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Rethinking "Dropped or Falling Objects" in Working at Heights Risk Management Strategies

When it comes to working at heights, most organisations focus on the obvious: fall from height and dropped tools and equipment. While these are significant hazards, they represent only a fraction of the risks posed by dropped or falling objects. From stored items and hung-up materials to failed structural components, the potential for catastrophic incidents is far greater than many realise. This article explores why organisations must expand their risk management and control frameworks to address all mechanisms of dropped or falling objects—not just the ones that fit neatly into a toolbox.

warehouse dropped object risks

The Narrow Focus: Why Tools and Equipment Aren’t Enough

Many organisations embed "dropped or falling objects" into their working-at-heights risk strategies, but their focus is often limited to tools and equipment. For example:

  • A worker drops a wrench from scaffolding, narrowly missing a colleague below.

  • A hammer slips from a ladder, causing minor damage but no injuries.


While these scenarios are dangerous, they represent only a small slice of the problem. By focusing solely on tools and equipment, organisations overlook other, potentially deadlier sources of dropped or falling objects.


The Hidden Risks: What’s Missing in Your Framework

Dropped or falling objects can come from a variety of sources, many of which are overlooked in traditional risk assessments. Here are the key mechanisms of drops that have the potential to kill or seriously injure someone:


1. Stored Items

  • Risk: Materials stored at height (e.g., pipes, bricks, or equipment) can fall due to improper securing, environmental factors (e.g., wind), or human error.

  • Example: A stack of metal beams on a high shelf collapses, sending heavy objects plummeting to the ground.

stored objects potential to fall

2. Hung-Up Materials

  • Risk: Materials suspended during lifting operations (e.g., cranes, hoists) can fall if rigging fails or loads shift unexpectedly.

  • Example: A steel beam being lifted by a crane slips from its sling, crashing onto the work area below.

    Crane lifting steel beam

3. Failed Structural Components

  • Risk: Structural elements like bolts, clamps, or scaffolding components can fail due to wear, corrosion, or improper installation.

  • Example: A corroded bolt on a platform gives way, causing a section of the structure to collapse.

structural failure

4. Environmental Factors

  • Risk Causes: Wind, rain, or seismic activity can dislodge objects or weaken structures, leading to falls.

  • Example: High winds blow unsecured materials off a rooftop, endangering workers and pedestrians below.

Falling object risk

5. Human Error

  • Risk Causes: Workers may accidentally knock objects over the edge or fail to secure items properly.

  • Example: A worker bumps into a stack of tools near the edge of a platform, sending them tumbling below.


Why Current Frameworks Fall Short

Many risk management frameworks fail to account for these broader risks because:

  1. Over-Reliance on Past Incidents: Organisations often focus on what’s happened before (e.g., dropped tools) rather than what could happen.

  2. Incomplete Risk Assessments: Assessments may lack input from workers who see these hazards daily.

  3. Lack of Awareness: Managers may not realise the full scope of dropped or falling object risks, leading to inadequate controls.


Expanding Your Risk Management Framework to Include Dropped or Falling Objects

To address all mechanisms of dropped or falling objects, organisations must take a holistic approach to risk management. Here’s how:


1. Broaden Your Definition of "Dropped or Falling Objects"

  • Include all potential sources of drops in your risk assessments, from stored items to structural failures.

  • Use a checklist to ensure no hazard is overlooked:

    • Tools and equipment

    • Stored materials

    • Hung-up loads

    • Structural components

    • Environmental factors


2. Conduct Comprehensive Risk Assessments

  • Involve frontline workers in risk assessments—they often spot hazards that managers miss.

  • Use tools like hazard mapping to identify areas where dropped objects are most likely to occur.


3. Implement Robust Controls

  • Engineering Controls: Install toe boards, tool tethers, and debris nets to prevent objects from falling.

  • Isolation Controls: Establish effective drop zones where there is a risk of dropped of falling objects that isn't being managed.

  • Administrative Controls: Develop clear procedures for storing, lifting, and securing materials at height.

  • PPE: Ensure workers wear hard hats and other protective gear - but treat this as a last line of defense.


4. Train Workers on All Risks

  • Educate workers on the full range of dropped object hazards, not just tools and equipment.

  • Include real-world examples in training to drive home the potential consequences.


5. Monitor and Improve

  • Regularly inspect work areas for new or overlooked hazards.

  • Investigate near-misses and incidents to identify gaps in your framework.


Case Study: A Near-Miss That Changed Everything

A construction company narrowly avoided tragedy when a hung-up steel beam slipped from a crane during lifting operations. The incident prompted a full review of their risk management framework, revealing gaps in how they addressed dropped objects. By expanding their controls to include hung-up materials, stored items, and structural integrity, they significantly reduced the risk of future incidents.


Conclusion:

Dropped or falling objects are more than just tools and equipment—they’re a complex, multifaceted hazard that demands a comprehensive approach. By broadening your definition, involving workers, and implementing robust controls, you can protect your team from the full spectrum of risks.


Don’t wait for a tragedy to rethink your strategy. Contact us today to learn how we can help you strengthen your risk management framework or considering a stand-alone Dropped or Falling Objects risk management strategy.





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