Lifeline Fall Protection

Lifeline Fall Protection for Truck Loading Safety

For industries managing flatbeds, tankers, and hoppers, consistent access is a daily challenge. SafeRack’s lifeline fall protection for truck loading systems provides a critical safety link, securing workers while performing tarping, loading, and inspection duties. Unlike temporary fixes, our Horizontal Lifeline systems (HLL) offer a permanent, OSHA-compliant environment that reduces liability without slowing down operations.

Why Choose Overhead Lifeline Systems?

Falls from heights remain a leading cause of industrial injury. In 2023, there were 885 workplace fatalities due to falls, slips, and trips. Transportation and material moving was the second deadliest industry with an average of 13.6 deaths per 100,000 workers. 

In 2022, non-fatal falls to lower levels accounted for 129,010 injuries resulting in days away from work, reduced, or transferred (DART). The median number of DART days was 28, resulting in countless lost work hours. Preventative measures save lives, medical costs, and lost productivity. 

SafeRack’s truck loading fall protection lifeline provides continuous anchorage and safety directly above the user, allowing a full range of motion on elevated containers while reducing risk. A few benefits that SafeRack’s overhead lifeline system offers include:

• Continuous Safety: The traveler glides seamlessly along the cable or rail, allowing workers to move the full length of the truck or railcar without unhooking.
• Reduced Deflection: Our systems are engineered to minimize cable sag (deflection) during a fall event. This is critical for low-clearance applications where every inch of stopping distance counts.​
• OSHA-Compliant: SafeRack equipment is designed to either meet or exceed all OSHA regulations. 
• Versatile Applications: Whether you need protection for a single bay or a multi-vehicle lane, our systems adapt to your specific traffic flow.
• Customizable Design: Every facility has unique constraints, with overhead cranes and tight spacing requiring attention. We can customize your truck loading lifeline fall protection to match your current infrastructure with minimal impact on ongoing operations. 

Lifeline Cable Systems VS Trolley Beams

SafeRack’s overhead lifeline fall protection for truck loading comes in trolley beam and cable system forms. Lifeline cable systems are lightweight and shock-absorbing horizontal fall protection made for truck tank container loading and unloading. It is adaptable and useful in environments with limited access and low-volume operations. They can span up to 200 feet, and support up to 4 workers at once. 

Trolley beam fall protection can use L or T-style support column lifelines. These systems have zero sag and are ideal for lower clearance facilities, such as inside buildings. The rigid track allows smoother travel across a truck and is made of galvanized steel that can keep operators safe for years. 

SafeRack: Your Safety Partner

SafeRack’s support does not end with providing safety equipment. We are a turnkey operation that can assist with every stage of the process. Our team can conduct onsite assessments to highlight areas where safety and efficiency can be improved, design components to match your facility, install units, lead training on how to use the systems, and provide complimentary safety checks. 

Contact us today to speak with a safety expert who can learn the issues you face and offer potential solutions that save you time and money while preventing serious injury. 

Frequently Asked Questions

What are the OSHA Requirements for Overhead Lifelines?

The OSHA requirements for overhead lifelines include many provisions we address. OSHA requires that horizontal lifelines be designed, installed, and used under the supervision of a qualified person as part of a complete fall arrest system. These systems must maintain a safety factor of two above the maximum arresting force of a fall. This means that if a fall would generate 2,000 lbs of force, the system must withstand at least 4,000 lbs. SafeRack’s systems are fully engineered to meet or exceed these rigorous standards.​

Can I Retrofit a Lifeline Into My Existing Warehouse?

SafeRack specializes in retrofitting lifeline fall protection into existing structures. We can clamp systems to your current overhead steel beams, install wall-mounted supports, or erect freestanding “inverted L” or “T-frames” if your building structure cannot support the load.

How Often Do Overhead Lifelines Need to Be Inspected?

OSHA requires a pre-use inspection by the user every single day to check for visible damage, such as frayed cables or loose tension. Additionally, a documented annual inspection by a “Competent Person” is required to certify that the system remains safe for use.