Applying the Hierarchy of Controls to Prevent Dropped Objects

In the world of occupational safety, we have a powerful tool for tackling risks: the Hierarchy of Controls. Think of it as a playbook that ranks safety measures from most to least effective. When it comes to the serious risk of dropped objects, this hierarchy is essential. It pushes us to think beyond simply telling everyone to wear a hard hat and instead focus on smarter, more reliable solutions that stop objects from falling in the first place.

Relying too heavily on the last line of defense is a gamble. This guide offers practical, real-world examples of how to use the full hierarchy to create a safer work environment at height.

1. Elimination: Get Rid of the Hazard Completely

The best way to prevent an accident is to remove the hazard entirely. It’s the most effective strategy because it makes it impossible for the incident to happen.

A Practical Example: Imagine a team is scheduled to assemble a large piece of equipment on an elevated platform. This task would involve handling numerous tools, nuts, and bolts at height, creating a significant dropped object risk. By asking a simple question—"Can we build this on the ground first?"—you can change the entire approach. If the crew can pre-fabricate the unit at ground level and then lift it into position as a single piece, you’ve just eliminated the risk of dropping individual components during assembly.

2. Substitution: Swap Out the Hazard for a Safer Alternative

If you can't eliminate the risk, the next best thing is to replace the hazardous element with a safer option.

A Practical Example: A work plan calls for a power tool that wasn't designed for use at height and has no built-in tethering point. Workers might try to attach a lanyard, but it's an awkward, makeshift solution. The safer choice is to substitute that tool with a modern version that has an engineered, load-rated attachment point built right in. This simple swap replaces a clumsy, unreliable setup with a secure, purpose-built one.

3. Engineering Controls: Redesign the Workspace to Keep People Safe

Engineering controls are physical changes to the work area or equipment that isolate people from the hazard. For dropped objects, these controls fall into two main categories.

Passive Systems (Protecting the Area):

These are "set it and forget it" solutions that protect everyone without needing individual action.

• Guardrails: The most common barrier, installed along open edges to prevent falls.
• Toe Boards (or Kickplates): A simple but crucial addition to guardrails, these low barriers stop tools and materials from getting kicked or rolling off the edge.
• Safety Netting: Debris nets installed below a work area to catch any items that do fall.
• Canopies: Protective overhead structures that act like a roof to intercept falling objects.
• Barrier Systems: Robust panels, like the Dropsafe Barrier, that attach directly to guardrails to seal gaps and prevent items from slipping through.

Active Systems (Preventing the Drop):

These are focused on stopping an object from falling in the first place.

• Tool Tethering: Securing tools and equipment to an anchor point (like a worker's tool belt or a fixed structure) with a rated tool lanyard. A complete system requires a secure anchor, a proper lanyard, and a reliable attachment point on the tool itself.
• Primary and Secondary Retention: Any piece of permanent equipment at height has a primary way of being secured, like bolts or clamps. A vital engineering control is to add a backup, or secondary retention, like a safety wire or load-rated strap. If the main connection fails, the backup ensures the equipment doesn't fall.

4. Administrative Controls: Change How People Work

These controls are about creating safer habits and procedures through training, clear communication, and workplace rules.

Practical Examples:

• Establish Exclusion Zones: Barricade off the area directly below overhead work and prohibit entry. This "drop zone" ensures that if something falls, no one is in the line of fire.
• Enforce Good Housekeeping: A clean, organized workspace is a safe workspace. Keeping platforms clear of loose tools, materials, and debris dramatically reduces the number of potential dropped objects.
• Use Clear Signage: Post warnings to alert everyone in the area to the potential for overhead hazards.
• Conduct Pre-Job "Toolbox Talks": Before work begins, gather the crew to specifically discuss the dropped object risks for that day's tasks and review the controls that will be used.

5. Personal Protective Equipment (PPE): The Last Line of Defense

PPE is the final and least effective control. It doesn’t prevent an object from falling; it only tries to reduce the harm if an impact occurs.

The Classic Example: The hard hat is the universal symbol of overhead protection. It is absolutely essential, but if you're relying only on hard hats to keep your team safe, it means that more effective controls have been missed or have failed.

A Systematic Approach for a Safer Site

By methodically applying the Hierarchy of Controls, you ensure that you are using the most effective and reliable measures to prevent dropped object incidents. When you start at the top of the list and work your way down, you shift your safety culture from just reacting to accidents to actively preventing them from ever happening.