Fall arrest systems and lifelines

Hierarchy of protection and types of systems

Prevention regulations establish a clear hierarchy for working at height: eliminate the need to work at height, protect with collective measures (guardrails, nets, protected platforms), and only when these are not feasible or do not sufficiently reduce the risk, resort to personal protective equipment. Within this category, the UNE-EN 363 standard distinguishes between restraint systems (which prevent access to the fall zone), positioning or restraint systems (which keep the worker in place with their hands free), rope access systems, rescue systems, and fall arrest systems, which stop a fall already in progress.

An effective fall arrest system requires three compatible elements: a fall arrest harness conforming to UNE-EN 361 with a dorsal or sternal attachment point; a connection subsystem that limits the braking force to 6 kN (lanyard with shock absorber according to UNE-EN 355, retractable device according to UNE-EN 360 or sliding device according to UNE-EN 353); and an anchor point or device of adequate strength, fixed (UNE-EN 795 types A, B, D or E) or linear (types C, horizontal flexible lines; type D, rigid rails), or a verified structural anchor.

Horizontal lifelines allow movement along roofs, facades, overhead cranes, or vehicles without disconnecting; vertical lifelines secure fixed ladders and allow for ascents. Their design requires calculation of sag and the loads transmitted to the structure, especially in flexible lines, where deformation in the event of a fall increases the necessary distance below the worker. INSST standards NTP 843 and 809 cover the selection and verification of anchor devices, and NTP 1218 covers fall arrest systems.

Usage requirements

• Assessment and work plan at height. Specific assessment, selection of the appropriate system (restraint versus fall arrest), identification of anchor points, calculation of free fall distance and rescue plan before starting work.
• Free fall distance. Check that the available height below the anchor point allows the fall to be stopped without impact against the ground or obstacles, adding the length of the lanyard, the extension of the energy absorber, the height of the worker, the sag of the line and the safety margin.
• Verified anchors. Anchor points and lines installed by competent personnel in accordance with the manufacturer’s instructions, with installation documentation, marking and periodic review, at least annually, by a competent person.
• Compatibility and conformity. Components with CE marking in accordance with Regulation (EU) 2016/425 as category III PPE, compatible with each other and used according to the manual; fixed anchor devices to the structure are not PPE, but must comply with UNE-EN 795 or the applicable technical specifications.
• Correct use. Harness adjusted, connection to the intended attachment point, connectors closed and locked, avoid the pendulum effect by anchoring above the head and limit the fall factor.
• Rescue. A worker suspended after a fall can suffer from inert suspension syndrome within minutes; a rescue plan, equipment, and team training are mandatory before work begins.
• Training. Specific theoretical and practical training in the use of the system, the prior inspection of the equipment, the anchors and the rescue, in accordance with Royal Decree 773/1997 and Royal Decree 2177/2004.
• Inspection and maintenance. Visual inspection before each use, periodic documented review by a competent person, removal of equipment that has stopped a fall or shows deterioration, and monitoring of the useful life indicated by the manufacturer.

Lifelines: design, installation and inspection

• Project. Analysis of the support structure, calculation of loads and deflection, number of simultaneous users, layout that avoids falls with pendulum and sharp edges, and choice between flexible or rigid line.
• Installation. By an installer authorized by the manufacturer, with verified anchors to the structure, identification plate, assembly documentation and installation certificate.
• Instructions for use. Manual with maximum number of users, compatible connector and absorber types, required clearance distance and usage limitations.
• Periodic inspection. At least annually and after any fall, by a competent person, with a record of the inspection and repairs.
• Temporary lines. Temporary construction lines (portable type B or C) require the same checks for anchoring, clearance and use, and are removed at the end of the work.
• Roofs and access points. The installation of lifelines on roofs must be accompanied by safe access points, protection of fragile areas, and signage.

Organizational application: how to manage fall protection systems in the company

1. Identify all work at height in the risk assessment and prioritize risk elimination and collective protections.
2. Define for each residual task the appropriate individual protection system (restraint, restraint or fall arrest), the anchor points and the free fall distance.
3. Inventory harnesses, lanyards, retractable devices, connectors and lifelines with their manuals, commissioning dates, useful life and revisions.
4. Contract the installation and inspection of lifelines and anchors to competent installers and inspectors, and file certificates and records.
5. Prepare the rescue plan for each work area, using available resources and trained personnel.
6. Train and instruct users in the use, pre-inspection, connection to anchors and rescue, and record the training.
7. Implement pre-use inspection and documented periodic review, removing damaged or expired equipment.

Preventive management software allows you to maintain the inventory of fall protection PPE and lifelines with their review dates and useful life, alert of expirations, record inspections and link work permits at height with the rescue plan and user training.

Limits and common mistakes

1. Use individual protection when railings, nets or protected platforms were feasible.
2. Anchoring to unverified points (pipes, railings, unforeseen scaffolding elements) or below the waist without calculating the fall factor.
3. Failure to calculate the free fall distance, with risk of impact against the ground or against obstacles despite the system.
4. Combining incompatible components or using lanyards without an energy absorber as a fall arrest system.
5. Working without a rescue plan or means to lower a suspended worker.
6. Maintaining in use equipment that has stopped a fall, deteriorated or with an exceeded useful life, or lifelines without annual inspection.

Detailed conditions of use are set out in Annex II of Royal Decree 1215/1997, in Royal Decree 773/1997 and in the INSST Technical Notes; this sheet is for informational purposes.

Regulatory and reference framework

• Royal Decree 773/1997, of May 30. Use by workers of personal protective equipment, including fall protection systems.
• Royal Decree 1215/1997, of July 18. Use of work equipment; Annex II on temporary work at height and rope access and positioning techniques.
• Royal Decree 2177/2004, of November 12. Amendment of Royal Decree 1215/1997 regarding temporary work at height.
• Regulation (EU) 2016/425 on personal protective equipment . Marketing requirements and conformity assessment of PPE, including fall protection equipment.
• NTP 1218: Personal fall protection systems: fall arrest systems (INSST) . Components, selection and use of fall arrest systems.
• NTP 843: Class C anchoring devices (INSST) . Horizontal flexible anchor lines: design, installation and use.

The INSST NTP 809 deals with the description and selection of anchor devices; the UNE-EN standards 363, 361, 355, 360, 353 and 795 and the CEN/TS 16415 technical specification define the requirements for components and anchors for various users.