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Understanding OSHA Requirements for Guardrail

As the leading resource on fall protection, we at Diversified Fall Protection are frequently asked for help understanding and complying with OSHA requirements for guardrail and safety railing systems.

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Below, we’ll explain OSHA’s official rules on guardrail for general industry applications and show you how your business can remain compliant with these regulations.

For more help, contact the team of experts at Diversified Fall Protection. Our engineers will design and implement a complete, OSHA-compliant guardrail system to protect your team when working on rooftops and other elevated surfaces.

What is a guardrail?

A guardrail, or guard rail, is a stationary, fixed fall protection system designed to prevent workers from stepping over the edge of a walking-working surface. OSHA .29(b) is the portion of the regulations that contains system requirements that employers must follow to ensure guardrail systems will protect workers from falling to lower levels.

Three main parts of a guardrail

There are three main parts of a guardrail: The top rails, the midrails, and the vertical posts. Each part of the guardrail must comply with OSHA’s rules, including material type, size, height, and location. We explain each of these below.

Guard Rail Requirements

Diversified Fall Protection provides turnkey guardrail systems that comply with all of the following OSHA requirements for guard rail.

Railing height for guard rail

According to OSHA, the top edge height of top rails (or equivalent guardrail system members) must be 42 inches (107 cm), plus or minus 3 inches (8 cm), above the walking-working surface. The top edge height may exceed 45 inches (114 cm), as long as the guardrail system meets all other criteria.

Guardrail is required for any platform 4 feet or higher above a lower floor or the ground. Guardrails are required have vertical heights of 42 inches from the upper surface of the top rail to floor, platform, runway, or ramp level.

Mid-rails

If there is not a wall or parapet at least 21 inches (53 cm) high, then midrails must be installed halfway between the top edge of the guardrail and the walking-working surface. Screens, mesh, intermediate vertical members, solid panels, or other equivalents can be considered “midrails” for this purpose.

If screens and mesh are used, they must extend from the walking-working surface to the top rail and along the entire opening between top rail supports.

Intermediate vertical members (such as balusters) must be installed no more than 19 inches (48 cm) apart. Other equivalent intermediate members (such as additional midrails and architectural panels) should be installed so that the openings are not more than 19 inches (48 cm) wide.

Guard rail strength

OSHA requires guardrail be strong enough to withstand force both outward and downward along the top rail and at the midrail section.

Guardrail systems need to be capable of withstanding a force of at least 200 pounds (890 N) at any point along the top rail. This force is applied in a downward or outward direction within 2 inches (5 cm) of the top edge. When tested in a downward direction, the top rail of the guardrail system must remain at least 39 inches (99 cm) above the walking-working surface.

Midrails, screens, mesh, solid panels, and other equivalent intermediate members must be capable of withstanding, without failure, a force of at least 150 pounds (667 N) applied in any downward or outward direction at any point along the intermediate member.

Smooth surfaces required for guardrail

Guardrail systems need to be smooth-surfaced. This is to protect employees from injury, such as punctures or lacerations, and to prevent catching or snagging of clothing. Our railings have a powder-coated finish to meet this requirement.

OSHA also requires that the ends of top rails and midrails do not overhang the terminal posts, which are the posts at each end. The only exception is if the overhang does not pose a projection hazard.

Similarly, steel and plastic banding are not permitted to be used for top rails or midrails, and guard rails must be at least 0.25-inches (0.6 cm) in diameter or in thickness. These requirements also protect workers from injury caused by too much force applied at these points.

Guardrail near hoist areas and holes

OSHA says that when guardrail systems are used at hoist areas, there needs to be a removable guardrail section placed across the access opening when employees are not performing hoisting operations. This section must have a top rail and midrail. You may use chains or gates instead of a removable guardrail section if you show they provide the same level of protection as guard rails.

Guardrail systems used around holes must be installed on all unprotected sides or edges of the hole. If materials will be passed through the hole, no more than two sides of the guardrail system can be removed at a time. When materials are not being passed through the hole, the hole must be guarded by a guardrail system along all unprotected sides or edges or closed over with a cover.

Guardrails at point-of-access holes

When used around holes that serve as points of access (such as ladderways), the guardrail system opening needs to have a self-closing gate that slides or swings away from the hole. The gate must have a top rail and midrail (or equivalent intermediate member) that meets the requirements for guardrail above. The other option is to offset it to prevent an employee from walking or falling into the hole.

Guardrail for ramps and runways

For ramps and runways, guard rail must be installed along each unprotected side or edge. You can use Manila or synthetic rope for top rails or midrails if it is inspected as necessary to ensure that the rope continues to meet OSHA strength requirements described above (the 200-pound and 150-pound tests).

Different Highway Crash Barriers:Guard Beams & Steel Wire Cable Guardrail

highway Guardrail System are used to provide good safe guard for highway and expressway.Here we introduce two forms of crash barriers,wave beam guardrails and steel wore cable guardrail.

beam guardrail is consisted of two beams and posts fixed between them.Beam barrier is the main form of the semi-steel railings,which is a continuous structure that is stitched with a corrugated steel guardrail and supported by a pillar.

It absorbs the collision energy through the deformation of the soil base, the post and the beam, and forces the uncontrolled vehicle to change direction and returns to the normal direction to prevent the vehicle from rushing out of the road,so as to protect the vehicle and passengers, and reduce the loss caused by the accident. Beam guardrail features strong ability to absorb the impact of energy, and good transport induced vision function. It can be coordinated with the road line shape,and can be used for roads with small radius curves.

The classification of the guardrail beams: Guardrail Beam is generally classified by location and crash level. According to the location,it can be divided into roadside guardrail and central divider guardrail. According to the crash level, it can be divided into A and S level. S-class rail is reinforced to be suitable for especially dangerous use of the roadsides, while A-level for the special roads.

The material for the guardrail beams are high quality steel plates with anti-corrosion treatment.The manufacturing process includes high-quality steel plate with pickling treatment, stamping into a double wave or three wave plate, after that is hot galvanized or hot galvanized plastic spraying treatment.Often used as railing, decoration, protection and other facilities for industrial, agricultural, municipal, transportation and other industries.

The other highway barrier is Steel Wire Cable Guardrail,also called cable crash barrier? normally.There are generally two specifications for wire cable guardrail: 5 layer cable guardrail and 6 layer cable guardrail. Cable barrier are all adopted hot galvanized treatment, and some with PVC dipping treatment, the two anti-corrosion guardrail measurements both make the steel wire cable have very good performance, while the dipping treatment cable guardrail has a better visual effect. According to the engineering requirements to choose from.

Steel Wire Cable Guardrail components: cable guardrail posts?, cable, cable guardrail middle post, spacer and so on. For the cable guardrail, the post mainly play the role of supporting the cable. The cable guardrail is supported at both ends of the post, and the cable need to be tighten up so as to ensure the effective protection of the whole guardrail.Main application: highways, railways and protective zone on the both sides of bridges;airport, port, wharf;mountain and tourist attractions road safety protection.

Compared with the traditional guardrail barrier, cable guardrail has better unobstructed view of the horizon for visitors to enjoy the natural landscape. The additional advantages includes preventing secondary injuries and reducing the safety accident of drivers and passengers; Better view of road surface, reducing the driver’s eye fatigue.

Guardrail And Safety Railing For Fall Protection

Falls from heights are one of the leading causes of severe injuries and fatalities in construction, manufacturing, and other industries. This is primarily why there is a shortage of workers in the construction industry, as workers risk their lives every day, and an incident causes pain and suffering to the victim and a financial burden to their family.

Thus, fall protection systems, such as guardrails and safety railings are an absolute necessity. This article will discuss the guardrail protection requirements and the available systems.

What Is a Guardrail?

Before diving deep into the topic, let’s first discuss what guardrails are and how they differ from handrails. Guardrails are protective railings along the roof, road, or other elevated spaces to prevent accidents on construction sites and other workplaces. According to the Occupational Safety and Health Administration (OSHA), guardrails are one of the three major ways to prevent falls when working at heights. Other options include fall arrest systems and safety nets.

Guardrails come in different styles and can be customized according to the site. Each guardrail consists of a top rail, an intermediate rail, and toeboards to prevent equipment and employees from falling off the ledge. Guardrails are used not only to avoid falls but also to alert employees about the presence of hazards and restrict access to unauthorized areas.

To simplify, guardrails are considered life-saving devices, and here is where they differ from handrails. Handrails provide a handhold for support on stairs, slopes, and other surfaces where people might need assistance climbing or walking. It provides stability and is not used for life-saving purposes.

Now that we know what guardrails are and how they are essential for fall protection, let’s move on to the types of guardrails.

Rooftop freestanding guardrails are fall protection systems that do not penetrate the roof membrane. They are long-lasting and versatile and can be customized according to your preferences.

One of the significant disadvantages of installing guardrail systems on the rooftop is that the bases and rails are heavy and add more weight. Therefore, you need proper weight-distributing structures. Freestanding guardrail systems have counterbalance systems that distribute the weight and reduce the strain on the roof. Moreover, a site can also opt for infill panels to convert the guardrail into a roof for added protection. It has lightweight modular counterweights that allow maximum flexibility on site.

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This guardrail system protects the roof hatch opening in construction sites. It also has a modular design and can adjust to fit an opening of any size. These guardrails also come with a swing gate, multiple mounting options, and a weather-resistant powder coating. Roof hatch guardrails are also non-penetrating and keep your site compliant with OSHA requirements.

If your construction site has high-sloped roofs, slippery metal roofs, or loading docks, you must install permanent guardrail fall protection systems to prevent employees and equipment from slipping off the edge. They are not as flexible as free-standing guardrails but ensure everyone is protected while working on elevated spaces.

A mobile guardrail comprises modular sections that can be assembled and disassembled when necessary. It is ideal for temporary solutions and can be laid out according to the structure of the roof or construction site. Workers can use these mobile guardrails in multiple construction sites without compromising on OSHA requirements. Mobile guardrails are non-penetrating fall protection systems held upright by galvanized steel collars and set screws.

Safety swing gates are also important for fall protection and to ensure employees’ safety when getting access to elevated heights. Swing gates open from both sides, thus offering quick access to safety in case of potential hazards. Moreover, swing gates also restrict the intrusion of unauthorized personnel into a working area. Swing gates are used for ladders, mezzanines, rooftop hatch, etc.

Metal rooftops have uneven surfaces, increasing the risk of rooftop hazards and falls. Guardrails for metal roofs are pre-engineered and can mount directly to the corrugated folds of a metal roof. The weight is distributed over a wide area with the help of base plates and ensures that the railing stays firm.

Requirements For Rooftop Safety Railing Protection

Effective guardrail and safety railing installation to prevent falls must meet the standards set by OSHA. In , OSHA updated its requirements, clarifying what employers and construction workers need to do to adhere to safety standards on the construction site. The requirements are divided into 3 sections for guardrails, which are laid out below.

Height Requirement

In guardrails, the top edge height of top rails needs to be 42 inches, plus or minus 3 inches, above the walking-working surface.

If there is no wall or parapet 21 inches high from the walking-working surface, then the intermediate rail, mesh, or screen needs to be installed between the top rail and the surface.

Opening Limitation

The midrail should be at least 21 inches so that a 19-inch or large spherical object cannot pass through the guardrail.

Load Requirement

Guardrails should be able to withstand, without failure, a load of 200 pounds applied downward or outward within 2 inches of the top edge.

Midrails, screens, mesh, and other vertical panels should be able to withstand, without failure, a load of 150 pounds applied downward or outward at all points along the intermediate member.

Other Requirements

For guardrail systems being used around holes, they should be installed on all unprotected sides of the hole.

The guardrail installed around a hole should also have a self-closing gate, like a swing gate, to prevent an employee from walking into the hole.

Final Thoughts

Now that you know the importance of guardrail fall protection systems, you need to call in experts for consultation and ensure your employees are protected at all costs.  

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By Roger Bligh, Contributing Author

When a vehicle leaves its intended course of travel and collides with an object, another vehicle or overturns, that is called a roadway departure crash. These types of crashes represent roughly 50% of roadway fatalities in the United States.

Roadside safety hardware refers to a family of devices designed to reduce the severity of roadside crashes. These devices include guardrails, median barriers, bridge rails, crash cushions, end treatments and breakaway support structures. 

The Texas A&M Transportation Institute (TTI)—where I manage the Institute’s Roadside Safety Program—has designed, tested and evaluated such safety devices for most of its 75-year history. 

I’ve worked at the TTI for nearly 40 years. As electric vehicles (EVs) become more prevalent on North American roadways, recent crash tests reveal that existing roadside safety barriers may not adequately protect EV occupants.

Making Safety the Standard

The current testing standard for these devices is the American Association of State Highway and Transportation Officials’ Manual for Assessing Safety Hardware (MASH). Today’s 276-page document began in as a single page—yes, one page—of recommendations titled Highway Research Circular 482. 

A barrier system that meets MASH standards is expected to contain and redirect a vehicle impacting within design parameters to keep the vehicle from going through, over or under the barrier to prevent a motorist suffering a fatal or serious injury during a crash. 

When vehicle specifications change, the MASH standards for testing roadside devices used to contain those vehicles must sometimes change too. Recent testing of EVs using MASH criteria established for ICE vehicles shows that some existing roadside barriers are inadequate when EVs impact them.

Looks Can Be Deceiving

While EVs might resemble their ICE counterparts, the physics that define how each type of vehicle interacts with roadside barrier systems can be different. 

The Tesla Model 3 test was even more interesting. The Tesla underrode the W-beam, which means it pushed under the guardrail, lifting it over the vehicle as the car’s momentum carried it past the system. At approximately 3,900 pounds, the weight of the Tesla is bracketed by the current MASH design test vehicles, which include a 2,400-pound passenger car and a 5,000-pound pickup truck. 

At first, the failure of the guardrail with the Tesla was surprising because MASH’s testing philosophy suggests that vehicles falling within the weight range of the design vehicles should have acceptable impact performance. 

It’s an interpolative rather than demonstrative assumption. However, the results of MwRSF’s impact testing challenge this conventional wisdom when it comes to EVs.

The Next Step in Testing

In June , TTI conducted its own EV crash test with a stronger, more robust system: the Thrie-beam guardrail. The Thrie-beam rail element is deeper, which reduces the ground clearance by 5 inches compared to the W-beam guardrail. 

We hypothesized that this might address the underride behavior observed in MwRSF’s W-beam test with the Tesla. Also, the deeper Thrie-beam has a greater cross-sectional area, meaning it’s stronger and more capable of resisting the force of impact than the W-beam. This Thrie-beam guardrail was successfully crash tested with ICE vehicles under MASH criteria, so it was a natural choice to test with EVs after the W-beam failure.

To compare with MwRSF’s findings, we performed the Thrie-beam guardrail test with a Tesla Model 3 passenger car weighing approximately 3,900 pounds. The impact speed and angle were 62 mph and 25 degrees, per MASH criteria. 

Guardrail: The installation consisted of a Thrie-beam guardrail system, chosen for this next step in testing based on its enhanced strength and containment capabilities.

Vehicle: A Tesla Model 3wasusedinthe crash test as a representative EV model. TTI selectedthisvehiclebasedonits physical characteristics, sales volume and relevance to previous guardrail crash-testing research on EVs.

Impact: The vehicle impacted the Thrie-beam guardrail at 62 miles per hour and 25 degrees. The guardrail ruptured, allowing the vehicle to pass through the system—a failure of MASH’s test criteria. During the impact, the vehicle wedged under the guardrail, compressing its bottom edge, and ruptured and went through the Thrie-beam guardrail.

Results: When tested with ICE vehicles, the Thrie-beam guardrail system passed the industry standard evaluation criteria. However, the EV’s failure to meet thesesamecriteria highlights the need for further research to adapt our hardware systems toaccommodatethechanging vehicle fleet.

The Thrie-beam’s failure when impacted by the Tesla was unexpected because the severity of the Telsa impact was within the range of current MASH crash testing. 

In my nearly four-decade long career, I had never seen a Thrie-beam guardrail rupture, and it has been tested with various sizes and weights of vehicles over the years, including a commercial single unit truck and a passenger bus.

Why Did the Devices Fail?

We know many characteristics of EVs are different from its ICE counterparts, and there are certain differences that affect compatibility with roadside barriers. 

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