Drop Test Results Highlight Essential Fall Protection Strategies for Steel Decking Safety

​A drop test was recently conducted by Derr & Gruenewald Construction at their facility in Henderson, Colorado, to replicate ironworkers in the process of throwing out steel decking. The objective of this test was to assess the structural integrity of steel deck sheets under impact conditions and to analyze various fall protection scenarios, particularly what might happen if an ironworker were to fall over the edge of a loose deck sheet.

​First Drop Test
In the initial test, a 315-pound test weight was suspended 5 feet above the working surface of the deck sheet. The test weight was connected to a 50-foot leading edge self-retracting lifeline (SRL), which was anchored to a horizontal lifeline (HLL) elevated 6 feet above the deck. The SRL was extended 25 feet from its anchor point to the test weight positioned at the edge of an unsecured deck sheet.

Upon release, the test weight dropped 5 feet before the SRL cable began to bear the weight on the unsecured decking. This action caused the non-working side of the deck sheet to lift slightly and move 3 feet back toward the anchor point. The movement stopped once the high and low hats of the unsecured deck locked into the secured deck sheet behind it. The total fall distance was 14 feet.

Second Drop Test
For the second test, the same 315-pound weight was suspended 5 feet above the leading edge of an unsecured deck sheet. This time, the weight was connected to a 50-foot leading edge SRL anchored to a swivel deck-mounted anchor located 12 feet from the test weight.

When the weight was dropped onto the edge of the unsecured deck sheet, the sheet remained in place. Although the SRL’s shock-absorbing pack engaged at the deck edge, it still deployed without showing any cuts or damage at the impact site. The total fall distance in this test was 9 feet.

Key Findings
The second test highlights why it’s critical to not use dorsal D-ring extensions with leading-edge applications. Doing so would prevent the shock-absorbing pack from deploying properly, leading to higher impact forces on the worker and connecting devices. It’s always best practice to anchor workers directly overhead.
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While some believe that anchoring an SRL to a 6-foot HLL will ensure safety during decking operations, the first test demonstrates the risks. If a worker falls and another employee is standing behind an unsecured deck sheet, that loose deck could shift, potentially causing injury to the worker at the non-working end. In contrast, the second test showed that using a deck-mounted anchor point at foot level led to a safer outcome, with the unsecured sheet remaining stable and a reduced fall distance, minimizing the risk of injury to others.

​This Safety Flash was contributed by Austin Reiner, Safety Manager, Derr & Gruenewald Construction in cooperation with SEAA’s Safety & Education Committee. It’s designed to keep members informed about ongoing safety issues and to provide suggestions for reducing risk. Best practices are gathered from a variety of sources. They may be more or less stringent than individual corporate policies and are not intended to be an official recommendation from SEAA. Always get approval and direction from your company officers on any new practice or procedure as these best practices may not work for all situations.  

Everyone benefits when a worker avoids injury. Submit your ideas for Safety Flash to [email protected].