Rope Access Guidebook
1-What is Industrial Rope Access?
2- Understanding the AHA, Access, Hazard, and Safe Zone 3-Equipment care, Inspection and Storage 4- Knots and basic rigging skills 5-Ascent & Descent equipment
1-What is Industrial Rope Access?
Industrial Rope Access is a proven method of achieving a safe work position at height or in areas of difficult access. It was initially developed from techniques used in caving to answer the need for a simple, safe and adaptable means of access with its first large scale use being for inspections on the oil and gas platforms of the North Sea. As its value as a work solution grew rope access has also developed onshore where it is to be seen undertaking all manner of work from high-rise window and facade cleaning and general maintenance to repair, geotechnical and inspection work on some of the world's most iconic structures. Rope access companies have delivered: o o o
an exemplary safety record based on a commitment to thorough training and diligent operational procedures a complete service that usually removes the need for the involvement of the majority of other access machinery or work equipment a minimal environmental footprint and the ability to work without disrupting public access or other work nearby
The main features of rope access in operation are: o o o o o o o o o
the rope access worker works from two ropes - a working rope and a back-up, safety rope - and is permanently attached to both each rope has a separate anchorage point in the unlikely event of the working rope becoming damaged or unusable, the safety rope prevents a fall to prevent accidental dropping all tools of a suitable weight are attached to the technician at all times; heavier items are independently suspended. a minimum of two technicians are required for any job so as to enable mutual surveillance - an extra safety feature all technicians receive extensive training and independent assessment and are required to undergo re-training every three years training includes rescue procedures even though Rope Access has an unrivalled record of safe working all equipment is regularly inspected and well maintained all training and operational work is conducted in line with Association Guidelines, wherever in the world it is conducted
Where is industrial rope access used? There are five main areas of work undertaken by rope access companies: Geotechnical/Civil Engineering Permanent Rock Anchorage Soil Nailing Sprayed Concrete Rock fall Prevention Meshing Pressure Pointing Inspection/Testing of Structures Structural Surveys Non-Destructive Testing (NDT) Various Maintenance and Repair, including Localized Concrete Repair Sealant Installation and Re-instatement Secondary Fixings Replacement Cladding and Glazing Cleaning and Painting Jet spray, grit blasting and three-tool method Spray Painting Roller brush Paining Full surface Preparation Facilities Management Building Services General Window Cleaning Glazing Inspection Replacement and Repair Services Repair Fitting and Maintenance Pest Control Façade Survey, Coating, inspection and maintenance Banner and Sign Erection
The benefits of using Rope Access The certainty of safe working and a single point of contact - teams provide both the safe means of access and undertake the work. Rapid set-up and dismantling, minimal disruption to building occupants, pedestrians and traffic flow. No security risk on site with all equipment removed overnight and no structure that might allow criminal use or vandalism.
The assurance that comes from employing a well-trained and supervised work force operating to effective and proven guidelines.
2- Understanding the AHA, Access, Hazard, and Safe Zone
Job Planning The Job Planning stage requires identifying the hazards, determining work methods that will mitigate these hazards, and outlining a rescue plan in the event of an emergency. Knowledge of the worksite, awareness of the hazards involved, familiarity with local personnel and emergency services are all crucial to planning a safe rope-access job. At a new or unfamiliar site, a preliminary site visit by the rope-access technician or even the whole team may be necessary to assure the work is completed in a safe and expedient manner. The rope-access Technician/Team Leader is responsible for completing the work plan and job hazard analysis (JHA) prior to the commencement of any rope-access work. All team members must review, comment, and sign the AHA prior to commencing the job. AHA’s Shall include: 1) 2) 3) 4)
• • • • •
5) • • • •
Site of rope-access work Dates of planned work Purpose of the work Rope-access personnel Titles Rope-access experience and certifications Mailing Addresses and mail stops Emergency contact numbers Team Leader designation Additional personnel Project or site representatives Safety Officers or S&H Professional
6)
• • •
7) 8) 9) • • • • • 10) 11) • • • • • • • • • • 12) 13)
Emergency phone numbers Project contacts Local emergency response contacts Communications during the work Structure and equipment status Lock out/ tag out procedures Facility or site contact name and number Special site or program requirements Equipment necessary Expected conditions during the work Hazards that may be encountered during the work Weather Biological (critters, insects, etc.) Rock fall Wet conditions Toxic/Low oxygen environments Height exposure Low-light conditions Dropped equipment Confined space entry plan Confined space air monitoring plan Work Methods Rescue plan, equipment and Personnel
Work Zones: Access, Hazzard and Safe zones
Work Zones The work site for rope access can usually be divided into three areas: the Access Zone; the Hazard Zone; and the Safety Zone . The Access Zone is defined as the area in which people are at risk from falling such as on-line or near a working edge. The Hazard Zone is any area where a person may be at risk as a result of the work being performed. The Safe zone is any area outside the Hazard Zone or the Access Zone. The Access Zone is the area where fall protection, fall-restraint, or rope-access techniques are required for safe work. Anchor points should be placed outside the Access Zone so that the worker can connect to the safety system before entering. Where the Access Zone is accessible to individuals other than the rope access personnel, the area shall be appropriately marked with signs or warning tape. This procedure may also serve to protect the rope-access workers below from outsiders tampering with anchors, knots, and rigging.
Frequently the Hazard Zone is below working rope-access personnel where any dropped or dislodged item might cause injury to workers or the public. Signs or warning tape can be used to prevent people from entering the Hazard Zone. Additional personnel may also be necessary to act as attendants both above and below the work area to make sure outsiders are not injured by straying into the Access or Hazard Zones. The Safe Zone is an area outside the direct influence of the rope-access operation. The Safe Zone must be designated well beyond the potential Hazard Zone, since dropped or dislodged items may bounce considerably farther than might be expected. Teams may use red “Danger, Do Not Enter” tape to cordon off the controls, or yellow “Caution” tape to isolate the access or hazard zones. Generally, red tape means: “do not enter”. It must be accompanied with a notice clearly prohibiting entry. This notice shall identify who must be contacted before the tape can be crossed.
3-Equipment care, Inspection and Storage Safety Checks Before beginning or proceeding with rope-access work, systematic safety checks must become a habit. The technician is responsible for doing these checks prior to entering the access zone. A co-worker must also perform these checks whenever possible. Below is a list of safety checks that must be performed before entering the Access Zone. The acronym RH3 can be used to help remember the fundamentals… Ropes: • Check ropes, knots, anchors, edge protection • Ropes are in good shape and not twisted • Knots are appropriate, properly tied, tightened, and with sufficient tails • Anchors are sound • Edge protection is in place Harness: • Properly fit, fastened, and connected • Buckles threaded properly • Fitted snugly • Screw links and other connectors coupled • No obvious damage to harness Helmet: Properly fit and fastened? Hardware: • Connectors locked and devices checked for function • Connectors are actually squeeze-tested to insure that they are locked. • Descender threaded properly and checked for function • Ascenders attached properly to harness and tested for function • Back-up device functional and properly attached.
Additional checking. In addition to the RH3 fundamentals, the following may also need to be checked: 1. Is extra gear (descenders, ascenders, footloops, runners, prusik loops, etc.) properly stowed so that the worker will not become entangled? 2. Are lanyards twisted around each other, under the worker’s legs, or parts of the harness such that they may cause difficulty? 3. Are the worker’s clothes appropriate for the conditions? 4. Are lights and communication devices adequately tethered to the worker? 5. Radio Check – all members of team?
Fall Factor The fall factor can be a useful way to describe the proportional seriousness of a fall. The fall factor is defined as the maximum distance a worker can fall divided by the length of rope (or lanyard connection) between the falling worker and the anchor.
Fall Factor = Free Fall Distance/Length of Rope (lanyard) The maximum allowed fall factor is 2. And whenever is possible the workers shall use anchor points above his/her head. It is possible to create a dangerous situation where the fall factor exceeds 2 when the worker has attached a lanyard to a vertical lifeline without a cable or rope grab. The resulting fall may be a fall factor of 3 or more, and will result in a very high and potentially lethal impact force! Important note: The fall factor only describes the distance of the fall in relation to the length of the connection to the anchor. It does not give you the more important measurement of peak impact force. But state that for the same distance fall a small Fall Factor means lower peak forces. With that in mind it is crucial to always be attached as high as possible.
Equipment Inspection
Proper documentation of origin, use and inspection of equipment is necessary to insure the integrity of rope access systems. The following guidelines shall be followed.
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Designate an equipment manager for the purpose of overseeing the care, storage, documentation, and replacement of equipment. Keep all manufacturer’s instructions and lot identification tags. Mark equipment so that it can be uniquely identified. A three-digit alphanumeric system (Example: ACD) will provide over 46 thousand unique combinations. Record equipment usage with notes regarding extreme or abnormal conditions of use. Immediately remove from service any equipment with signs of deterioration or excessive wear, or if it has exceeded manufacturer’s recommended work life. Each operator should visually inspect equipment before and after each use. Equipment should be thoroughly inspected and results documented by a competent person periodically (every 90 days is recommended).
Maintenance and Inspection of Software Components
Product All Synthetic
Care and Maintenance Avoid prolonged exposure to
Inspection and Retirement
Marking
Retire immediately if shock-loaded or
Use indelible marker on non-load bearing
Software
sunlight
including nylon and polyester sewn webbing, harnesses, ropes, lanyards and shock absorbers
Avoid chemical contaminates especially strong acids and bases Protect from sharp and abrasive surfaces Wash with mild detergent and warm water
signs of wear are noted. Check for:
components, tags, or tape
Unique identification Abrasion, fraying, or tears in fabric or stitching Fading, glazing, or unusual stiffness caused by heat, chemical contamination, or prolonged UV exposure
Hang dry and do not store wet Store in cool and dry location out of direct sunlight Harnesses
See above.
In addition to above check for: Wear, corrosion, cracks, and deformities of metal components
Use indelible marker on non-load bearing components (e.g. outside of padded waist belt).
Proper function of buckles and connectors (see inspection of connectors) Ropes
In addition to above: Avoid stepping on rope - dirt and sand pushed through the sheath can damage the core
Exposed core fibers or substantially worn sheath (50% of sheath fibers cut or abraded)
Store only dry ropes coiled or stacked in rope bags
Inconsistencies in rope texture or stiffness: Soft spots, bulges, or obvious changes in diameter indicate core damage
Use edge protection and anchoring techniques to protect ropes from sharp and abrasive surfaces
Lanyards and
In addition to above check for:
Use indelible marker on electrical tape and cover with heatshrink tubing. A recommended marking system includes: Rope type Diameter Length
Custom rope washers can be used
Unique ID number
Daisy chain ropes before washing ropes in basin or front loading washing machine
Date in Service
See above.
In addition to above check for: Signs of dynamic loading
Shock Absorbers
Maintenance and Inspection of Hardware Components
See above.
Product
Care and Maintenance
All Steel and Alloy Components Including connectors, descenders and rope grabs
Use keeper slings and good technique to avoid dropping while in use
Inspection and Retirement
Marking
Retire immediately if shock-loaded, dropped from 10 feet or above onto hard surface or if signs of wear are noted. Check for:
Light engraving on non-load bearing components
Clean before inspecting Unique identification Lubricate with silicon or Teflon™-based lubricant as needed after inspection
Hairline cracks and deep nicks
Do not store wet
Deformation
Store in dry environment
Grooving from rope wear Corrosion Sticky or frozen mechanisms Signs of shock-loading
Connectors (carabiners
In addition to above:
In addition to above:
Lubricate carabiner gates and quick-link threads
Function of locking mechanisms
Close quick-links before storing to avoid damaging threads
Look closely for cracking around pin and latches
and quick-links)
Descenders
In addition to above: Keep side plates of descenders closed when not in use Ensure latch is fully closed before loading
In addition to above check for: Wear of cam (the Petzl ID has a wear indicator)
Engrave lightly individual ID on locking sleeves or create batch identification and inventory system using paint (avoid moving parts) Location of light engraving will vary by type
Integrity of bolts, rivets, springs Proper function
Ascenders and Rope Grabs
In addition to above: Keep latches closed while not in use to avoid accidental damage
In addition to above check for: Condition of cam
Location of light engraving will vary by type
Integrity of bolts, rivets, cables, and springs Proper function
Wire Slings
See above.
In addition to above check for: Broken wires (especially
Separate ID tag can be fitted. ID # can be engraved lightly onto swage
around the swages) Cracks and deformities in swages Cable ends protrude beyond swage slightly (not more than 1/3 diameter of wire
Maintenance and Inspection of Other Safety Components
Product Helmets
Care and Maintenance Avoid chemicals, especially strong acids and bases, and avoid prolonged exposure to sunlight Clean prior to inspection
Inspection and Retirement
Marking
Retire immediately if helmet sustains an impact or is dropped from 10 feet or more onto hard surface. Check for:
Mark helmets with an indelible marker on harness, or on tape inside the helmet. Avoid using marker directly on shell. Especially avoid paint markers
Unique identification marking
Warm water and light detergent can be used
Conformity to relevant standards (CE or ANSI Z89)
Store dry and clean away from contaminates and direct sunlight
Cracks, dents or deep nicks in shell Deformation of shell
Avoid rough handling that can scar or groove shell Do not modify or alter shell or suspension in any way Headlamps should be mounted only on compatible fixtures or straps
Integrity of harness strapping system, buckles, and rivets anchoring it to the shell Check to make sure suspension points are firmly snapped into place
As stated in 29 CFR 1910.66 Appendix C, Section I, Paragraph (f), personal arrest systems must be regularly inspected. Any component of the system with significant defects such as: cuts, tears, abrasions, mold, undue stretching, alterations or additions, which will affect its efficiency, and damage due to deterioration, contact with fire, acids, or corrosives, distorted hooks or faulty springs, tongues unfitted to the shoulder buckles, loose or damaged mountings, nonfunctional parts and any wearing or internal deterioration of the ropes must be taken out of service immediately and should be tagged or marked as unusable or destroyed. All FP equipment shall be inspected before each use by the user and by a competent person at intervals of no more than one year (ANSI Z359.1 [6.1.1]). Inspection of the equipment by the competent person should be documented. All components and sub-components of the selected fall arrest, positioning, and restraint systems shall be compatible. As a general rule, always consult equipment manufacturers’ recommendations for use, inspection, care and maintenance.
Anchorage Systems: • • • • • •
Inspect all components of the anchorage systems. Observe any abrasions, wear points, damaged threads, or swags in the sling material before use. For synthetic slings and anchor straps inspect all sewing and loops for wear, chemical damage, burn damage, and/or ultraviolet deterioration. Refer to the anchorage-attached tags to determine when the sling should be retired. Inspect cable slings for excessive damage to the steel fibers. Certify the anchorage system exposed to weather or corrosive conditions.
Snap Hooks and Carabiners: • • • • • • • •
Inspect on regular basis and before each use. Retire snap hooks, carabiners, and all integral components if any discoloration deformation, cracks, or abrasions are detected. Retire immediately if it has sustained any fall, or if the spring brake and gate are bent, or if the gatekeeper no longer engages the slot cleanly. Damaged snap hook and carabiners shall be tagged and removed from service and the inventory list. Dirty snap hooks and carabiners shall be cleaned with kerosene, WD-40, or similar solvent and immersed in boiling water for 30 seconds to remove cleaning agent; dry with a soft cloth to ensure that the gate and gatekeeper operate properly. Carabiners shall not be loaded along the gate side. Snap hooks shall not be side-loaded. Ensure that only double-locking-type gates are used.
Lanyards and Energy Absorbers: • • • •
• • • • •
Inspect lanyards put under a slight tension on a regular basis. Check all components for abrasion, discoloration, cracks, and torn stitching. Wash lanyards and energy absorbers on a regular basis to remove dirt and grit, which can abrade the fibers. Lanyards and energy absorbers shall have a permanently attached label indicating the manufacture’s name, serial number/lot number, manufacturer date, maximum elongation, maximum arresting force, maximum free fall, and capacity. The lanyards and energy absorbers must also have permanently attached labels that indicate they meet OSHA & ANSI Z359.1 requirements. Lanyards baring the markings of ANSI A10.14 only are not acceptable and they should be taken out of service. Use and review manufacturer’s logbook provided with the equipmen to determine the age of the lanyard and energy absorber. Lanyards and energy absorbers shall be inspected by the user prior to each use and by a competent person other than the user at least once a year. Maximum usage of a lanyard shall not be more than 5 years, once put in service (assuming the new unused lanyard is stored in a climate-controlled location, [i.e., in a plastic bag not exposed to fumes, and in a cool location out of direct sunlight]. Retire the lanyard:
• • • •
After a hard fall When the shock absorber has been even slightly impacted If the lanyard has been used for any other purpose other than fall protection If the equipment show excessive wear, chemical damage, burn damage, and/or ultraviolet deterioration
Fall Arrester (Rope Grab) • • •
Inspect regularly. Check for signs of wear, corrosion, rust, and other anomalies. If any sign of wear or malfunction, remove devise from service immediately.
Self-Retracting Lifelines (SRL): • • • •
Inspect before each use. Inspect by a competent person once every six months and by the manufacturer annually. SRL shall be returned to the manufacturer for servicing and re-certification once a year. If SRL housing becomes yellow, gathers condensation, or the indicator has been engaged, remove from service immediately, and return it to the manufacturer for repair and re-certification.
Body Support (Harness): •
Inspect on a daily basis or before each use for frayed threads, cuts, tears, or loose
• • • • • • • •
•
connections. Inspect the stitched areas thoroughly. Look for burn holes from welding or other heat sources. Ensure harnesses are not painted or marked. Store harnesses in a cool, dry, and safe environment; ideally in a locked storage area. A competent person other than the user shall inspect the harness periodically, or at least once a year. Wash the harness in a mild soap and rinse multiple times to remove any soap residue and hang to dry out of direct sunlight in a cool, dry environment. Maintain a logbook indicating the date of entry into service, the nature of the work performed, washing the harness, or other relevant details. Retire harnesses from service after five years from the date put in service (assuming the new unused harness is stored in a climate-controlled environment [i.e., in a plastic bag not exposed to fumes, and in a cool location out of direct sunlight]). The body support harness shall have a permanently attached label indicating manufacturer’s name, serial number/ lot number, manufacturer date, capacity, and that it meets OSHA & ANSI Z359.1 requirements.
Ropes (Natural or Synthetic Fibers): • • • • • • •
Inspect rope periodically for broken fibers, severely worn areas, or change in the consistency of the core; inspect under slight tension and check for soft areas, bulges, or excessive stiffness. Avoid exposing rope to hazardous chemicals, moisture, acids, or oils. Do not use the rope after it is impacted or damaged. Wash the rope on regular basis to remove dirt or grit with lukewarm water and mild detergent; rinse several times to remove soap residue and hang in a dry, cool, dark area. Store rope in a strong weatherproof bag. Rope should always be dry before placing in storage. Rope shall have a permanently attached label indicating manufacture’s name, serial number/ lot number, manufacture date, capacity, and that it meets OSHA & ANSI Z359.1 requirements. Retire rope after five years of service. If it is damaged, impacted, or exposed to chemicals, remove from service immediately.
Vertical Lifelines (Flexible): Refer to manufacturer’s recommendations regarding inspection, care, and maintenance. Ladder Climbing Systems: • •
Inspect on a regular basis and as per equipment manufacturer’s requirements. The sleeve should run freely without hand operations or guidance.
• •
Check cable and rails for abrasions, wear, looseness, and cracks. Before climbing, check integrity of cable, systems, and ground level.
Raising/Lowering Devices (Rescue): • • •
Inspect before each use. Check for wear and corrosion. Refer to the rope section for additional information.
4- Knots and basic rigging skills
Knots and hitches are indispensible tools for a rope-access technician. Only appropriately trained personnel shall use knots in industrial applications. Sewn or swaged terminations (Figure ) are often used as an alternative to knots because they are usually stronger and require less training to use. Factory-installed terminations, however, limit the adjustability of the connection to the rope.
Swaged Termination , maintains 100% strength of rope Knots, or any tight bend for that matter, will weaken rope by as much as forty percent, depending on the knot used (Table 6-1). This, however, may be an academic point since ropes would be of little use without knots and safe working loads for ropes are usually figured at 10:1 to account for the decrease in strength attributed to knots. The strength of knots is often expressed as a percentage reflecting the residual rope strength after the knot is introduced. The residual rope strength will depend on the type of rope and how it is tied. Cleaning up a knot and making sure to minimize twists and tight bends is called dressing a knot. A well-dressed knot is generally stronger and easier to inspect. It is critical to use knots for their intended purpose. Some knots require a back-up knot, while most knots must be tied with at least 4 inches of tail.
Common Knots and Hitches Figure-8 knot – a convenient and commonly used end knot that is easy to tie and inspect. The knot can be rethreaded and tied through a fixed loop, such as a harness D-ring.
Butterfly Knot – a middle knot used to form a connection point or isolate a damaged section of rope. Note: If both ends of the knot will not be tensioned then a figure 8
Water knot (a.k.a. ring bend or tape knot) -- used to tie the ends of webbing together. Note: The water knot is susceptible to working itself loose through cyclic loading.
Barrel Knot – used as an end or stopper knot. Note: The barrel knot cinches down onto a carabiner if used as an end knot.
Double fisherman’s knot -- used to tie the ends of ropes or accessory cord together.
Prusik –a friction hitch that can be used as a rope grab on a tensioned line. Note: A prusik loop is formed using about 5-6 feet of 7 or 8 mm accessory cord tied into a loop using a double fisherman’s knot. The prusik knot can be used as an emergency mechanical ascender, back-up device, and in various rescue situations. The strength of prusik knots varies considerably depending on the combination of rope and cord used. Prusiks should not be used in lieu of back-up devices in regular work applications.
Girth hitch—used to create anchor Points
-Inspection of anchors -Assessment on equalization and direction of pull
5-Ascent & Descent equipment
Rope adjustment devices: Descenders e.g. (Petzl ID, Petzl Stop) These are used to attach the worker to the main working line and to control the descent. It is recommended that only descenders of a design that have a known history of safe use are used. Descenders must give the user suitable control over the speed of descent, should not cause undue shock loads to the working line when braking and be such that, if the user loses control, they will stop, or allow only a slow, automatically controlled descent in the hands-off position. In addition, they should not cause significant abrasion, plucking or stripping of the sheath when suddenly clamped onto the working line. They should be of a type that cannot be accidentally detached from the working line or become detached under any circumstances while carrying a person's weight. If a connector is used to attach it to the user, only an appropriate locking connector should be used. For long descents, preferred descenders should be those with good heat dissipating properties to prevent burning of the hands and melting of the working line, and those that reduce cumulative twisting of the rope to a minimum.
Rope adjustment devices: back-up devices o rope grab e.g. (Petzl ASAP, Petzl Shunt) These are devices by which the operator is attached to the safety line. In the event of a failure of the working line or loss of control by the operator, they are intended to lock on to the safety line without causing damage to the line and also to absorb the limited shock load that may occur. Ideally, back-up devices should always be positioned on the safety line so that in the event of a failure in the working line system, the load will be taken immediately on the back-up device without a fall occurring. There is an advantage in using back-up devices that can be released by the operator without de-weighting first. However, correct functioning of this type of back-up device critically relies on the loading being applied via the cam and not the body (i.e. grabbing the body of the device may cause it to slide down the rope and prevent it from functioning properly). It is recommended that back-up devices are of a type that will not slip below a static load of 2.5 kN. Ideally, these devices should require minimal operator manipulation.
Rope adjustment devices: ascenders e.g. (Petzl Croll, Hand ascender) These devices are attached to the working line and are used when the operator wishes to climb up it. They should be chosen bearing in mind the suitability for use in the prevailing environmental conditions, e.g. wet, muddy, icy, abrasive or corrosive conditions. Typically, there are two types of ascender used in the system. The first type is used to connect the operator directly to the working line. The other type is attached to a foot loop to aid climbing, but is also connected back to the harness to provide additional security. Ascenders should be of a type that cannot be accidentally detached from the line and should be chosen so that the risk of damage to the line is minimized when in use. Any dynamic loading should be avoided as damage could result to either the ascender or the line.
Cow’s tails or Dynamic Lanyards 'Cow’s tails' used to connect the worker's harness to the safety line via the back-up device should be able to withstand any dynamic forces that may be imposed upon them in times of emergency. They should be of a quality and dynamic strength at least equal to that of a ‘single’ dynamic rope. If an energy absorber is incorporated into the system (other than that provided by the energy absorbing qualities of the material used in the construction of the cow’s tail), it should meet the requirements of OSHA. In normal use, the length of the cow’s tail should be limited to the person’s reach(aprox 3 feet), which will vary from user to user.
Minimal Compulsory Rope Access Worker equipment: (not visible on picture: chest croll, hand ascender, short sling)
By: Vertical Specialist Ponce, Puerto Rico www.verticalspecialist.com
