Don’t let your business become a statistic.
According to both the Bureau of Labor Statistics and the National Safety Council, slips, trips, and falls are the 2nd leading cause of injury in the workplace, with 25,000 daily incidents. The most common cause of slip and fall accidents is due to wet and/or uneven walk surfaces which account for approximately 55% of all accidents or incidents.
Ray Evans, who has been with SafeRack since 2003 and currently serves as a Market Specialist, offers insights into the impact of material choices on safety, productivity, and overall business success, particularly regarding stairs and access solutions.
Contact Ray or follow him on LinkedIn
Slips, trips, and falls (STFs) pose significant risks in industrial facilities, leading to injuries that can disrupt operations and impact productivity. These risks impact every worker regardless of title or job responsibilities, but certain tasks naturally have a higher exposure than others. Often, the cause of an STF incident is multifactorial, encompassing human and environmental risk factors. An STF-related disability can greatly diminish the occupational capability and quality of life of the workers you employ.
STFs are addressed in OSHA’s General Industry Guidelines OSHA 29 CFR 1910.20-.30. While OSHA does not define formal training requirements for STFs, it is your company’s responsibility to train employees to recognize, report, and avoid unsafe practices or conditions.
This paper focuses on the causes of STFs in industrial settings, presents statistical insights, and suggests effective preventive measures to enhance workplace safety.
Common Causes of Slips, Trips and Falls
The list of factors contributing to STFs is numerous. While some are dependent on the nature of the work being performed and others are inherent in everyday life, your company is responsible and liable for all of them when it comes to keeping workers safe.
Causes of STFs include:
| SLIPS | TRIPS | FALLS |
| Loss of balance or traction | Foot hitting an object or obstacle throwing you off balance | Occur whenever you move too far from your center of balance |
| Wet surfaces, spills, or weather hazards like ice or snow | Likely to happen while walking while in a hurry | Jumping off landings or loading docks – always use the stairs |
| Being in a hurry or wearing improper footwear | Not watching where you are going or your surroundings | Broken or loose stairs or handrails |
STFs can be organized into 3 main categories:
| Environmental | Employee-Related | Equipment & Machinery |
| Oil or chemical spills on factory floors | Inadequate training on handling hazardous materials | Poorly maintained machinery leading to leaks |
| Uneven surfaces due to wear and tear | Failure to wear appropriate footwear | Obstructed pathways around heavy equipment |
| Inadequate lighting in production areas | Lack of awareness regarding safety protocols | Inadequate warning signs for high-risk zones |
Statistical Information in Industrial Settings
According to the Bureau of Labor Statistics (BLS), STFs consistently rank among the top causes of non-fatal injuries in the industrial sector. Industries such as manufacturing and construction report a higher incidence of STFs when compared to other sectors. Beyond physical harm to the employee and the potential loss of quality of life, lost productivity and increased workers’ compensation claims are financial consequences worth noting. STFs in industrial workplaces can significantly impact the financial health of the business.
To keep your facility operating at peak performance, careful consideration and planning must be made to mitigate risks that prevent injury anywhere workers or visitors require access.
Mitigating Risks for Slips, Trips & Falls in Industrial Facilities
Environmental Modifications:
- Implement regular floor inspections and maintenance
- Use anti-slip coatings on floors and staircases
- Provide adequate lighting in all areas, particularly in high-risk zones
Employee Training and Awareness:
- Provide comprehensive training on handling hazardous materials and machinery safely
- Emphasize the importance of wearing appropriate footwear
- Conduct regular safety drills and awareness programs
Equipment and Machinery Safety Protocols
- Establish and enforce protocols for machinery maintenance
- Provide comprehensive training on the use of proper equipment to perform maintenance activities
- Clearly mark hazardous areas and ensure unobstructed pathways
- Install audible alarms and visual signals near high-risk zones
Management and Supervision
- Implement strict housekeeping policies to reduce clutter
- Conduct regular safety audits and inspections
- Promote a safety culture through leadership and employee involvement
The True Cost of Injuries
Slips, Trips & Falls are the number one most common safety hazard.
99M
Production Days Lost
$70B
Yearly in Medical Cost
Brand Damage
Safety Violations Erode Trust
By The Numbers
Cause 15% of all accidental deaths
Make up 20% of all job-related injuries
Responsible for 1 in 6 of all lost-time work injuries
The significant impact slips, trips, and falls can have on the overall success of any business is undeniable. Their impact on a company’s bottom line due to loss of production time and medical expenses, not to mention the associated loss of morale among workers, as well as brand loyalty and lack of trust from partners and prospective customers should not be underestimated. But with careful consideration and planning, your business can take steps to prevent these accidents and protect the integrity and profitability of your business.
Best Practices to Stay Safe and Compliant
Loading Dock
In the picture on the left, there is a potential fall hazard at the loading bay. This risk was mitigated by installing an OSHA-compliant retractable physical barrier so that it was impossible to accidentally walk off the edge and fall to the ground below.
Warehouse Loft Access
The steps in the image on the left are problematic for two reasons. They exceed the standard rise/run and end with a trip hazard. In the same photo, it is apparent that the trip hazard was mitigated by adding the platform, however, it does not meet the OSHA requirement of a 36” platform when changing stair riser heights. The best practice was a compliant safe access system with consistent riser heights that also eliminated the trip hazard.
Pipeline Terminal Valve Access
In the image on the left, a portable ladder or mobile work platform is required to access the valve terminal at this pipeline terminal. By installing a permanent work and access platform (right image), operators can now use an OSHA-compliant ladder to access the valve without compromising efficiency or safety. The image on the right shows how this solution was replicated to all valves along the pipeline manifold.
Standby Power Generators
Power generation is becoming more prevalent as companies in a variety of industries weigh the impact loss of power has on productivity. Backup systems ensure continued operations in the event of a power failure. The image on the right shows the benefits of installing a permanent and compliant access solution to ensure safe and easy access to power generators.
Vessel Manufacturer
The photo on the left shows a workers using a ladder to access the top of the vessel. In addition to being difficult to transport to the task at hand, ladders are a common cause for workplace injuries. Improper placement, incorrect use, and the use of worn or damaged equipment are the most common issues that can contribute to the problem of ladder safety at work. The photo on the right demonstrates the benefits of using our mobile platform to perform the same task. Easy to move, easy to secure, and fully compliant, our mobile platforms keep workers safe and productive.
Barge and Ship Access
In image on the left, the non-compliant gangway is installed at an unsafe angle, is missing stanchions and handrails, and shows loose netting with significant signs of wear. In comparison, our gangway installation on the right is ergonomically balanced and provides safe, fully compliant access from shore to ship.
Valve Maintenance
The valve maintenance access shown in the photo on the left is an accident waiting to happen. In addition to human error, the use of multiple ladders presents a multitude of potential problems. Workers are much more likely to take short cuts such as choosing the wrong ladder, improperly placing the ladder, or putting themselves in harm’s way in the name of efficiency. Our pre-engineered modular platform, shown in the photo on the right, eliminates the guesswork and makes keeping workers working safely and efficiently totally easy.
Pipe Crossover
Crossing over a 12” pipe seems simple enough, but that’s exactly where a slip, trip, or fall could happen if the operator is in a hurry and not paying attention. Don’t let your company become a statistic.
Roof Top Maintenance
Roof top maintenance is usually an afterthought for a builder or contractor; they design an entry door or opening but there’s most likely a large step down required to access the roof top creating the potential for a slip, trip, or fall.
Let’s recap….
In industrial facilities, addressing the specific causes of slips, trips, and falls requires a targeted and comprehensive approach. By focusing on environmental modifications, employee training, safety protocols for equipment and machinery, and effective management strategies, industrial workplaces can significantly reduce the occurrence of STFs. Prioritizing safety in these settings not only protects the workforce but also contributes to enhanced operational efficiency and reduced financial liabilities associated with workplace injuries.
Slips
Slips can be caused by wet surfaces, spills, or weather hazards like ice or snow. They are more likely to occur while hurrying or running, wearing the wrong kind of shoes, or walking while distracted.
You can help prevent slips at work by following these safety precautions:
- Practice safe walking. Take short steps on slippery surfaces to keep your center of balance under you and point your feet slightly outward.
- Clean up or report spills right away. Even minor spills can be hazardous.
- Don’t let grease accumulate at your workplace.
- Be extra cautious on smooth surfaces such as newly waxed floors. Also be careful walking on loose carpeting or mats.
Trips
Trips occur whenever your foot hits an object, and you are moving with enough momentum to be thrown off balance.
To prevent trip hazards:
- Don’t carry loads that you cannot see over. Keep the path visible in front of you.
- Keep walking and working areas well lit, especially at night.
- Keep your workplace clean and tidy. Store materials and supplies in the appropriate storage areas.
- Arrange machinery and equipment so that it doesn’t interfere with walkways or pedestrian traffic.
- Properly maintain walking areas, and always report potential hazards.
Falls
To prevent falls, consider the following measures:
- Don’t jump off landings or loading docks. Use stairs with handrails.
- When using stairs, always keep one hand on the top handrail for 3 points of contact.
- Repair or replace stairs or handrails that are loose or broken.
- Keep walkways and aisles well lit and clear of clutter.
- Wear appropriate footwear with non-slip soles.
Equip your workplace with safety solutions to prevent slips, trips, and falls. Contact a SafeRack representative to help safeguard your team.
