Fixed ladders, ladder safety systems and job-built ladders

Not every ladder is portable. Fixed ladders are permanently attached to buildings, tanks, towers, silos, machines and roofs, and they are often the only way to reach equipment that needs regular maintenance. On construction sites, carpenters sometimes build wooden ladders to suit the job. This lesson covers the design features of fixed ladders, the move away from cages toward ladder safety systems and personal fall arrest, inspection of fixed ladders, and the rules for job-built ladders.

Features of a fixed ladder

A fixed ladder is attached to a structure and usually rises vertically or nearly so. Because it is permanent, it must be designed and installed correctly from the start, usually to a national standard and the building code.

OSHA's 1910.23(d) sets design requirements for fixed ladders in general industry. Typical requirements include:

• rungs spaced 10 to 14 in apart, evenly, and at least 16 in clear width between rails;
• at least 7 in of clearance behind the rungs for the toes, and 30 in on the climbing side;
• side rails extending 42 in above the top landing, or grab bars that provide the same support;
• rungs, rails and anchorages strong enough for the expected loads;
• landings and platforms with guardrails and self-closing gates at the top, so that the climber is not exposed to the edge when stepping off;
• rest platforms at intervals on tall ladders;
• protection against corrosion, ice and slippery surfaces.

From cages to ladder safety systems

For decades, tall fixed ladders were fitted with cages: hoops around the climbing space attached to vertical bars. Cages give a sense of security, but research and incident experience show they do little to stop a fall. A falling climber can slide down inside the cage, hit the hoops and bars, or be trapped with injuries. Cages also make rescue difficult.

Modern practice uses ladder safety systems, also called fall arrest systems for fixed ladders or climbing protection. A rigid rail or a vertical cable runs the height of the ladder. The climber wears a full body harness and connects the front chest D-ring to a sliding device, the fall arrester, which travels with them and locks automatically if they fall. The free fall is very short, usually well under 0.6 m. Alternatively, a self-retracting device anchored above the ladder can be used for some climbs.

OSHA's 2016 walking-working surfaces rule changed the requirements for general industry. Under 1910.28(b)(9), fixed ladders that extend more than 24 ft above a lower level must have a ladder safety system or personal fall arrest system. New fixed ladders installed on or after November 19, 2018 must have one. When a section of an existing ladder is replaced, that section must get one. By November 18, 2036, all fixed ladders over 24 ft must have a ladder safety system or personal fall arrest system, and cages and wells will no longer count as fall protection. Construction rules in 1926.1053(a)(19) still allow cages, wells, ladder safety devices or self-retracting lifelines on fixed ladders over 24 ft.

Using a fixed ladder safely

• Inspect the ladder safety system, the fall arrester and your harness before climbing. The arrester must suit the rail or cable and be installed the right way up.
• Connect to the system from a safe position before you reach the fall hazard, and stay connected until you are on a guarded landing.
• Climb with three points of contact. The ladder safety system is a backup, not a handrail; do not lean back on it.
• Do not carry tools or materials by hand. Use a hoist or bag on a line.
• Use rest platforms on long climbs. Climbing a tall ladder is tiring, and fatigue leads to slips.
• Have a rescue plan. A worker arrested on a ladder safety system may be injured or exhausted. HSE-212 covers suspension intolerance and rescue.

Inspecting fixed ladders

Fixed ladders are exposed to weather, corrosion and damage, and they are often in places nobody looks at closely. Include them in the periodic inspection program. Check:

• anchorage to the structure, including bolts, welds and brackets;
• rungs for looseness, bending, corrosion and wear;
• side rails for cracks, corrosion and deformation;
• the ladder safety system rail or cable, tension, anchors, gates and stops;
• cages and hoops, if present, for damage;
• landings, platforms, guardrails and self-closing gates;
• ice, bird droppings, oil or other slippery build-up.

OSHA's 1910.22(d) requires walking-working surfaces, including fixed ladders, to be inspected regularly and as necessary and maintained in safe condition; ladder safety systems also need inspection by a competent person as the manufacturer requires, usually at least once a year.

Roof ladders and access hatches

Roof hatches and ladders from inside buildings are a common route to rooftop equipment. The opening at the top is a fall hazard both for the climber and for anyone walking on the roof. Hatches should have guardrails or a self-closing safety railing system around the opening, and grab bars or rail extensions to help the climber step out. Keep the hatch closed when nobody is using it, and never leave it open unguarded. Roof ladders that hook over a ridge are used on steep roofs by roofers and should be secured and used with fall protection.

Job-built ladders

On construction sites, a carpenter may build a wooden ladder for a specific location, for example to reach a formwork deck or to get in and out of an excavation. Job-built ladders must be built to a recognized design.

OSHA's 1926.1053(a) applies to job-made ladders as well, including rung spacing of 10 to 14 in, and ANSI A14.4 covers job-made wooden ladders. Single-cleat ladders are for limited lengths and one-way traffic; double-cleat ladders, with a center rail, are used where 25 or more workers use the ladder or two-way traffic is expected (1926.1051). The ladder must still extend above the landing and be secured.

Job-built ladders must be inspected like any other ladder, kept clean and removed when no longer needed. Nailed cleats should be fastened as the design specifies, with filler blocks between cleats where required, and never made of scrap or damaged lumber.

Planning for the change to ladder safety systems

Building owners with many fixed ladders face a long upgrade program. A typical approach is to survey every fixed ladder, record its height, condition and protection, rank the ladders by risk and frequency of use, and schedule upgrades. Ladders that can be replaced by stairs or eliminated by moving equipment should be considered first. Budgeting a few ladders a year is easier than replacing all of them at the last minute.

Ladders on equipment and vehicles

Fixed ladders are also found on machines, trucks, tanks, rail cars and mobile equipment. Getting on and off equipment is a common cause of falls in mining, transport and agriculture. The same principles apply: steps and rungs evenly spaced and slip-resistant, handholds at the right places, three points of contact, facing the equipment when climbing down, and never jumping from the last step. Keep equipment ladders clean of mud, ice and oil, and replace bent or broken steps promptly. Many equipment standards set step and handhold dimensions, and manufacturers' operating manuals describe safe mounting and dismounting.

Ships' ladders and alternating tread devices

Some workplaces have steep stairs called ship stairs, or alternating tread-type stairs, where space is too tight for ordinary stairs. OSHA's 1910.25 sets angles and dimensions for ship stairs (between 50 and 70 degrees) and alternating tread-type stairs (between 50 and 70 degrees, with specific tread rules). Users should descend facing the treads and hold both handrails. Where possible, replace them with standard stairs during renovations.

Retrofitting a fixed ladder

Retrofitting a ladder safety system to an existing fixed ladder is usually done by a specialist installer. The installer checks that the ladder and its anchorage can take the arrest loads, chooses a system compatible with the ladder's rungs or rails, installs it per the manufacturer's instructions and provides training and an inspection schedule. Owners should also check the top landing: a ladder safety system is of limited use if the climber has to unclip to step over an unguarded parapet at the top. A guarded landing with a self-closing gate completes the system.