FP LightweightUsers Pres

Fall Protection for the
Lightweight Worker A Systems

and Program Approach
Katie Miller
NAVAIR
Navy Mishap Prevention & Hazard Abatement Program
Shawn Smith MA, MEng, CSP

NAVFAC
Disclaimer
This presentation is not necessarily the views or
position of the Department of the Navy
Scope of Risk
Concerns of Light Weight Workers (LWW, < 130
lbs.) have been known for over a decade.
The approach was mitigation through
management and selection of personnel for use
of Personal Fall Arrest System (PFAS)
Considered to be limited population so limited
exposure.
If LWW was to have to use PFAS, same
recommendation as Heavy Weight Worker
(>310 lbs.) medical should be involved per Navy
Fall Protection Guide.
MV-22 Rethink Scope

MV-22 Osprey
-Fall of 2013 call with questions
on harnesses
-Early 2014 Competent Person
training
-Fall 2014 asked to support MV22 Osprey fall protection Tiger
Team
-
Integrated Fall Protection
Integrated Fall Protection
What is the Risk?

Risk= Probability x Severity
Probability
Frequency of Tasks
Duration of Tasks
Driven by flight hours
Population
Exposure of LWW
Severity
20G Ejection Seats

10G?
Discussions at ANSI
Types of injuries
Population
2010 USMC
Anthropomorphic Survey
published in 2013
12 MV-22 Squadrons
400 people per squadron
4800 people potentially
using PFAS
200 or 5% LWW
25000 LWW across

Department of Navy
~ 7500 PFAS users
Severity
Pre Fall
Fall
-Blunt force
-Fear
trauma
-Anxiety
-Heat Stress -Lacerations
-Hypothermia
-Frost Bite
-Pre Existing Condition
Arrest
-Neck,
Spine
-TBI,
Concussion
-Internal
organs
Secondary
Impact
SWING FALL
-Blunt force
trauma
-Lacerations
Suspension
-Orthostatic
Intolerance
-Syncope
-Compartment
Syndrome
Rescue
Compart
-Reflow
Syndrome
ment
-Shock
Syndrom
e
Reflow
Syndrom
e
Testing at NAVAIR Human

Systems Dynamic Test Lab
Human Systems Dynamic Test Labs

Perform testing to improve crew
safety during crash or in-flight escape
Ejection Tower
Windblast
Horizontal
Accelerator
(HA)
Test Equipment
Anthropomorphic Test Devices
(ATD)
5th Female 50th Male 95th Male
JPATS Case 1 Case 6 others
Instrumentation
Acceleration, Force, Displacement
High speed data acquisition

20,000+ samples/sec
High speed video

1080p HD; 1000fps+
8. Page of 08103
EVAluation Version: 2.4.8 Sample.def
Integration
S0SLED000001ACXD / CFC60 R08103

SGX2 9/3/2008 10:12:27 AM
0.0 m/s
0.0 kg
6.5
6.0
45
50
0.0
40
5.5
35
5.0
30
4.5
20
3.5
15
3.0
10
2.5
2.0
1.5
0.5
-10
-5
1.0
88
time [ms]
144
-0.5
-20
-15
0.0
31
200
displacement [ft]
acceleration [g]
25
4.0
-25
ATD Instrumentation
Head
Acceleration
Thoracic Acceleration
Upper Neck
Forces / Moments
Chest Deflection
Lower Neck
Forces / Moments
Lumbar
Forces / Moments
Pelvic Acceleration
Current Standards
ANSI Z359.13-2009 Personal Energy
Absorbers and Energy Absorbing Lanyards
Rated for users between 130 to 310 pounds
Dynamic qualification testing for lanyards
282lb steel ballast
2010 Anthropometric Survey of United States

Marine Corp (USMC)
46% of females weigh under 130lb
3% of males weigh under 130lb
What is the risk of injury to maintainers weighing

less than 130 pounds?
Current Standards
6 Free Fall
Maximum lanyard
deployment distance
48in
Maximum arrest force

1,800lb
Average arrest force

900lb
12 Free Fall
Maximum lanyard
deployment distance
60in
Maximum arrest force

1,800lb
Average arrest force

1350lb
Current Standards
Max Arrest Force: 1251lb
6ft Drop with

5th Female
ATD
Average Arrest Force: 968lb
Dynamic Testing
Purpose: To
investigate effects of
personal energy
absorbing lanyards on
lightweight
maintainers
Test
Device
Fall Height
6 Free Fall
MFR A
Anthropometric
Test Device
Manufacturer
Ballast
5th percentile
Female
(110lb)
Test
Weight
12 Free Fall
99lb
MFR B
Anthropometric
Test Device
5th percentile
Female
(110lb)
Ballast
99lb
50th
percentile
Male (164lb)
112lb
50th
percentile
Male (164lb)
112lb
95th
percentile
Male (206lb)
127lb
95th
percentile
Male (206lb)
127lb
17
Energy Absorbing Lanyards

MFR A
MFR B
Dynamic Testing
Test
Torso
Ballast
Test
Weights
Anthropometric Test Device (ATD)
5th percentile
Female (110lb)
50th percentile
Male (164lb)
95th percentile
Male (206lb)
5th Female (110lb) 12 Free Fall
20
95th Male (206lb) 12 Free Fall
21
Lanyard Deployment Distance

Lanyard Deployment for 6 Free Falls
48in limit
Deployment Distance (in)
45
40
35
30
5th female (110lb)

50th male (164lb)
95th male (206lb)
25
20
15
10
5
0
6' MFR A
6' MFR B
Lanyard Deployment Distance

Lanyard Deployment for 12 Free Falls
Deployment Distance (in)
60
60in limit
50
40
5th female (110lb)
50th male (164lb)
95th male (206lb)
30
20
10
0
12' MFR A
12' MFR B
Maximum Arrest Force

Maximum Arrest Force for 6 Free Fall
1800
1800lb limit
Max Arrest Force (lb)
1600
1400
1200
1000
5th female (110lb)

50th male (164lb)
95th male (206lb)
800
600
400
200
0
6' MFR A
6' MFR B
Maximum Arrest Force

Maximum Arrest Force for 12 Free Fall
2000
Max Arrest Force (lb)
1800
1800lb limit
1600
1400
1200
5th female (110lb)

50th male (164lb)
95th male (206lb)
1000
800
600
400
200
0
12' MFR A
12' MFR B
Average Arrest Force

Average Arrest Force for 6 Free Fall
1200
Avg. Arrest Force (lb)
1000
900lb limit
800
5th female (110lb)
50th male (164lb)
95th male (206lb)
600
400
200
0
6' MFR A
6' MFR B
Average Arrest Force

Average Arrest Force for 12 Free Fall
1350lb limit
Avg. Arrest Force (lb)
1200
1000
800
5th female (110lb)

50th male (164lb)
95th male (206lb)
600
400
200
0
12' MFR A
12' MFR B
Selected Injury Criteria

Neck
Neck Injury Criteria (Nij)
Multi-Plane Neck Injury Index (MPNI)
Neck Moment Index (NMI)
Lateral Bending
Twisting
Load Duration
Tension
Compression
Shear
Chest
Acceleration
Deflection
Lumbar Loading

Neck
Lateral Bending
Twisting
Load Duration
Tension
Compression
Shear
Chest
Acceleration
Deflection
Lumbar Loading

0.5
0.5 limit
(ejection criteria reference)
0.45
0.4
114%
greater
0.35
199%
greater
Nij
0.3
0.25
101%
greater
138%
greater
0.3 target
(5 star NCAP rating)
0.2
0.15
5th female (110lb)

50th male (164lb)
95th male (206lb)
0.1
0.05
0
6' MFR A
6' MFR B 12' MFR A 12' MFR B

Neck
Lateral Bending
Twisting
Load Duration
Tension
Compression
Shear
Chest
Acceleration
Deflection
Lumbar Loading

Neck
Lateral Bending
Twisting
Load Duration
Tension
Compression
Shear
Chest
Acceleration
Deflection
Lumbar Loading
Chest Acceleration
Chest Acceleration
20G limit
(ejection criteria reference)
20
Chest Acceleration (G)
18
16
111%
greater
95%
greater
76%
greater
111%
greater
14
12
5th Female (110lb)

50th Male (164lb)
95th Male (206lb)
10
8
6
4
2
0
6' MFR A
Chest Deflection
Chest Deflection
2.5in limit
(automotive crash
criteria reference)
Chest Deflection (in)
2.5
2
5th Female (110lb)

50th Male (164lb)
95th Male (206lb)
1.5
0.9in target
(5 star NCAP rating)
1
0.5
73%
less
61%
less
80%
less
50%
less
0
6' MFR A

Neck
Lateral Bending
Twisting
Load Duration
Tension
Compression
Shear
Chest
Acceleration
Deflection
Lumbar Loading
Lumbar Load
Lumbar Load
95th male limit: 2,675lb
2500
Lumbar Load (lb)
50th male limit: 2,280lb
2000
1500
5th
5th Female (110lb)

50th Male (164lb)
95th Male (206lb)
female limit: 1,338lb
1000
47%
less
62%
less
56%
less
61%
less
500
0
6' MFR A
Dynamic Testing Conclusions

Ballast testing does not allow detailed
injury assessment of the system
Measured and calculated injury
probabilities below established injury
thresholds with proper use of equipment
Lightweight maintainers are at an
increased risk of injury
Reduced load tolerance
Higher accelerations
Modeling & Simulation
File: NAVAIR Brief
38
Program Management
As weight of user decreases, risk of injury from arresting forces
increase
Four imperatives
1. Training- End User, Competent Persons, Program Managers,
Medical personnel
2. Supervision
3. Harness Fit- One size does not fit all
4. Medical Screening
5. Command must make risk decision
Future Human Systems Work

Testing
Improper use of Equipment
Swing Fall
Head Impacts in Swing Fall
Other models of harness and lanyard
Out of Service Equipment
Modeling& Simulation
Predictive Injury Analysis
5% Female
50% Male
95% Male
Incorporate arrest into model
12 and 6
Specific Lanyards Models
Specific Harness Models
SRDs
Future Program Management

Develop Medical pre and post fall screening criteria
Pre existing conditions
Medications
Illness
Develop Fall Injury Criteria

Fall Protection in Design and Requirements
Incident Investigation
Use of Human Factors Classification System
Fault Tree Analysis
Culture Assessment
Safety Culture is a measure
Behavior
Behavior Shaping Techniques

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Fall Protection for the

Lightweight Worker A Systems

Navy Mishap Prevention & Hazard Abatement Program

Shawn Smith MA, MEng, CSP

Navy Mishap Prevention & Hazard Abatement Program

MV-22 Rethink Scope

Navy Mishap Prevention & Hazard Abatement Program

Integrated Fall Protection

Navy Mishap Prevention & Hazard Abatement Program

Integrated Fall Protection

Navy Mishap Prevention & Hazard Abatement Program

What is the Risk?

20G Ejection Seats

Navy Mishap Prevention & Hazard Abatement Program

25000 LWW across

Navy Mishap Prevention & Hazard Abatement Program

Testing at NAVAIR Human

Navy Mishap Prevention & Hazard Abatement Program

Human Systems Dynamic Test Labs

Navy Mishap Prevention & Hazard Abatement Program

High speed data acquisition

High speed video

S0SLED000001ACXD / CFC60 R08103

Navy Mishap Prevention & Hazard Abatement Program

Navy Mishap Prevention & Hazard Abatement Program

2010 Anthropometric Survey of United States

What is the risk of injury to maintainers weighing

Maximum arrest force

Average arrest force

Navy Mishap Prevention & Hazard Abatement Program

Maximum arrest force

Average arrest force

6ft Drop with

Average Arrest Force: 968lb

Navy Mishap Prevention & Hazard Abatement Program

Navy Mishap Prevention & Hazard Abatement Program

Energy Absorbing Lanyards

Navy Mishap Prevention & Hazard Abatement Program

Anthropometric Test Device (ATD)

5th Female (110lb) 12 Free Fall

Navy Mishap Prevention & Hazard Abatement Program

95th Male (206lb) 12 Free Fall

Navy Mishap Prevention & Hazard Abatement Program

Lanyard Deployment Distance

Deployment Distance (in)

5th female (110lb)

Navy Mishap Prevention & Hazard Abatement Program

Lanyard Deployment Distance

Deployment Distance (in)

Navy Mishap Prevention & Hazard Abatement Program

Maximum Arrest Force

Max Arrest Force (lb)

5th female (110lb)

Navy Mishap Prevention & Hazard Abatement Program

Maximum Arrest Force

Max Arrest Force (lb)

5th female (110lb)

Navy Mishap Prevention & Hazard Abatement Program

Average Arrest Force

Avg. Arrest Force (lb)

Navy Mishap Prevention & Hazard Abatement Program

Average Arrest Force

Avg. Arrest Force (lb)

5th female (110lb)