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The Importance of Structural Engineering in Fall Arrest System Design

Posted by HITE-Engineering On April 7, 2025

Falls from heights continue to be one of the leading causes of workplace injuries and fatalities in Ontario. According to the Ontario Ministry of Labour, Immigration, Training and Skills Development (MLITSD), falls account for a significant percentage of lost-time injuries in construction and industrial settings. The Occupational Health and Safety Act (OHSA) mandates strict fall protection requirements, while the CSA Z259 series establishes the engineering and performance standards for fall arrest systems (FAS).

A properly designed fall arrest system, backed by structural engineering expertise, ensures safety, compliance, and legal protection for employers. This article explores the critical structural considerations in designing and implementing fall arrest systems, including anchor points, lifelines, and building integration.

Key Elements of a Safe Fall Arrest System

1. Anchor Points and Load Requirements

Anchor points are a fundamental component of any fall arrest system. These points must be designed and installed to withstand extreme forces, as they are responsible for stopping a worker’s fall.

According to CSA Z259.16: Design of Active Fall Protection Systems, permanent anchor points must be capable of sustaining at least 22 kN (kilonewtons) of force. For temporary or non-certified anchor points, additional testing and engineering evaluations are required to ensure safety.

Proper Placement of Anchor Points

Proper anchor placement minimizes fall distances and eliminates potential swing hazards. Structural engineers determine the best positioning based on:

Fall clearance calculations
Potential obstructions in the fall path
Load distribution on structural elements

Without proper engineering assessments, improperly placed anchors can increase fall distances, leading to severe injuries. At HITE Engineering, we conduct detailed evaluations to ensure CSA Z259.16 compliance and safe anchor installations.

2. Horizontal Lifelines & Vertical Systems

A fall arrest system may include horizontal lifelines (HLLs) or vertical systems (such as fixed ladders with safety rails). These systems allow workers mobility while ensuring fall protection.

Engineering Considerations for Lifelines

Load distribution: Lifelines must support multiple users while maintaining stability.
Deflection control: Excessive deflection can increase fall distances and injury risks.
Tensioning & energy absorption: The system must absorb dynamic forces effectively to prevent sudden stops that could cause injury.

Regular Load Testing & Recertification

According to CSA Z259.13: Flexible Horizontal Lifeline Systems, horizontal lifelines must undergo regular load testing and recertification to ensure continued compliance. Load testing verifies that lifelines, anchors, and connectors can still handle fall impact forces safely.

If your fall protection system has not been tested or recertified recently, schedule an inspection with HITE Engineering today.

3. Building Structural Considerations

Before installing a fall arrest system, engineers must evaluate the existing structural capacity of a building or worksite. Older buildings, particularly those constructed before modern Ontario Building Code (OBC) revisions, may require reinforcements to accommodate new fall protection systems.

Key Structural Engineering Factors

Load-bearing assessment: Can the structure handle the forces of a fall event?
Reinforcement needs: Are additional steel supports, bracings, or anchors required?
Compatibility with existing materials: Will new installations compromise structural integrity?

The Ontario Building Code (OBC) outlines the minimum requirements for structural modifications. Compliance with these regulations ensures both safety and legal protection.

At HITE Engineering, our team conducts structural assessments to confirm whether your building can safely support a fall arrest system or if reinforcements are required.

Why Engineering Matters

1. Preventing System Failure Under Dynamic Loads

One of the biggest risks in fall protection is system failure due to dynamic forces. A worker’s fall generates forces that can exceed 5,000 lbs (22 kN) within seconds. If a fall arrest system is not properly engineered, failure can occur due to:

Weak anchor points
Insufficient load distribution
Inadequate energy absorption mechanisms

To prevent this, engineers use Finite Element Analysis (FEA) to simulate fall impact forces and identify system weaknesses before installation.

At HITE Engineering, we leverage structural analysis tools to ensure every fall arrest system we design can withstand real-world conditions.

2. Compliance with Regulatory Standards

Employers have a legal obligation under OHSA and CSA Z259 to provide a safe working environment. Non-compliance can lead to:

Fines & legal liability (OHSA Fines & Penalties)
Increased insurance costs
Worker injuries & fatalities

Ensuring compliance with CSA Z259 standards and Ontario’s OHSA regulations is essential. HITE Engineering specializes in compliance assessments and certification of fall protection systems.

For details on ensuring your workplace meets safety standards, visit our fall protection compliance page.

3. Enhancing Worker Protection & Confidence

Beyond compliance, a properly engineered fall protection system increases worker confidence. Employees who trust their safety equipment are more productive and less prone to errors.

Well-designed fall protection systems:

Reduce worker hesitation when working at heights
Minimize accident rates
Improve overall safety culture in the workplace

By partnering with HITE Engineering, you ensure that your workforce is protected by the highest engineering standards in the industry.

Structural engineering is the backbone of safe and compliant fall arrest system design. By integrating CSA Z259 standards, OHSA regulations, and Ontario Building Code guidelines, engineers ensure that fall protection systems prevent fatalities and reduce liability risks.

At HITE Engineering Corporation, we specialize in:

✅ Structural assessments for fall arrest systems

✅ Custom anchor point and lifeline designs

✅ Regulatory compliance consulting

✅ Load testing & recertification per CSA Z259.13

💡 Don’t take risks with worker safety—ensure your fall arrest systems meet engineering standards.

📞 Contact HITE Engineering today to schedule a fall protection system evaluation!