue equipment should be evaluated. In some situations, equipment that allows employees to rescue themselves after the fall has been arrested may be desirable, such as devices that have descent capability. According to the Occupational Safety and Health Administration (OSHA), suspension trauma, which can cause physical injury, can occur in less than 30 minutes. This time is based on person in better health. The AIR employee needs to assess the hazard and the availability of rescue prior to working at height.
7. Inspection.
a. Significant Defects. PF ASs must be regularly inspected and the annual inspection by a competent person must be documented. AIR employees can request to see this documentation.
Additionally, horizontal lifeline systems must have documentation on the engineering required.
If there is any component with any si ificant defect, such as cuts, tears, abrasions, mold, or gn undue stretching; alterations or additions which might affect its efficiency; damage due to deterioration; contact with fire, acids, or other corrosives or solvents; distorted hooks or faulty hook springs; tongues unfitted to the shoulder of buckles; loose or damaged mountings; non functioning parts; or wearing or internal deterioration in the ropes, it must not be used by AIR employees.
b. Expected Life of Equipment. Most fall protection equipment manufacturers will not state the expected life of the equipment. Most will say as long as it passes the competent person inspection, it can continue to be used.
(1) If it is an operator's harness, use only harnesses that are under 5 years old since the history of the equipment is unknown. It must still pass the prior to use inspection by the user.
C-2 03/03/2023 IR 3900. 72A Appendix C (2) For AIR-purchased harnesses/lanyards, the service life may be extended beyond the 5 years since it will be used less frequently and AIR will know how it has been maintained.
(3) AIR-owned harnesses/lanyards will be tested where necessary to verify exceeding the five years.
8. Tie-Off.
a. Anchorage Installation. Properly planned anchorages should be used if they are available. In some cases, anchorages must be installed immediately prior to use. In such cases, a registered professional engineer with experience in designing fall protection systems, or another qualified person with appropriate education and experience should design an anchor point for installation.
b. Arresting Force. Anchorages have to meet a 5,000-pound arresting force for fall arrest or be designed by an engineer with a safety factor of at least 2.
c. Anchor Point from Existing Structures. In other cases, it is recognized that there will be a need to devise an anchor point from existing structures. Examples of what might be appropriate anchor points are steel members or I-beams if an acceptable strap is available for the connection (do not use a lanyard with a snaphook clipped onto itself) or guardrails or railings if they have been designed for use as an anchor point. Improvised anchors like these should be used only after reviewing any system documentation and if they are found to meet the requirements outlined in the initial AIR or FS provided training.
d. Knots. Tie-off using a knot in a rope lanyard or lifeline (at any location), to reduce its length, is prohibited since it can reduce the lifeline or lanyard strength by 50%. A tie-off location can be raised or lanyard length can be shortened to minimize free fall distance.
e. Beams. Tie-off of a rope or webbing lanyard or lifeline around an H- or I-beam or similar support is prohibited since it can reduce its strength by as much as 70 percent due to the cutting action of the beam edges. Anchorage connectors such as beam clamps, or tie-off adapters with abrasion pads must be used to help connect the system to the anchorage.
Exception: some lanyards are designed to be wrapped around structural members, but this must be stated on the label.
f. Sharp Surfaces. A tie-off where the line passes over or around rough or sharp surfaces reduces strength drastically. Anchorage connectors should have abrasion pads to resist damage to the material and reduce this risk.
g. Horizontal Lifelines. Horizontal lifelines may, depending on their geometry and angle of sag, be subjected to greater loads than the impact load imposed by an attached component.
Therefore, the design of systems using horizontal lifelines must only be done by qualified persons. The procedure, capacity, and limitations should be documented for the AIR employee's review. The required testing of the system should also be documented and available for the AIR employee's review.
C-3 03/03/2023 IR 3900. 72A Appendix C h. Eyebolts. The strength of an eyebolt is rated along the axis of the bolt and its strength is greatly reduced if the force is applied at an angle to this axis (in the direction of shear). Also, care should be exercised in selecting the proper diameter of the eye to avoid accidental disengagement of snaphooks not designed to be compatible with the connection.
9. Vertical Lifeline. Each employee must have a separate lifeline when the lifeline is vertical, since a second person can fall if the first person incurs a fall due to movement of the lifeline.
10. Snaphook.
a. Locking Snaphooks. Locking snaphooks designed for connection to suitable objects (of sufficient strength) are required. OSHA prohibits non-locking snaphooks. Locking snaphooks incorporate a positive locking mechanism in addition to the spring loaded keeper, which will not allow the keeper to open under moderate pressure without someone first releasing the mechanism.
b. Avoidances. Avoid the following connections because they may result in rollout: (1) Direct connection of a snaphook to a horizontal lifeline.
(2) Two (or more) snaphooks connected to one D-Ring.
(3) Two snaphooks connected to each other.
( 4) A snaphook connected back on its integral lanyard.
(5) A snaphook connected to webbing or webbing lanyard, unless designed to do so.
(6) Improper dimensions of the D-Ring, rebar, or other connection points in relation to the snaphook dimensions which would allow the snaphook keeper to be depressed by a turning motion of the snaphook.
11. Free Fall. The AIR employee should at all times be aware that a system's maximum arresting force is evaluated under normal use conditions established by the manufacturer, and in no case using a free fall distance in excess of 6 feet (1.8 m). A few extra feet of free fall can significantly increase the arresting force on the employee, possibly to the point of causing injury.
To avoid injury, the tie-off attachment point to the lifeline or anchor should be located at or above the connection point of the fall arrest equipment to harness. Attaching to the elevated working surface will often result in a free fall greater than 6 feet. For instance, if a 6-foot lanyard is used, the total free fall distance will be the distance from the working level to the body harness attachment point plus the 6 feet of lanyard length. Another important consideration is that the arresting force on the body and the system also goes up with greater distances of free fall, possibly exceeding the strength of the system.
12. Elongation and Deceleration Distance. Other factors involved in a proper tie-off are elongation and deceleration distance. During the arresting of a fall, a lanyard will experience a length of stretching or elongation, whereas activation of a deceleration device will result in a certain stopping distance. These distances should be available with the lanyard or device's instructions and must be added to the free fall distance to arrive at the total fall distance before an C-4 03/03/2023 IR 3900. 72A Appendix C employee is fully stopped. As required by the standard, sufficient distance to allow for all of these factors must also be maintained between the employee and obstructions below, to prevent an injury due to impact before the system fully arrests the fall.
13. Obstruction. The location of the tie-off should also consider the hazard of obstructions in the potential fall path of the employee.
14. Swing Fall. If the self-retracting lifeline or anchor is not close to directly over the worker's body, there is a potential for the person to swing if they fall and possibly impact another object.
The general rule is to stay within a 30-degree angle from your anchor overhead.
15. Other Considerations. Because of the design of some PFASs, additional considerations may be required for proper tie-off. For example, heavy deceleration devices of the self-retracting type should be secured overhead in order to avoid the weight of the device having to be supported by the employee. Also, if self-retracting equipment is connected to a horizontal lifeline, the sag in the lifeline should be minimized to prevent the device from sliding down the lifeline to a position which creates a swing hazard during fall arrest. In all cases, the manufacturer's instructions should be followed.
C-5 03 / 03 / 2023 IR 3900. 72A Appendix D Appendix D. Applicable Standards and Regulations The current editions of the following standards, regulations and requirements apply to the AIR Fall Protection Program: 1. FAA Order 3900.19, Federal Aviation Administration (FAA) Occupational Safety and Health Policy, Chapter 4, Fall Protection 2. Title 29 of the Code of Federal Regulation (29 CFR) Part 1910, Occupational Safety and Health Standards a. Subpart D, Walking-Working Surfaces: • Section 1910.21, Scope and Definitions.
• Section 1910.22, General Requirements.
• Section 1910.23, Ladders.
• Section 1910.28, Duty To Have Fall Protection and Falling Objects Protection.
• Section 1910.29, Fall Protection Systems and Falling Objects Protection- Criteria and Practices.
b. Subpart F, powered Platforms, Manlifts, and Vehicle-Mounted Work Platforms, § 1910.67, Vehicle-Mounted Elevating and Rotating Work Platforms.
c. Subpart I, Personal Protective Equipment,§ 1910.132, General Requirements.
3. Title 29 CFR Part 1926, Safety and Health Regulations for Construction.
a. Subpart E, Personal Protective and Life Saving Equipment,§ 1926.104, Safety belts, Lifelines, and Lanyards.
b. Subpart L, Scaffolds: • Section 1926.451, General Requirements.
• Section 1926.453, Aerial Lifts.
c. Subpart M, Fall Protection: • Section 1926.501, Duty to Have Fall Protection.
• Section 1926.502, Fall Protection Systems criteria and Practices.
• Section 1926.503, Training Requirements.
4. American National Standards Institute (ANSI) Accredited Standards Committee (ASC) A14.7-2011, American National Standard for Mobile Ladder Stands and Mobile Ladder Stand Platforms.
D-1 0 3 /0 3 / 2 0 23 IR 3900. 72A Appendix D 5. ANSI/American Society of Safety Professionals (ASSP) Z359, Fall Protection and Fall Restraint.
a. ANSI/ASSP 2359.0-2012, Definitions and Nomenclature Used for Fall Protection and Fall Arrest.
b. ANSI/ASSP 2359.1-2016, The Fall Protection Code -Part of the Fall Protection Code.
c. ANSI/ASSP 2359.2-2017 - Minimum Requirements for a Comprehensive Managed Fall Protection Program.
d. ANSI/ASSP 2359.3-2017 - Safety Requirements for Lanyards and Positioning Lanyards.
e. ANSI/ASSP 2359.4-2013 - Safety Requirements for Assisted-Rescue and Self-Rescue Systems, Subsystems and Components.
f. ANSI/ASSP 2359.6-2016 - Specifications and Design Requirements for Active Fall Protection Systems.
g. ANSI/ASSP 2359.7-2019 - Qualification and Verification Testing of Fall Protection Products.
h. ANSI/ASSP 2359.11-2014 - Safety Requirements for Full Body Harness i.
ANSI/ASSP 2359.12-2009 - Connecting Components for Personal Fall Arrest Systems ANSI/ASSP 2359.13-2013 - Personal Energy Absorbers and Energy Absorbing Lanyards j.
k. ANSI/ASSP 2359.14-2014, Safety Requirements for Self-Retracting Devices for Personal Fall Arrest and Rescue Systems.
I. ANSI/ASSP 2359.15 -2014, Safety Requirements for Single Anchor Lifelines and Fall Arresters for Personal Fall Arrest and Rescue Systems.
m. ANSI/ASSP 2359.16-2016, Safety Requirements for Climbing Ladder Fall Arrest Systems.
n. ANSI/ASSP 2359.18-2017, Safety Requirements for Anchorage Connectors for Active Fall Protection Systems -Part of the Fall Protection Code.
D-2 03/03/2023 IR 3900. 72A Appendix E Appendix E. Directive Feedback Information Directive Feedback Information Please submit any written comments or recommendations for improving this directive, or suggest new items or subjects to be added to it. Also, if you find an error, please tell us about it.
Subject: FAA Order 3900.72A, Aircraft Certification Service (AIR) Fall Protection Program (FPP) To: Directive Management Officer, 9-AVS-AIR-Directives-Management-Officer@faa.gov (Please check all appropriate line items)
□ An error (procedural or typographical) has been noted in paragraph _____ on
page _______
□
Recommend paragraph _______ on page _______ be changed as follows: attach separate sheet (if necessary)
□ In a future change to this order, please include coverage on the following subject
(briefly describe what you want added): D Other comments: □ I would like to discuss the above. Please contact me.
Date: Submitted by: ---------------- -------- - Telephone Number: Routing Symbol:
------------ ---- -
FAA Form 1320-19 (08/21) Supersedes Previous Edition E-1