Ladder inspection, care and storage

A ladder can look sound from a distance and still be dangerous. A hairline crack in a fiberglass rail, a worn foot, a rung lock that does not fully engage or a bent stepladder brace can turn an ordinary climb into a fall. Inspection is how those defects are found before they hurt someone. This lesson covers who inspects ladders and when, what to look for on each type, how to tag and remove defective ladders, and how to clean, store and transport ladders so that they stay in good condition.

Who inspects, and when

OSHA requires ladders to be inspected by a competent person for visible defects on a periodic basis and after any occurrence that could affect their safe use (1926.1053(b)(15)), and in general industry before the initial use in each work shift and more often as necessary (1910.23(b)(9)). In practice, three levels of inspection work together:

• Pre-use inspection by the user, every time the ladder is used. It takes a minute or two and focuses on obvious damage, missing parts and function.
• Periodic inspection by a competent person, often monthly or quarterly depending on use, with a written record. It is more thorough and includes parts that users may not check closely.
• Special inspection after an incident, a fall, a drop from a vehicle, exposure to fire, chemicals or heat, or when someone reports a problem.

Many employers mark each ladder with an identification number and keep a simple log of periodic inspections. A tag or sticker on the ladder showing the last inspection date helps users see that the system is working.

What to check on every ladder

• Labels and markings: the manufacturer's label, the grade or duty type, the maximum length and the safety instructions must be present and readable. A ladder without its label cannot be confirmed to meet the standard.
• Side rails: no cracks, splits, bends, dents, corrosion, burns or chemical damage. On fiberglass look for cracks, chips, fiber bloom and delamination. On aluminum look for bends, dents and sharp kinks. On wood look for splits, rot, warping and loose joints.
• Rungs and steps: tight, straight, not bent, worn smooth or missing, and free of oil, grease, paint and mud. Slip-resistant surfaces should be intact.
• Feet and pads: present, the right type for the surface, swivelling freely, not worn through to the metal and not loose.
• Hardware: rivets, bolts, braces and brackets tight and undamaged; no missing fasteners.
• Cleanliness: no slippery contamination, and no build-up that could conceal defects or conduct electricity.

Extra checks by ladder type

What to do with a defective ladder

A ladder with any defect that could affect its safety must be removed from service immediately. Do not try a quick fix such as taping a crack, wiring a broken spreader or straightening a bent rail. Ladders are designed as a system, and field repairs usually cannot restore the original strength.

• Tag it as dangerous or do not use, with the date, the defect and your name.
• Move it out of the work area so that nobody picks it up by mistake.
• Report it to the supervisor.
• Repair it only if the manufacturer allows the repair and uses approved parts, done by a competent person, and inspect it again before return to service.
• Otherwise, destroy it so that it cannot be used, for example by cutting it in half, and dispose of it.

Periodic inspection records

A periodic inspection record usually includes:

• ladder identification number, type, grade or duty type, material and length;
• inspection date and inspector's name;
• a checklist of each component with pass or fail;
• defects found and actions taken: repaired, tagged out or destroyed;
• the next inspection due date.

Records help show that the employer met the inspection requirements if OSHA investigates, and they reveal patterns such as a particular model failing repeatedly or a crew damaging ladders during transport.

Cleaning and care

Clean ladders regularly with mild soap and water, especially after exposure to mud, paint, oil, grease, concrete or chemicals. Contamination makes rungs slippery and can hide defects. On fiberglass ladders, manufacturers may recommend periodic application of a protective coating to slow UV weathering. Lubricate locks, pulleys and hinges as the manufacturer directs, and never use a ladder that has been exposed to fire or strong chemicals until a competent person has inspected it.

Storage

Poor storage damages ladders as surely as misuse does.

• Store ladders indoors or under cover, away from heat sources, sunlight and moisture.
• Support straight and extension ladders horizontally on racks with supports at several points so that they do not sag, or store them vertically secured against falling.
• Do not hang ladders from a single rung or stack heavy material on them.
• Keep stepladders closed and secured so they cannot fall over.
• Keep ladders out of traffic routes and away from vehicles and doors.
• Secure ladders against unauthorized use, especially near open excavations, roofs or by the public.

Transport

Ladders are often damaged on vehicles. Use proper ladder racks with padded supports, secure the ladder at both ends so it cannot slide or bounce, and avoid overhanging loads that can strike other vehicles or pedestrians. Flag long overhangs as required by provincial or state traffic rules. Do not drop ladders from vehicles; impact can crack fiberglass and bend aluminum. After a ladder has been dropped or hit, give it a special inspection before use.

Inspecting in the field

Pre-use checks are quick only if they become a habit. Keep a short checklist on the ladder or in the truck, and make inspection part of the job briefing. Supervisors should spot-check ladders during site visits and ask workers to show them a pre-use inspection. A culture where workers feel comfortable tagging out a ladder and asking for a replacement prevents the pressure to make do with damaged equipment.

A pre-use inspection routine

A routine makes pre-use checks quick and thorough. One practical sequence is to inspect from the bottom up and then test the ladder:

• Lay the ladder down or stand it up in a clear area with good light.
• Check the label: grade or duty type, length and instructions present and readable.
• Check the feet and pads, then work up each side rail looking for damage.
• Check each rung or step, and the hardware holding it.
• On a stepladder, open it, lock the spreaders and check that it stands square without rocking; check the top cap.
• On an extension ladder, raise the fly a few rungs and check that both locks engage, the guides hold and the rope runs freely.
• Look for contamination on rungs and on the soles of your own boots.

If anything fails, stop there, tag the ladder and get another one. A two-minute check is far quicker than an incident investigation.

Why ladders get damaged

Knowing how ladders are damaged helps prevent it. Common causes are dropping ladders from vehicles or roofs, overloading, using ladders as planks or ramps, leaving them in the sun or in the weather, storing them under heavy materials, side loading during use, and contact with chemicals such as acids, solvents and concrete. Fiberglass is more sensitive to impact and sunlight than aluminum; aluminum is more prone to bending and denting. A ladder fleet that is being damaged quickly is a sign that work methods, storage or transport need attention, not just more replacement ladders.