Planning fixed ladder fall protection upgrades
Before the 2016 Walking-Working Surface revisions, OSHA required cages on fixed ladders over 20 feet. Employers can no longer use cages as primary fall protection, but do not necessarily need to remove them. Now, OSHA requires special fall protection on fixed ladders over 24 feet.
Fixed ladders over 24 feet installed after November 19, 2018, must include a personal fall arrest system or ladder safety system. Also, fixed ladders already in place by that date must be upgraded with a personal fall arrest or ladder safety system by November 18, 2036.
Ladder height
Determining when a fixed ladder is over 24 feet might seem like a simple measurement, but the length of the ladder is not the only factor. OSHA considers the total length of climb or total potential falling distance, counting all sections and including any vertical distance between ladder sections.
For example, a ladder with two offset sections of 16 feet each would qualify as “more than 24 feet” because the length of climb totals 32 feet. Similarly, if a ladder is 20 feet high but employees access the ladder at a point 10 feet above a lower level, creating a total potential fall of 30 feet, OSHA considers that ladder over 24 feet and would require a fall protection system.
Ladders under 24 feet do not require a fall protection or ladder safety system. In fact, even though ladders over 20 feet previously required a cage or well, those systems are not required on new ladders under 24 feet.
Cages and wells
Although, cages and wells are longer allowed as the primary means of fall protection on new ladders fixed ladders, ladders exceeding 24 feet that were installed before November 19, 2018, may continue to rely on cages or wells until upgraded. Eventually, all fixed ladders over 24 feet must include a fall protection system or ladder safety system.
The regulation at 1910.28(b)(9)(iv) clarifies that employers do not have to remove cages or wells when installing a ladder safety system or personal fall arrest system, provided the cage or well does not interfere with that new system. In addition, OSHA does not prohibit installing cages and wells on new fixed ladders in addition to ladder safety or personal fall arrest systems. OSHA simply clarified that employers may not install cages and wells instead of ladder safety or personal fall arrest systems.
Minor repair vs. replacement
Finally, the regulation says that when an employer replaces a fixed ladder, cage, well, or portion of a ladder, the employer must install a personal fall arrest system or ladder safety system. If only one section of the ladder needs replacement, the employer may upgrade only that section, but leave other sections for future upgrades.
This raises the question of what, exactly, counts as “replacing” a ladder component. In the preamble to the regulation, OSHA clarified that it does not require adding a fall protection system for minor repairs such as replacing a bolt or fixing a weld on a cage. However, if the need for repair involves the structural integrity of the ladder, the employer must add the new system. For example, when employers must replace a portion or section, the replacement must include a ladder safety or personal fall arrest system.
Key to remember: Although employers have until 2036 to upgrade fixed ladders, planning for those upgrades requires identifying all affected ladders and understanding when repairs require an upgrade.