Working at heights: ladders, scaffolds, lifts and fall protection

Film crews spend a surprising amount of time off the ground. Electricians climb ladders to set practicals and hang lights from pipe grids; grips build scaffolds for high camera positions and work on catwalks above sound stages; rigging crews work from boom lifts and scissor lifts to hang frames and fixtures; camera operators ride cranes. Falls from height are one of the leading causes of serious injury and death at work across all industries, and the film industry is no exception. A fall of only 2 or 3 m onto a hard floor can cause a fatal head injury. This lesson covers ladders, scaffolds and rolling towers, mobile elevating work platforms such as scissor lifts, boom lifts and condors, the hierarchy of fall protection, calculating fall clearance and the legal thresholds for fall protection in Canada and the United States. It is awareness-level only. Using fall protection or operating a lift requires specific certified training.

Why falls happen

Falls rarely happen to people doing something unusual; they happen during routine tasks done in a hurry.

• Overreaching from a ladder instead of moving it.
• Using the wrong equipment, such as standing on a chair, apple box stack or the top cap of a stepladder.
• Working near open edges of rooftops, catwalks, set platforms and loading docks without guardrails.
• Unstable bases: ladders on uneven or slippery ground, rolling towers with unlocked wheels.
• Climbing with tools or equipment in hand, without three points of contact.
• Fatigue, poor lighting and rushing at the end of a long day.
• Holes and openings in set floors, trap doors and stage pits left unguarded.

The hierarchy of fall protection

Like the general hierarchy of controls in Lesson 1, fall protection follows an order of preference.

• Eliminate the need to work at height: pre-rig fixtures at ground level and raise them on a lift or motor, use telescopic poles to adjust lights from the floor, use remote heads and wireless control.
• Passive fall prevention: guardrails, covers over openings, scaffolds and platforms with rails. These protect everyone without training or equipment use.
• Fall restraint: equipment that prevents a worker from reaching an edge, such as a short lanyard attached to an anchor.
• Fall arrest: a harness, lanyard or self-retracting lifeline and anchor that stop a fall after it begins. It requires training, clearance below and a rescue plan.
• Administrative controls: warning lines, safety monitors and procedures, which are least effective and allowed only in limited situations.

When fall protection is required

Laws set heights above which fall protection is required. The thresholds differ between jurisdictions, and between general work and construction, and some apply at any height where a fall could cause injury, such as falling onto machinery or into water.

In the United States, federal OSHA requires fall protection at 4 ft in general industry (29 CFR 1910.28) and 6 ft in construction (29 CFR 1926.501), with 10 ft for scaffolds in construction. Productions working on stages are often treated as general industry, while set construction on location can fall under construction rules. State plans such as Cal/OSHA may have their own thresholds. Fall protection equipment is covered by the ANSI/ASSP Z359 series of standards, and US Safety Bulletin 22 covers scissor lifts and aerial boom lifts.

Ladders

Ladders are simple tools that cause many injuries.

• Choose the right type and length: stepladders for free-standing work, extension ladders for access to upper levels, and platform ladders for longer tasks.
• Choose the right duty rating for the user plus tools and equipment. Ladder standards are CSA Z11 in Canada and ANSI A14 in the US.
• Inspect before use for damaged rails, rungs, feet and locks.
• Set extension ladders at a 4:1 angle: the base 1 unit out for every 4 units of height to the support point.
• Extend ladders at least 1 m (3 ft) above a landing used for access, and secure the top and bottom.
• Maintain three points of contact while climbing; carry tools in a belt or raise them with a line.
• Never stand on the top cap or top step of a stepladder, and never use a stepladder folded and leaning.
• Keep your belt buckle between the rails; move the ladder rather than overreach.
• Use non-conductive ladders (fiberglass) near electricity.

Scaffolds and rolling towers

Scaffolds give stable working platforms for camera positions, lighting and set construction.

• Scaffolds must be erected, altered and dismantled by competent workers following the manufacturer's instructions and applicable regulations.
• Use full guardrails (top rail, mid rail and toe boards) on working platforms, and safe access by built-in ladders or stairs, not by climbing the frame.
• Set scaffolds on firm, level bases with base plates and mud sills, and use outriggers or ties as required for height.
• On rolling towers, lock casters before climbing, and never move a tower with people or loose equipment on it.
• Respect the height-to-base ratio set by the manufacturer and regulations; taller towers need outriggers or ties.
• Inspect scaffolds before each shift and after any alteration or severe weather.

Mobile elevating work platforms

Scissor lifts, boom lifts (including articulating and telescopic booms) and the large truck-mounted or self-propelled booms the industry calls condors carry crew and lights high above the set. They are invaluable and dangerous.

• Operators must be trained and familiarized on the specific type and model, as required by standards and regulations.
• Inspect the lift before each use, including controls, emergency lowering, tires, outriggers and platform gates.
• Check the ground: firm, level, no holes, soft ground, buried vaults or slopes beyond the manufacturer's limits.
• Respect the platform's rated capacity, including people, fixtures, cable and accessories. A fixture and a large frame can exceed capacity and create huge wind loads.
• In boom lifts, wear a full-body harness and short lanyard attached to the platform's designated anchor; this is fall restraint, keeping the worker in the basket. In scissor lifts, guardrails are normally the primary protection, though some employers and manufacturers require harnesses too.
• Never climb on guardrails or use ladders inside a platform.
• Keep clear of power lines (Lesson 4), overhead obstructions and traffic.
• Observe the manufacturer's maximum wind speed. Many outdoor-rated lifts are limited to 12.5 m/s (about 45 km/h or 28 mph), and some allow less. Lights and frames mounted on the basket add sail area that the rating may not include (Lesson 8).
• Have a rescue plan and ground crew who can use the emergency lowering controls.

In the United States, the ANSI/SAIA A92 series (A92.20 design, A92.22 safe use and A92.24 training), in effect since 2020, covers mobile elevating work platforms, and OSHA requires trained operators. US Safety Bulletin 22 covers scissor lifts and aerial boom lifts on productions.

Personal fall arrest and fall clearance

Personal fall arrest systems include an anchor, a connector, a full-body harness and a lanyard with an energy absorber or a self-retracting lifeline. They work only if there is enough clear space below the worker to stop the fall before hitting the ground or an obstruction.

• Anchors must be strong enough, typically about 22 kN (5,000 lb) per worker or designed by a qualified person.
• Harnesses must fit correctly and be inspected before each use.
• Lanyards with energy absorbers extend as they slow the fall; self-retracting lifelines lock quickly and usually need less clearance.
• Suspension after a fall can cause suspension trauma within minutes, so a prompt rescue plan is essential.

Fall clearance is the distance needed below the anchor or working surface to stop a fall safely. A common calculation adds the free fall distance, deceleration distance, harness stretch and D-ring shift, the height of the worker's D-ring above their feet and a safety margin.

Catwalks, grids and set platforms

Sound stages have catwalks and permanent grids high above the floor, and sets often include platforms, staircases and balconies.

• Stay on catwalks and walkways; never walk on grid pipes, ceilings or set walls not designed to be walked on.
• Keep catwalk gates closed and toe boards in place to prevent dropped objects.
• Tether tools and small items when working above others, and keep exclusion zones below.
• Guard open edges of set platforms with railings and mark them; cover or guard openings and trap doors.
• Light access routes and keep them clear of cable and equipment.

Rescue planning

Every plan to use fall arrest or lifts must include a rescue plan. Waiting for emergency services may take too long for a worker suspended in a harness.

• Identify how a fallen or stranded worker will be reached: from the ground with a lift, by using the lift's emergency lowering controls, or with a rescue kit used by trained people.
• Make sure rescuers are trained and equipment is on site.
• Practice the plan where possible and include it in the safety meeting.