Falls and Lifting in Steel Structure Erection

Steel erection safety: where does the risk begin?

The steel frame of an industrial building rises within a few weeks. For most of this time, erectors work on a structure with no guardrails, no decking and often no fixed point to attach to. Steel erection safety therefore starts long before the "wear your harness" instruction, when decisions are made on the erection sequence and equipment.

The Regulation on OHS in Construction Work governs steel structure work with both general and specific provisions:

Annex 4 (A), work at height: Erection work that does not have to be done at height is done at ground level as far as possible; safety is ensured first by collective protection measures such as guardrails, platforms and safety nets. Where collective protection is not enough, anchor points or lifelines are created and full body harnesses are used. The anchor points needed for lifelines are determined at the project preparation stage.
Annex 4 (B), Art. 87–91: Steel members, including temporary supports and props, are planned to withstand the loads placed on them; corroded or deformed material is not used without the necessary measures.
Annex 2, item 11: The erection and dismantling of heavy prefabricated members is among work involving particular risks; specific measures for this work must be included in the health and safety plan (Art. 10/1-b).

Erection plan: sequence, temporary stability and roles

A written erection plan shows which member will be erected in which order, with which crane and which fall prevention method. The plan should cover at least the following:

Erection sequence: The first columns and beams are chosen so that the structure forms a stable "box". Advancing on a single unstable column creates a risk of collapse in wind or on impact.
Temporary connections: When the beam has been seated, when can the crane rope be released? The regulation does not set a number of bolts; in international practice, for example in the steel erection standard of the US Occupational Safety and Health Administration (OSHA), the load is not released from the rope until the member is secured with at least two bolts at each connection. The temporary connection detail set by the project's structural engineer should be written into the plan.
Temporary bracing and props: Which temporary supports will be used until permanent stability members are complete, and when they can be removed.
Fall prevention method: Which of platform, net or lifeline will be used at each erection stage.
Personnel: Erection supervisor (competent person), crane operator, signaller and slinger, erectors and the rescue team.

If more than one employer is working on site, the plan should be linked to the health and safety plan of the employer responsible for the whole construction site. For the general framework of the regulation, see our article on the Regulation on OHS in Construction Work.

Why should walking on beams be the last option?

Walking on beams means the erector moving along a narrow flange several metres up with no point to attach to. Shuffling along astride the beam does not remove the risk of falling either. Safer alternatives are:

Method	When is it suitable?	Point to watch
Scissor lift or boom lift	If the ground is firm and level and the height is within the platform's reach	The harness is attached to the anchor point specified by the manufacturer in the basket
Lifeline fitted in advance at ground level	If stanchions and rope can be fitted on the ground before the beam is lifted	Anchorage and sag of the line according to the manufacturer's instructions
Safety net	Erection of wide-span roofs and floors	The net is installed close to the working level with enough clearance below
Beam clamp and twin-leg lanyard	Short moves	One leg always stays attached; the anchor capacity is verified

For selecting and using platforms, see our article on scissor lifts and boom lifts. Work at points that cannot be reached by platform should be planned with a work at height permit form.

Installing the lifeline early, and fall clearance

Lifelines are often installed after erection is finished, yet the moment they are most needed is the erection itself. The solution is to fit the lifeline stanchions and rope to the beam at ground level before it is lifted by crane. That way, the line the erector will attach to is ready the moment the beam is seated. For types of anchors and lifelines, see our article on anchor points and lifelines.

For a harness to work, the falling person must stop before hitting anything. A simple example calculation:

Length of the energy-absorbing lanyard: 2 m
Deployment of the energy absorber (maximum under TS EN 355): 1.75 m
Distance from the harness attachment ring to the soles of the feet: about 1.5 m
Safety margin: 1 m

Total: about 6.25 m. If the anchor point is at foot level or a horizontal lifeline is used, the sag of the line is added to this distance. If there is not this much clearance below, the lanyard cannot stop the fall in time; a short lanyard, a retractable fall arrester or a safety net should be considered. Always do the calculation with the values in the manual of the product being used. For harness selection, see our article on full body harnesses, and for rescuing a suspended worker, suspension trauma and rescue.

Crane work in steel erection: lifting and guiding

In steel erection crane work, some accidents are caused not by falls but by being struck by a swinging load or being under the load. Annex 4 (B) of the regulation requires lifting accessories suited to the type, size and shape of the load, and audible and visual warnings on lifting equipment (Art. 58, 60). The following rules should be applied on site:

For every lift, the load weight, centre of gravity, crane radius and load chart are checked in advance.
The beam is slung in balance relative to its centre of gravity; slings and hooks suit the load's weight. For details, see slings, chains and lifting accessories.
The load is guided not by hand but with a tag line; nobody goes under a suspended load.
A single signaller communicates with the operator. For the role description, see our article on crane signallers and slingers.
If the wind speed exceeds the limit set by the crane manufacturer, lifting is stopped. Roof panels with large surfaces are more affected by wind; see cranes and work at height in strong wind.

Mobile cranes and lifting accessories are subject to annual periodic inspection under Annex III of the Work Equipment Regulation; tower cranes are inspected by accredited inspection bodies. These inspections are carried out by authorised persons and organisations. For the operator's certificate, see our article on the crane operator certificate.

Bolting at height: tools and falling objects

When bolting at height, the risk is not only the erector falling; a dropped nut or spanner is a serious hazard for anyone below. Measures:

Spanners and nut runners are tethered to the wrist or harness with a tool lanyard.
Bolts and nuts are carried in a lidded bucket; the bucket is lowered in a controlled way on a suitable rope, not by crane.
The reaction torque of a nut runner can unbalance a worker at the edge of a platform; the tool is held with both hands and the body stays inside the platform.
No walkway is left below the erection level; the area is closed off under Art. 90.
If site welding is carried out, an MYK (Vocational Qualifications Authority) certificate is required for steel welders; see welder certificate.

Site checklist

Before starting each erection day:

Has the team read the erection plan and the day's lift list?
Is the competent person on site, and does everyone know who they are?
Have lifelines and anchors been checked; has the daily visual check of harnesses been done?
Has the erection area been taped off, and is anyone working below?
Is the crane's periodic inspection report valid, and has wind speed been measured?
Are the rescue equipment and rescue team ready?

At Bursa Sistemer OSGB, as part of our OHS specialist services on sites in Bursa and neighbouring provinces, we link the erection plan to the risk assessment, and we plan periodic inspections of cranes and lifting equipment with authorised persons and track them through the periodic inspection schedule. For other risks specific to the construction sector, see our construction page.

Frequently Asked Questions

Is wearing a harness enough in steel erection?

No. The regulation first requires collective protection measures: platforms, guardrails and safety nets. The harness is used where these are not possible, together with an anchor or lifeline for which the fall clearance has been calculated.

Is walking on beams prohibited?

There is no prohibition by that name in the regulation; however, the principles that work not required to be done at height is done at ground level and that collective protection takes priority mean that walking on beams is acceptable only when no other method can be applied, and only while attached.

Who should manage the erection?

A person competent in steel erection appointed by the employer. This person applies the erection sequence in line with the design, checks temporary connections and is responsible on site for the safety of the erection area.

Can people work below the erection area?

No. The Regulation on OHS in Construction Work explicitly requires that no workers be present below the place where erection work is being carried out.