In 1977, five ironworkers fell to their deaths from improperly erected scaffolding on the construction site of a power plant in the Midwest. Donald, the site superintendent of the ironworkers, had been complaining about scaffolding deficiencies for several months. During one rather heated exchange, the general contractor’s superintendent told Donald he was making a big deal out of minor discrepancies — after all, nobody has died in all this time (a bad excuse for ignoring safety).
Then the superintendent told Donald to “quit being such a crybaby.” Nobody who reports a safety problem is a crybaby. Adding to the irony, Donald was one of the Chosin Few — a Korean War hero of unquestionable courage. This case (based on a true story, although names have been changed for privacy) illustrates how ignorantly that label can be tossed at someone who voices concern for workplace safety.
The day after those men died, Donald resigned. A few years later, Donald’s nephew fell between two unsecured scaffolding planks at a refinery expansion project in Louisiana. This scaffolding rose above the dome of a 210-ft cracking tower; thus, its top deck was a long way above the cement below. As the nephew slid down the dome toward the vertical tower wall, he got lucky and was able to grab a thermocouple well with his left hand. His work partner pulled him back onto the scaffolding, but the ordeal took considerable effort — and they almost failed.
We sure have come a long way on scaffolding safety since the 1970s. Right? Not according to the data collected from OHSA. Last year, scaffolding took the No. 4 spot for the number of violations. It wasn’t an off year, either. Scaffolding also took the No. 4 spot the previous year. In fact, scaffolding ranked third in 2019, 2018, 2017, 2016, 2015, and 2014. It took first place in 2013 and third place the prior year (2012).
If you keep going back, you find the number of OSHA citations for scaffolding violations for any given year is at or near the top — and never lower than fourth place.
If you are a scaffold user (but not a scaffold erector), as Donald’s nephew and those ironworkers were, you should understand that just because it’s up doesn’t mean it’s safe.
Part of the problem is many companies let unqualified people erect scaffolding. One solution, especially on large sites, is to outsource scaffolding erection to a company that specializes in it. But when such companies have labor shortages, they may take qualification shortcuts or have other problems that result in unsafe scaffolding.
Construction
Even if you don’t erect scaffolding, become familiar with the main rules. This will help you spot problems in how someone else is erecting the scaffolding, plus help you inspect it once it is erected. So, let’s look at some of the rules these people are supposed to follow; then we’ll look at how you can protect yourself whether they follow those rules or not. If you want to read the original OSHA text, it’s in 29CFR1926 Subpart L (1926.450 through 1926.454) plus the five appendices that follow (A, B, C, D, and E). It is dense reading.
- Only a “qualified person” can lawfully erect scaffolding. The term “qualified person” gets a lot of abuse, often being redefined on the fly for the sake of expediency. In this context, it means that everyone erecting, adjusting, maintaining, and removing scaffolding has the specific training and experience to correctly perform those functions. If your company’s insurer or the site policies require certification, make sure you have that before trying to erect whatever scaffolding that’s present.
- Have a solid foundation. Use base plates, mud sills, or other adequate firm foundations on which to set supported scaffold legs, poles, posts, frames, and uprights.
- Brace for non-impact. Check the legs, poles, posts, frames, and uprights to ensure they are plumb. If they sway or could be displaced, add bracing.
- Don’t forget the tip. What is the height to base width ratio (including outriggers) of your scaffolding? If it exceeds four to one, use guy cables or braces. Make sure you secure the cantilevered portions of platforms so they don’t tip; you may need to block the cantilevered end.
- Don’t use narrow platforms. Scaffold platforms and walkways must be at least 18 in. wide unless space doesn’t allow it. If there’s a space limitation, accommodate that in some way (e.g., erect a guardrail). This requirement does not apply to some types of scaffolds (such as roof bracket ones) that must be at least 12 in. wide.
- No partial planking. This just leaves a hole that someone can step through. So, ensure each platform on each working level is fully planked or decked.
- Secure to structures correctly. If that scaffolding must be secured to the structure (often a requirement due to needing the extra stability), use the prescribed methods at the prescribed positions. In one case, a contractor bolted to the fascia of the building rather than to a structural component. Upon loading, the fascia was torn off, and the scaffolding nearly tipped over.
- Heed overhead clearances. Allow for the height and reach of workers on the scaffolding — not just the height of the highest deck.
Inspection
An inspection tag doesn’t mean the scaffolding was correctly inspected. Donald encountered plenty of these. The scaffolding his nephew fell from bore such a tag. But don’t ignore these tags; aside from meeting pro forma requirements, they can be helpful (we will get to that in a moment).
Always conduct a thorough inspection. Don’t feel rushed to do this, and don’t skip the steps.
- Read the inspection tag. This is not done to see if the scaffolding is safely erected. It’s done to see how long it’s been since someone allegedly inspected it. Each inspection tag is supposed to have an expiration date on it. If that date is not even on the tag, report the scaffolding as being uninspected and thus unusable — same if the date is present but now expired.
- Ask about the installer(s). Ascertain whether qualified persons installed this scaffolding you are about to trust your life to. That does not mean asking your boss, “Did a qualified person install this?” Get some proof. It may mean asking to see the qualification certificates of those who installed the scaffolding. Will that cause a major kerfuffle on the job? Only if there’s not an attitude of safety first or if the boss is quick to toss out the “crybaby” slur.
- Give it a quick look-over for problems. Check each level that you can see from the ground to see whether the planks or decks look secure. Do any fasteners look loose? Is it set on a firm foundation? Does it look plumb, or is it tilting? Don’t try to fix any of these problems unless you are a “qualified person” for this particular scaffolding. Report any problems to your foreman, and use the scaffolding only after all those problems are resolved.
- Ensure each deck is clear. If there is junk (e.g., scrap wood or process waste) on a deck, remove it before using the scaffolding. If the scaffolding is outside and there is snow or ice on it, use a proper deicing method to eliminate the slipping hazard.
Use
The safety features of properly erected scaffolding can be defeated by improper use. Follow these tips.
- Keep it clear. For example, keep tools and small parts in buckets rather than strewn about.
- Use the correct fall protection for the situation. You can still fall, so have this as a backup.
- Control loads. When large items must be hoisted up to a level of scaffolding, ensure the hoisting process won’t tip the scaffolding.
- Don’t supplement with makeshift platforms. If the scaffolding won’t quite reach, add another stage rather than stand on a box or other object.
Ladders
If you use a ladder on a scaffold:
- Secure the scaffold against any lateral force from the ladder.
- Ensure all ladder legs are on the same platform or are isolated from unequal platform deflection.
- Secure the ladder legs, to prevent movement.
Beat the odds
It is well within the reach of any company to have zero violations for scaffolding requirements, instead of being average (mediocre) and letting this be among the company’s top safety problems. But for that to happen, scaffolding safety must be a team effort. Now that you know your part, you can help your team beat the odds.
Mark Lamendola is an electrical consultant based in Merriam, Kan. He can be reached at [email protected].
