safety lifeline wire rope size manufacturer

The Gemtor™complete Horizontal Lifeline System is a simple, effective and economical means for achieving complete fall protection and worker mobility in a variety of elevated work sites.

When it comes to any at-height industry, fall protection is an important part of the job. Not to mention you will probably spend some time in situations where tying off to an appropriate anchor can be difficult. That"s why having the best lifeline is important. Our gear experts have spent years sourcing the best lifeline rope available and our hand-picked selection will help you stay safe and get the job done. We feature a range of styles, colors, lengths, and sizes of rope. You can choose a rope from 300, 600, or 1,200 foot pre-cut lengths, or if you need a custom length rope - we’ve got you covered there too. Diameters include ?, 7/16, ?, and ½ inch options and come in a variety of styles including HTP static, 3-strand, and unicore. We’ve also got a range of colors so that each lifeline can be visibly different than the others for easy identification.

The 5° angle fixed length, pre-engineered Horizontal Lifeline System (HLL) is for use by 3 workers in fall restraint or 2 in fall arrest. This 3rd party engineered horizontal line kit is a cost-effective way to have multiple workers on the roof with room to move freely. A 20’ lifeline will have a 5° total sag angle vs. the 30° sag angle with our model number 1323. This kit includes our coil non-mechanical energy absorber that is specified for use with this HLL System. Super Anchor Safety fixed length horizontal lifelines, when used with our specified anchorage devices provide an engineered system for rafter spacing of 10’ up to 20’. For accurate rigging, each fixed length horizontal lifeline is labeled for the correct rafter spacing.

Most folks think lifelines when it comes to fall protection, but if you quiz them about how these systems work or when they are good fits for an application, they come up short. So what is a cable-based fall protection system, and what are the pros and cons of lifeline systems?

Cable fall protection systems take many names, including rat lines, HLL’s, and horizontal lifelines just to name a few. In their simplest form, cable fall protection systems consist of wire rope secured by a series of terminal and intermediate anchor points. By connecting a body harness and lanyard to a shuttle traveling the length of the line, a worker can safely move along a horizontal (or vertical) plane. Cable systems are deceptively simple in design, but done properly, they are actually highly engineered fall protection systems.

In a previous post titled “Is My Horizontal Lifeline Safe?”, we shared pictures of some home-made rat lines we have encountered in the field. Lifelines made from combinations of wire rope, wire rope clips, and turnbuckles may look safe, but these home-made solutions share little in common with the engineered lifelines we design and install at DFP.

With years of knowledge, our team can supply everything from wire rope through to individual and bespoke fittings used in these systems. Some of our main components are listed below:

M12 Thread with a swaging dimension of 12.5mm. This is smaller than the standard 16mm dimension usually associated with 8mm rope, which makes it popular among engineers swaging on site using an Electro/Hydraulic hand tool.

1910.29(c)(11) - The employer must ensure that each horizontal lifeline is designed, installed, and used under the supervision of a qualified person; and is part of a complete personal fall arrest system that maintains a safety factor of at least two.

1910.140(c)(5) - A competent person or qualified person must inspect each knot in a lanyard or vertical lifeline to ensure that it meets the requirements of paragraphs (c)(4) and (5) of this section before any employee uses the lanyard or lifeline

1926.104(b) - Lifelines shall be secured above the point of operation to an anchorage or structural member capable of supporting a minimum dead weight of 5,400 pounds.

1926.140(c) - Lifelines used on rock-scaling operations, or in areas where the lifeline may be subjected to cutting or abrasion, shall be a minimum of 7/8 in. wire core manila rope. For all other lifeline applications, a minimum of 3/4 in. manila or equivalent, with a minimum breaking strength of 5,000 lbs., shall be used.

Lifelines, safety belts, and lanyards shall be used only for employee safeguarding. Any lifeline, safety belt, or lanyard actually subjected to in-service loading, as distinguished from static load testing, shall be immediately removed from service and shall not be used again for employee safeguarding.

Lifelines shall be secured above the point of operation to an anchorage or structural member capable of supporting a minimum dead weight of 5,400 pounds.

Lifelines used on rock-scaling operations, or in areas where the lifeline may be subjected to cutting or abrasion, shall be a minimum of 7⁄8 -inch wire core manila rope. For all other lifeline applications, a minimum of 3⁄4 -inch manila or equivalent, with a minimum breaking strength of 5,000 pounds, shall be used.

Safety belt lanyard shall be a minimum of 1⁄2 -inch nylon, or equivalent, with a maximum length to provide for a fall of no greater than 6 feet. The rope shall have a nominal breaking strength of 5,400 pounds.

All safety belt and lanyard hardware shall be drop forged or pressed steel, cadmium plated in accordance with type 1, Class B plating specified in Federal Specification QQ-P-416. Surface shall be smooth and free of sharp edges.

All safety belt and lanyard hardware, except rivets, shall be capable of withstanding a tensile loading of 4,000 pounds without cracking, breaking, or taking a permanent deformation.

Protecting your team from fall risks without restricting productivity is a delicate balance. When your workers need the ability to move around freely in worksites with fall hazards, the self-retracting lifeline is a great addition to your fall protection system. Useful for a variety of applications, these vertical connectors offer both flexibility and security. With the right care and use, self-retracting lifelines can empower your workers to do excellent work without threatening their safety.

Self-retracting lifelines (SRL) include two major components, a lanyard and a housing unit, also called a self-retracting device (SRD). When you pull out and release the lanyard, it retracts itself into the housing unit, the feature that gives it its name.

If a worker falls while using an SRL, the sharp tug on the lifeline engages an automatic braking system inside the housing unit and restricts the falling distance to only a few inches. As long as the tension is maintained, it won’t release any more of the lifeline, holding the worker in place until they are rescued.

It helps to think about a self-retracting lifeline like a seatbelt, which extends and retracts as needed, but locks when tugged with sudden force. This design not only prevents falls but limits the amount of force placed on the worker’s body if one does occur. It also minimizes the potential injuries and dangers workers face on the job.

In the industry, this piece of equipment has many names. Along with self-retracting lifelines, you may hear them called yo-yos, blocks, devices, retractables, retractable lanyards, and automatic fall arrest devices.

An automatic braking system was first added to connectors in 1963, using a disk block to stop lifeline payout during a fall. In 2002, a new design added teeth and pawls to improve the braking system. If the lifeline suddenly started paying out too quickly, the pawls and teeth would engage to halt the lifeline securely. Self-retracting lifelines continue to feature this design today.

As technology advanced, regulations did too. In 2012, ANSI released the Z359.14-2012 standard, which outlined proper use, maintenance, and performance requirements. It also created two classes for self-retracting lifelines, Class A and Class B.

You may also hear self-retracting lifelines referred to as “overhead” or “personal” SRLs. Overhead just means that the equipment is used with an overhead anchorage. You can use both SRLs and SRL-Rs with overhead anchorages, for example, but leading edge lifelines need lower anchorages.

Personal SRLs have a lighter, more compact version of the self-retracting device that connects directly to the dorsal D-ring. Their smaller size makes them easier to work with than the more common, larger form of SRLs. If you want to use personal SRLs, you can find both SRLs and SRL-LEs in this smaller size. Lifelines equipped with rescue capabilities, however, can not be used with personal SRDs.

It’s also critical to understand that overhead SRLs cannot be used over a leading edge. The materials and design are not made to withstand a fall over a leading edge, so the device may fail if used improperly.

Though workers can’t go as far, they won’t have to worry about how they move while they work. The connection point on the SRD uses a swivel feature to keep the lifeline from twisting, simplifying movements. Unfortunately, some personal SRL designs are uncomfortable to carry, which may prompt some workers to work without them. When choosing one of these products, look for designs that limit back discomfort, such as our line of Duratech self-retracting lifelines.

SRL-Rs include integral rescue capabilities, such as retrieval winches and brackets that can be attached to rescue tripods. When you can’t get down to your fallen worker, these features allow you to lift them quickly to safety. Since these lifelines are designed for rescue, however, they are not available as personal SRLs.

Lifelines are most commonly made from webbing, rope, or cable, which is typically either stainless or galvanized steel. These connectors can be as short as 6 ft. and as long as 195 ft., depending on the product.

The housing unit is contained in a hard outer casing that can range from a few inches to over a foot in size, depending on the length of the lifeline. Along with the coiled lifeline, this casing holds the braking system, mechanisms for smooth payout, and a retraction spring that keeps the lifeline taut when it moves in or out of the housing unit.

Both self-retracting lifelines and energy absorbing lanyards offer adequate fall protection when used correctly. Because of the added range of motion, SRLs are the better choice when you have the ability to use an overhead anchorage. Retractables also arrest falls faster than EALs, minimizing the amount of force placed on the worker.

The first thing to consider when choosing your self-retracting lifeline is application. How do you plan on using it and what conditions will it be used in? This will help you determine which material is best. Cable is the most durable and common option, but webbing or rope lifelines may be more appropriate for your needs.

Since self-retracting lifelines are made for specific uses and situations, you must choose an SRL that works for your specific needs. Don’t let price or convenience drive this process. The consequences can, and very well may, be fatal if you make the wrong decision. Following the steps below and working closely with your competent person will help you find the right equipment.

First, determine what you will use your self-retracting lifeline for. If your equipment is exposed to damaging conditions, take these needs into consideration. For employees that work with or near electricity, for example, you will need to choose a lifeline that protects against arc flash, such as one made of rope. You will also need to consider whether your work involves leading-edge or confined-space hazards. If so, choose the retractor with the capabilities you need, such as one with a winch or an option made from material strong enough to withstand contact with a sharp edge.

After your competent person conducts their fall hazard analysis, review the hazards they found and where they are located. Next, identity your anchor points. If the workplace has a leading edge or requires a low, horizontal anchorage, you also have to calculate the swing fall. In these situations, workers that fall over an edge may swing when the lifeline’s brake engages. They may then collide with structures in the swing radius, causing new injuries.

You will also need to select the lifeline material. Cable is the most common SRL material and may be leading-edge-resistant depending on the product and cable thickness. Webbing is another common option, though it is expensive to repair. You can find SRL-LEs made of webbing, but the thickness required for the leading-edge rating makes them even more costly. Additional materials include polyester, Kevlar, Nomex, Dyneema, rope, and wire rope.

Once you know what you want from your lifeline, research the reputations of the manufacturers you find. Unfortunately, some disreputable companies will label products incorrectly, such as saying an SRL is leading-edge rated when it’s not. When these connectors are used in hazardous situations, they often fail, causing horrible accidents. Protect your workers by carefully reviewing the Declarations of Conformity and testing documentation for every product. You can also reach out to industry experts, such as our team, to get advice on choosing a safe self-retracting lifeline.

Slowly pull the cable out, looking for rust, cuts, pitting, corrosion, deterioration, modifications, or frayed, worn, or broken strands. Also check for crushed, jammed, or flattened strands, bulges in cable, gaps between strands, and heat damage, such as torch burns and electrical arc strikes. There shouldn’t be kinks, bird caging, core protrusion, or frozen wire rope. If you find any of these damages, remove the device from service.

For webbing, search for holes, tears, abrasions, discoloration, and fraying. Be sure to check both sides, pulling on the webbing as you go. Bend the lifeline into a U-shape to look for shiny spots or broken fibers. Take off your gloves and feel for hard spots. Make sure there isn’t any loose stitching and that the wear pad is present. If you find any holes or tears, remove the lifeline from service. If more than 10% of the lifeline has other damage, remove it from service.

There should be no cracks, bends, or discoloration on the carabiner. Test the lock to make sure it functions properly. The mechanism should move smoothly and lock by itself without catching when released.

Next, do a retraction and tension test. Pull out 50% of the lifeline, maintaining light tension on it, then let it retract. Repeat the test after pulling out 100% of the lifeline. Always keep light tension to keep the lifeline from retracting too quickly. All movement, in or out, should be smooth.

Finally, conduct a braking test. Give sharp, steady tugs to the lifeline to engage the brakes. Hold tension on the lifeline until the brakes are fully engaged. You shouldn’t see any slippage while the brakes are engaged. Release the lifeline and allow it to retract under light tension. It should retract smoothly. Repeat the test with the lifeline pulled out at different lengths. If you see any problems, remove the device from service.

Lifeline maintenance is important because it keeps your equipment functional and ready to save lives when needed. While proper pre-use inspections can catch potential problems, caring for your equipment can help prevent issues from developing.

Freewheeling is one of the most common causes of lifeline damage. When you completely release the lifeline rather than maintaining light tension as it retracts, the spring will coil too fast. Sometimes, this leaves some of the lifeline hanging out of housing since it didn’t coil tightly enough. Other times, the hook or karabiner hits the housing at high speeds once the cable retracts, engaging the lock mechanism. Someone then has to find a way to safely climb up to the housing unit to release the cable for future use. Freewheeling can also damage internal mechanisms and is known to destroy SRLs.

Mechanically, SRLs function like a tape measure, but have an internal braking system that works like a seatbelt. You can pull the lifeline out and let it retract smoothly. If you give it a sharp tug, such as the sudden force applied during a fall, the braking system engages and locks the lifeline in place to minimize the freefall distance.

As long as your SRLs pass inspection and meet manufacturer guidelines, they are safe to use. There is no shelf life or expiration date for a self-retracting lifeline.

Since self-retracting lifelines use an automated braking system, there is not a mandated maximum length. The maximum length available varies by manufacturer.

ANSI mandates that self-retracting lifelines must support as little as 130 lbs and as much as 310 lbs. Some SRLs have a higher capacity, but the maximum weight threshold will vary by manufacturer.

The automated braking system on an SRL reduces the fall distance and makes rescue easier. Its additional length and ease of movement also support many more applications than a lanyard. For these reasons, self-retracting lifelines are superior to other connectors and often the better choice.

FallTech’s products meet the highest standards in quality, design, and safety. Manufactured in America and tested in our ISO-rated lab, our self-retracting lifelines and other fall protection equipment have never failed. We ensure that every product is ANSI and OSHA compliant, helping you build a strong safety program. Most importantly, you can confirm our performance claims against our Declaration of Conformity and testing documentation, all published online.

Buying fall protection from FallTech means gaining access to a comprehensive safety resource. As industry experts, our staff can help you stay up to date on industry changes and new compliance requirements. Our sales team is always available to answer questions and help you find the right systems. When the average set-up doesn’t meet your needs, we’ll work with you to find a solution that does.

At FallTech, we treat each customer’s safety concerns like our own. We are invested in every detail, giving you the time and attention you deserve. Our small chain of command means you get answers faster, empowering consistent safety for your team. From safety education to top-of-the-line fall protection equipment, FallTech is your solution.