Fall Hazards in Construction: The #1 Cause of Worker Deaths—and How to Stop Them

Not all roofs present the same danger. OSHA distinguishes between low-slope roofs and steep roofs because their pitch changes how workers can lose their footing and how fast a fall can occur.

Hazard assessment for low-slope roofs is defined under 29 CFR 1926.501(b)(10) as having a pitch of 4 inches vertical to 12 inches horizontal or less. And though the risk of slipping is lower, fall hazards are still present. Water, dust, loose roofing material, or debris can make the surface slippery. Workers performing tasks such as installing equipment, inspecting surfaces, or making repairs may need to work close to unprotected edges, increasing the chance of a falling accident. 

Although OSHA requires less stringent fall protection measures for these low-sloped scenarios, the effects and injuries from a fall can be just as fatal. Employers should gauge their risk tolerance and put in protective measures for their company, recognizing that going beyond mere compliance is sometimes necessary to ensure true safety.

Steep roofs, with a slope greater than 4:12, present a higher fall risk due to the increased angle. The sharper angle, as defined under 29 CFR 1926.501(b)(11), makes it harder to maintain balance, and a slip can quickly turn into an uncontrolled slide toward the edge. Wet, icy, or dusty surfaces reduce traction and increase the risk. Because of the slope, there is very little time to stop or recover once a worker starts to lose footing.

Unprotected Sides and Edges 

Work-related injuries often occur when perimeter edges don't have proper protection. This remains one of the most common and dangerous fall hazards I encounter in construction safety reviews. A colleague of mine, a contractor performing hazard assessment on a warehouse project, recently shared an incident involving workers installing metal decking on the second floor. 

The area lacked guardrails along the perimeter, creating a serious fall risk. The site manager identified the hazard and halted the work until measures were implemented to control the risk.

Under 29 CFR 1926.501(b)(1), any employee working 6 feet (1.8 meters) or more above a lower level on a walking or working surface, whether horizontal or vertical, is considered to be at risk if that edge is unprotected.

Steven Stogner, a Certified Safety Professional with experience serving various industries, emphasized that even standard protections like guardrails aren’t failproof.

“In some facilities I’ve worked in over the past 15 years, I have seen falls occur even on surfaces and roofs equipped with handrails and guardrails. This demonstrates the increasing need for regular inspections of guardrails by competent persons,” Stogner said.

Leading Edges

A leading edge is the unprotected, advancing edge of a floor, roof, or formwork while construction is in progress. This type of edge changes position as new sections are built, creating a constantly shifting fall hazard. As outlined in 29 CFR 1926.501(b)(2), employees constructing or working on leading edges at heights where a fall could result in serious injury are considered exposed to this hazard.

The risk is not limited to the workers directly installing materials along the edge. Personnel working in the vicinity can also be exposed, particularly when their tasks bring them close to the open edge or within areas designated for active construction. When a controlled access zone (CAZ) is in place, its control line can serve as a boundary along an edge that runs parallel to the leading edge, but the fall hazard remains present until the work is complete and the edge is no longer exposed.

Opening and Hole Hazards

Among the many risks present on a job site, openings and holes are especially critical because they often appear in routine phases of construction, like roof work, floor installation, and mechanical access. While they may not seem hazardous at a glance, they’re a leading cause of common fall hazards when left unprotected.

Because these hazards don’t always stand out, they’re easy to miss during fast-paced work. That’s exactly why they demand extra attention. A secure cover,  barrier, or sign saying “Floor Covering - Do Not Remove,” can mean the difference between a normal shift and a serious incident. 

Specific Work Activity Hazards

There are fall hazard examples that stem from certain construction tasks, which are unique to the nature of the work being performed. These activities often require workers to operate in positions or locations where the risk of losing balance is increased. OSHA identifies these tasks separately in 29 CFR 1926.501 because their conditions and movements present distinctive fall hazards that must be assessed and controlled.

Overhand Bricklaying Operations 

Overhand bricklaying presents a significant fall hazard due to the positioning of workers near open edges and the need to lean beyond the wall line during placement. As described under 29 CFR 1926.501(b)(9), this activity is recognized as requiring special consideration because it often occurs at elevated heights and with limited footing space.

This hazard can occur when masons lay brick along the edge of a multi-story wall, work over parapets to complete veneer finishes, or install corner brick returns that require extended reach. It also includes tasks where workers bend below the walking surface to spread mortar just under the course they are laying.

Falls from overhand bricklaying can result in severe fractures, spinal cord injuries, traumatic brain injury, internal organ damage, or fatal head and neck trauma, depending on the height and landing surface.

Precast Concrete Erection Work 

Precast concrete erection presents significant fall hazards due to the size, weight, and handling requirements of the components. Workers are often positioned near open edges while guiding wall panels into place during crane operations, aligning beams on upper levels, or grouting precast slabs along the perimeter of a structure. 29 CFR 1926.501(b)(12) states this activity as a high-risk operation where the nature of the work places employees in direct proximity to fall exposures.

In one case from 2021, a worker in Texas fell 17 feet to his death while helping guide a precast panel at an unprotected edge. No guardrails or fall arrest systems were in use, and no alternative protection plan had been implemented. OSHA cited the employer for failing to meet fall protection standards.

Residential Construction Activities 

This type of work is covered under 1926.501(b)(13), particularly framing and exterior work. Carpenters building second-story walls, siding crews working along gable ends, or installers placing trim around upper windows all operate on unstable or elevated surfaces and are all exposed to fall risks. The fall hazard in these situations can result in serious injuries such as broken bones, spinal cord damage, head trauma, internal bleeding, or death, depending on the height and surface struck.

Formwork and Reinforcing Steel Work 

This involves vertical surfaces and often requires workers to climb or lean into confined areas. For example, ironworkers tying vertical rebar cages or crews assembling tall wall forms from ladders or temporary platforms are at high risk of falling due to limited footing and awkward positioning. When a falling accident happens, workers may receive multiple fractures, spinal injuries, impalement on rebar, or fatal injuries from impact with lower levels or surrounding structures.

Hoist Areas 

Working in this type of area brings another unique challenge. Guardrails are sometimes removed temporarily to allow material delivery or debris removal. Workers may need to lean through or over these openings when guiding steel into position, unloading trusses, or directing debris into a chute. These transitional moments, when attention is divided between the load and the edge, create a high risk of sudden loss of balance, which can result in blunt force trauma, crushing injuries, pelvic fractures, severe lacerations, or fatal impact with structures or materials positioned below.

Equipment and Environmental Hazards

Dangerous Equipment 

Work performed above or near machinery presents a high fall hazard, even when the working height is minimal. According to 29 CFR 1926.501(b)(8), employees working above machinery are at risk because a fall in these areas often results in contact with moving parts, sharp edges, or hard surfaces.

Exposure can occur when employees are positioned above conveyors, rotating equipment, or cutting machinery during maintenance or installation. Such incidents can cause amputations, deep puncture wounds, crushing injuries, or severe burns if contact is made with energized or heated components.

A case investigated by OSHA further illustrates this type of fall hazard. An employee was working above a piece of operating equipment when he lost his balance and fell, not from a great height, but directly into the machinery. The worker came into contact with moving components before striking a hard surface below. The injuries were fatal, showing that even a short fall can be deadly when it involves contact with active machinery or hard industrial surfaces, particularly in areas without protective barriers in place.

Weather Conditions 

Adverse weather significantly increases the likelihood of falls by affecting footing, stability, and control over tools or materials. While these conditions aren't explicitly addressed in 1926.501, experience shows that poor weather often demands additional precautions.

Wind can cause loss of balance or unexpected movement of suspended loads, while rain, snow, and ice reduce surface traction and make climbing or walking more hazardous. Extreme cold can impair grip strength and reaction time, further increasing the risk. Falls under such conditions can lead to joint dislocations, severe contusions, bone fractures, hypothermia from prolonged exposure after a fall, or fatal injuries when the impact occurs from elevated heights.

When Is Fall Protection Required?

Under OSHA Subpart M (29 CFR 1926.501), fall protection is required whenever construction activities place workers in situations where a loss of balance could result in a fall to a lower level. These standards are designed to prevent workers from having serious injuries and fatalities, which can be avoided with effective safety measures.

Once the 6-foot threshold is reached, employers or project managers must implement appropriate fall protection equipment such as guardrails, administrative controls, or personal fall arrest systems.

I've noticed how contractors struggle with this seemingly simple rule because they don't realize how broadly it applies. Any injury can be prevented with the right safety measures. The thing is, regardless of whether the work is happening on a flat roof or a seemingly stable surface, once there's a significant risk of falling to a lower level, OSHA’s requirements must be followed. In some cases, compliance at the minimum level isn’t enough to be “safe”.

How to Prevent Fall Hazards in Construction?

Fall protection in the construction industry must be tailored to the specific nature of the work being performed. OSHA’s standards under 29 CFR 1926.501 outline mandatory fall prevention methods for various situations, but practical implementation depends on factors such as roof slope, structural phase, equipment use, and site conditions. Below are work-specific strategies to prevent falls based on regulation and field-tested experience.

Roofing Work

• Low-slope roofs (slope < 4:12):

• Use warning line systems combined with safety monitoring per 29 CFR 1926.501(b)(10).

• Place warning lines at least 6 feet from all unprotected edges.

• Assign trained safety monitors who perform no other tasks while monitoring. 

• Eliminate the presence of mobile phones as much as feasible.

• Mechanical equipment areas:

• Within 6 feet of mechanical equipment edges, warning lines alone are not sufficient.

• Use guardrails, safety nets, or personal fall arrest systems (PFAS) in these zones.

• Steep roofs (slope ≥ 4:12):

• Require stricter measures such as PFAS, guardrail systems with toeboards, or safety nets, according to 29 CFR 1926.501(b)(11).

• Best roof work safety tips:

• Inspect roof surfaces before work begins to identify weak spots.

• Monitor weather; delay work on wet or icy roofs.

• Secure all roof openings with covers or protection.

• Train workers on load-bearing limits of various roofing materials.

• Ensure scaffolding meets all OSHA requirements and load ratings 

Unprotected Sides and Edges

• Marking and securing perimeters:

• Install barriers as early as possible in the construction phase to reduce exposure time per 29 CFR 1926.501(b)(1).

• Use visible markers or barricades where permanent guardrails are not yet installed.

• Ensure warning signs are posted at all access points to unprotected edges.

• Reassess perimeter protection daily to account for changes in work layout.

• Worker awareness and training:

• Provide task-specific training on hazard recognition at open edges.

• Emphasize maintaining safe distances when performing material handling or equipment operation near perimeters.

• Instruct crews to immediately report missing or damaged edge barriers.

Leading Edge Work

• Safety monitoring systems:

• Assign a competent person with authority to recognize and correct fall hazards 1926.501(b)(2).

• Provide monitors with specialized training beyond general safety awareness.

• Controlled access zones (CAZ):

• Define a CAZ extending 6 feet from the leading edge.

• Limit access to workers actively engaged in leading edge tasks.

• Fall protection plans:

• Required when guardrails, nets, or PFAS are infeasible or create greater hazards.

• Must follow criteria under 29 CFR 1926.502(k) and include detailed analysis and alternatives.

• Ensure PFAS equipment is rated for “Leading Edge.”

• Work with a fall protection specialist, if possible, to recommend protection methods. 

Opening and Hole Hazards

• Floor holes, roof holes, and walking surface holes:

• Install secured covers capable of supporting at least twice the maximum expected load, according to 29 CFR 1926.501(b)(4).

• Mark covers with “HOLE” or “COVER” for visibility.

• Use guardrail systems around larger openings when covers are not practical.

• Inspect covers daily to ensure they have not been moved or damaged.

• Wall openings:

• Installing guardrails or temporary barriers, as stated in 29 CFR 1926.501(b)(14), until permanent closures are in place

• Block or mark openings that meet the size criteria (≥30 in high, ≥18 in wide, lower edge <39 in above the surface).

• Use debris nets or temporary panels where guardrails cannot be installed immediately.

• Skylights, floor opening, and roof openings

• Install skylight screens or rated covers before work starts in the area per 29 CFR 1926.501(b)(4).

• Avoid standing on elevated platforms or placing materials directly on skylight glazing.

• Use warning lines or barricades to maintain distance from openings during roof work.

• Excavation edges

• Safely positioned fencing or barricades around excavation edges as covered under 29 CFR 1926.501(b)(7).

• Use high-visibility marking when edges are not immediately obvious due to site conditions.

• Maintain clear access points for equipment while ensuring pedestrian traffic is blocked from hazardous zones.

With his extensive experience in risk assessment and mitigation, Stogner shares that the key to preventing falls altogether is controlling how and when those protections are altered in the first place:

“In my experience, most people fall into a hole or over a side that they have created,” he said. “Some companies and facilities I’ve worked with recently are requiring maintenance and contractor personnel to have supervisors complete handrail and/or walking and grating removal approval forms, followed by processes that ensure these protections are replaced. This ensures the process is covered and that holes, handrails, and gratings are properly restored.”

By focusing on proactive control measures and reinforcing accountability, organizations can drastically reduce the likelihood of accidents. As Stogner’s insight makes clear, true safety means stopping hazards before they start.

Specific-Task Hazards

Equipment-Related Hazards

• Install guardrails or equipment guards around all edges where workers could fall into machinery. This is required even if the height is less than 6 ft if dangerous equipment is below.

• Use harnesses and secure tie-off points when guardrails are temporarily removed or infeasible.

• Shut down and secure machinery during maintenance to eliminate motion hazards during falls.

• Ensure work platforms are level, slip-resistant, and wide enough to allow safe movement around tools and materials.

• Keep non-essential workers out of areas below elevated machinery work.

Weather-Related Hazards

• Use site-specific forecasts to schedule high-elevation work in safer conditions.

• Stop elevated work during high winds, lightning, or severe storms.

• Clear work surfaces of ice or snow before starting work.

• Lay down temporary traction mats or grit on icy ramps, runways, or scaffolds.

• Provide insulated gloves with good grip, non-slip footwear, and layered clothing that doesn’t restrict movement.

• Use PFAS at all times in gusty conditions; secure loose materials that could become airborne hazards.

• Maintain three points of contact on ladders/scaffolds; use tool lanyards in windy or wet conditions.

• Secure or lower suspended loads when winds exceed safe limits for crane or hoist operations.

By understanding the unique risks tied to each specific work activity and applying controls that meet or exceed OSHA requirements, construction teams can address hazards before they lead to incidents. This targeted approach forms the foundation for broader fall prevention strategies, which integrate planning, equipment selection, training, and ongoing oversight.

How Often Is Fall Protection Training Required?

OSHA’s fall protection training requirements under 29 CFR 1926.503 specify that employees must be trained before being exposed to fall hazards, with retraining required in certain conditions, such as changes in equipment, work conditions, or when a lack of knowledge or improper use is observed. However, these regulatory requirements represent the minimum standard.

In practice, many construction employers implement more frequent training schedules to maintain safety awareness and ensure compliance in dynamic jobsite environments. While OSHA does not mandate annual training, industry best practices recommend the following approach:

• Annual refresher training for all workers exposed to fall hazards to reinforce core principles and account for changes in procedures or equipment.

• Retraining as needed based on site audits, behavioral observations, or incident investigations.

• Project-specific orientation that includes fall hazard identification and equipment procedures relevant to the unique site conditions.

• Frequent safety briefings, such as weekly toolbox talks, focusing on fall protection themes to maintain a culture of awareness.

Employers are also expected to maintain accurate documentation of all training sessions, including participant names, training dates, and the identity of the qualified trainer or competent person conducting the training.

Although OSHA outlines when retraining is required, the frequency and depth of fall protection training should be tailored to site complexity, worker turnover, trade-specific hazards, and the level of risk exposure. In high-risk sectors such as roofing or steel erection, more frequent reinforcement may be necessary to prevent lapses in safe behavior. Many PPE and PFAS providers offer programs with free training resources, so checking them can be a valuable step.

It demands a proactive, ongoing training approach that goes beyond regulatory checkboxes to ensure workers understand and apply fall protection procedures consistently. Regular, targeted training reduces incidents, strengthens compliance, and builds a culture of safety.

What Are the 5 Areas of Employer Responsibilities Concerning Fall Hazards?

Employers play a critical role in preventing fall-related incidents on construction sites. OSHA regulations make it clear that fall protection is not just about equipment, it’s about proactive planning, consistent application, and continuous oversight. The following five responsibilities apply to all types of fall hazards, regardless of the work being performed.

1. Hazard Identification

• Conduct a thorough inspection of all work areas before starting operations.

• Identify locations with unprotected edges, floor openings, unstable surfaces, or environmental factors that increase fall risk.

• Reassess hazards whenever site conditions change, such as after weather events or during phase transitions in construction.
  
  

2. System Provision

• Supply fall protection systems, such as guardrails, safety nets, or PFAS, when required by OSHA standards.

• Ensure that all components meet the performance criteria outlined in 29 CFR 1926.502.

• Avoid makeshift or unverified systems that cannot support required loads or meet safety factors.
  
  

3. Safe Work Practices

• Establish written procedures for working near fall hazards and ensure they are practical for the specific site.

• Define clear access and exclusion zones to separate workers from hazard areas when possible.

• Integrate fall protection planning into daily job briefings and pre-task planning meetings.
  
  

4. Training & Competency

• Provide comprehensive training under 29 CFR 1926.503 on hazard recognition, safe work methods, and proper use of equipment.

• Verify that workers can demonstrate correct application of fall protection systems before allowing exposure.

• Offer refresher training when new hazards, equipment, or procedures are introduced.
  
  

5. Ongoing Oversight

• Assign competent persons to monitor compliance, inspect systems, and correct unsafe conditions promptly.

• Maintain regular inspection schedules for both equipment and protective systems.

• Keep records of hazard assessments, training sessions, and corrective actions for accountability and compliance verification.

By consistently applying these five areas of responsibility, employers can significantly reduce the likelihood of fall incidents, improve worker confidence, and maintain compliance with OSHA requirements.

FAQS

What is the most common cause of death in construction work?

Falls are the leading cause of death in construction. In 2023, they accounted for 421 of 1,075 worker fatalities, nearly 40%, per OSHA/BLS data.

What are the hazards of falls in construction?

Fall hazards include unprotected edges, roof work, floor openings, scaffolds without guardrails or incomplete or modified scaffolds, and unsafe ladders. These can cause serious injury or death if workers are not protected as required by OSHA Subpart M.

When is a personal fall arrest system required?

A personal fall arrest system (PFAS) is required when other fall protection methods aren’t feasible. It must be used when working at heights of 6 feet or more, especially on steep roofs, scaffolds, or around openings without guardrails or nets.

Under which circumstances must an employer provide a guardrail?

Guardrails are required when employees work 6 feet or more above a lower level on unprotected edges, ramps, walkways, holes, or other surfaces, unless another OSHA-approved fall protection system is used.

What is the best way to keep everyone safe from holes/openings?

OSHA Subpart M requires covering or guarding all holes and openings 6 feet or more above lower levels. Covers must be secured, able to support weight, and clearly marked to prevent falls and trips.

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