"Master Fall Safety: Comprehensive Guide to Heights Protection"

Standing near a roof edge or on a tall ladder can make even the most confident person pause. That is normal. The smart move is to plan ahead, so you never have to rely on luck.This how-to guide will walk you through building a working-at-heights fall protection plan from the ground up, in plain language, with zero fluff.

You will learn the basics first, such as spotting common hazards and deciding whether the work can be done from the ground. Then we will map out controls in the right order, from guardrails and scaffolds to lifelines and harnesses. We will show you how to choose the right gear, set clear roles, write simple procedures, and train your team so everyone knows what to do. You will also develop a rescue plan, schedule inspections, and maintain clean records that comply with safety rules.

By the end, you will have a straightforward checklist and a repeatable process you can use on any site. No jargon. Just step-by-step actions that keep people safe and work moving.

Prerequisites and Materials

Step 1: Know your legal duties under the WHS Act

Before you touch a ladder or harness, clarify your obligations as a PCBU or supervisor. Under the Work Health and Safety Act 2020 (WA), you must eliminate or minimise fall risks so far as is reasonably practicable, using the hierarchy of control. Start with prevention, for example, guardrails or scaffolds, then work on positioning, for example, rope access, and only use fall arrest as a last resort. The model Code of Practice explains these controls and typical solutions for different tasks. Read the national overview here for a solid foundation, then apply it to your WA site: Working at heights guidance.

Step 2: Gather the core kit

Your basic fall protection kit includes a full‑body harness, an energy‑absorbing lanyard or SRL, and compliant anchors. Look for equipment that meets AS/NZS 1891.1 for harnesses and ancillary gear, AS/NZS 1891.2 for lanyards, and AS/NZS 1891.4 for selection, use, and maintenance. Single‑point anchors should comply with AS/NZS 5532:2013. Keep inspection records, manufacturer instructions, and proof of conformity handy. For quick checks of applicable standards, see this summary: Australian fall protection standards overview.

Step 3: Align with Western Australian requirements

In WA, construction work that involves a risk of a person falling more than 2 metres is high-risk construction work, so you will need a SWMS. WorkSafe WA has extended the construction falls transitional period to 30 September 2026, followed by a six‑month Statement of Regulatory Intent to support industry. Use this time to verify your controls, documentation, and training pathways align with the Regulations and Codes. Stay current via WorkSafe WA transitional advice for falls in construction.

Step 4: Confirm training and documentation

Anyone planning, supervising, or performing work at height must be trained and competent, including in the use of equipment and emergency rescue. Keep copies of current Statements of Attainment, toolbox talk records, and equipment inspection logs. Schedule refresher training based on risk, changes in work methods, and company policy.

Step 5: Use Safety Heights and Rescue Training resources

Before the job, tap into Safety Heights and Rescue Training pre‑course advice, gear checklists, and rescue planning guidance. Expected outcome: a site‑specific, WA‑compliant fall protection plan, a ready rescue procedure, and a competent team.

Step 1: Conduct a Thorough Hazard Assessment

Prerequisites and materials

Before you start, confirm your duties under the Work Health and Safety Act 2020 (WA) and the Work Health and Safety (General) Regulations 2022. In WA, any construction work with a risk of a person falling more than 2 metres is high-risk construction work, so you must prepare or review a SWMS before work begins. Have the right tools on hand: a current site plan, a tape or laser measure, a camera or phone for photos, a simple risk matrix, manufacturer instructions for plant like EWPs, and recent inspection tags for ladders, scaffolds, and anchors. Check whether the Safe Work Australia Code of Practice, Managing the risk of falls at workplaces, applies to your tasks, then align your assessment with it. The goal is clear: a site-specific hazard register that will drive your working at heights fall protection plan.

How to assess hazards, step by step

1. Identify fall hazards. Walk the entire work area, from roof to ground, and list unprotected edges, floor or roof openings, and brittle or fragile surfaces, such as skylights, ladders, scaffolds, EWPs, elevated platforms, and access points. Verify that surfaces have the strength and integrity to support the load before stepping on them, and note any electrical hazards, such as overhead lines and exclusion zones. Look for environmental risks, for example, strong afternoon sea breezes in Perth, rain on metal roofs, or poor lighting. Capture locations, heights in metres, and photos, for example, “north parapet, 4.2 m drop, no edge protection.”

2. Evaluate severity and probability. Use your WHS risk matrix to consider height, duration and frequency, task complexity, load handling, worker competence, and weather. A quick rule: higher, longer, more complex, and more frequent means higher risk. Record existing controls, for example, temporary guardrails, and identify gaps. Rate each hazard before and after controls so you can show risk reduction.

3. Plan controls using the WA hierarchy. Eliminate the need to work at height where practicable, for example, relocate work to ground level or use extension tools. If elimination is not reasonably practicable, isolate with edge protection, scaffolds, or work platforms, or use work positioning like restraint systems, then use fall arrest as a last resort with a prompt rescue plan. Where fall arrest is used, ensure anchors, harnesses, and lanyards comply with AS/NZS 1891, and that anchors are rated and tagged. For construction above 2 metres, ensure the SWMS clearly details these controls.

4. Document and assign actions. Build a hazard register that includes location, description, photos, initial and residual risk ratings, selected controls, responsible persons, and due dates. Brief the crew at pre-start, capture sign-offs, and verify understanding. Schedule inspections, for example daily edge protection checks and weather monitoring, and log outcomes in your WHS system. This record becomes the backbone of your working at heights fall protection plan.

Pro tip from the trainers

Safety Heights and Rescue Training recommends mapping all permanent and temporary anchors on a simple roof plan, tagging out anything unverified, and confirming rescue capability and timing during your assessment. This small step prevents delays, and more importantly, it keeps your team safe and compliant.

Step 2: Select the Right Fall Protection Systems

Before you buy gear, set yourself up to choose well. Prerequisites include your Step 1 hazard assessment, site drawings or photos, accurate measurements of edges and anchor locations, and the required clearances below work areas. Have the relevant Australian Standards on hand and manufacturer data sheets. The materials you need are options for both passive and active controls that fit your tasks. Your expected outcome is a short, justified list of systems that slot neatly into your working at heights fall protection plan.

1. Prioritise passive systems first. The WA WHS Act 2020 and the WHS (General) Regulations 2022, Part 4.4 on Falls, expect you to use the highest level of protection that is reasonably practicable. Think compliant guardrails, walkways, and covers, for example to AS/NZS 1657 for fixed platforms and edge protection. Passive controls reduce reliance on user behaviour and are ideal for routine roof access. For a quick refresher on passive controls, see this overview of passive fall protection systems.

2. If passive is not practicable, select task‑matched active PPE. Use full body harnesses to AS/NZS 1891.1, fall‑arrest devices such as lanyards and self‑retracting lifelines to AS/NZS 1891.3, and anchors verified to AS/NZS 5532, with selection, use, and maintenance following AS/NZS 1891.4. Build in a rescue procedure before anyone clips on, as required under WA regulations. Require pre‑use checks and scheduled inspections by a competent person at intervals specified by AS/NZS 1891.4 and the manufacturer.

3. Prefer energy‑absorbing lanyards for arresting a fall. They limit arrest forces on the body, typically to 6 kN in line with Australian practice, which reduces injury risk source: energy‑absorbing lanyard FAQ. Calculate fall clearance using manufacturer charts, including lanyard length, device deceleration, harness stretch, and a safety margin. Near lower levels, consider an SRL or a restraint setup to prevent any free fall.

4. Verify compliance and get tailored help. Record the standards each component meets, for example AS/NZS 1657 for guardrails, AS/NZS 4389 for safety nets, and the AS/NZS 1891 series and AS/NZS 5532 for fall‑arrest systems. Keep an inspection register and tag gear. Engage competent height safety professionals for system design and installation, and book Nationally Recognised Work Safely at Heights training with Safety Heights and Rescue Training to ensure correct selection and use in WA.

Step 3: Train Workers Effectively

Prerequisites and materials

• Your Step 1 hazard assessment and Step 2 equipment list, including harnesses, lanyards or SRLs, anchors and a rescue kit

• Current copies of the WHS Act 2020 (WA), WHS (General) Regulations 2022, and the Managing the risk of falls at workplaces Code of Practice

• A draft site rescue procedure and, for construction, the SWMS for work where a fall of more than 2 metres is a risk

• Training records template, attendance sheet, and a simple verification of competency checklist

How to deliver effective training

1. Map training to WA legal duties. Under the WHS Act 2020 (WA) s.19 and WHS (General) Regulations 2022 reg 39, PCBUs must provide information, training and instruction that is suitable and easily understood. Align content with Part 4.4 Falls, plus SWMS briefings for any high risk construction work that involves a risk of falling more than 2 metres. Cover hazard recognition, correct setup and inspection of systems to AS/NZS 1891.4, and anchors in line with AS/NZS 5532. Finish each session with a short assessment so you can record competence against the unit RIIWHS204E Work Safely at Heights.

2. Use a comprehensive, hands-on program. Blend classroom basics with realistic edge, ladder, EWP or roof scenarios so workers can practice pre-use checks, fit harnesses properly and connect to compliant anchors. Include emergency roles and a site-specific rescue procedure, do not rely on calling 000 alone. Aim for small groups so each person gets multiple repetitions on the actual equipment listed in your working at heights fall protection plan. This keeps training relevant to your site risks and controls.

3. Leverage Safety Heights & Rescue Training. As a WA RTO, they deliver practical skills that stick and offer refreshers that reflect current law and technology. Their guidance notes that regular coaching and refreshers can lift incident reduction from 26 percent in year one to nearly 69 percent by year five, and return about $4.50 for every dollar invested. See their summary on refresher expectations here, Understanding the validity of working at heights training.

4. Embed drills and refreshers. Run toolbox micro-drills monthly, do a supervised rescue drill at least every 6 to 12 months and schedule formal refreshers every 1 to 2 years, or sooner after equipment or procedure changes. Track outcomes like near-miss trends, rescue drill times and assessment scores. Use this data to fine tune your plan and to brief supervisors before issuing permits to work at height.

Step 4: Implementation of the Fall Protection Plan

Prerequisites and materials

Bring your Step 1 hazard assessment, Step 2 system choices, and Step 3 training records. In WA, align with the Work Health and Safety Act 2020, the Work Health and Safety General Regulations 2022, and the WA Code of Practice Managing the risk of falls. Prepare a SWMS for any high risk construction work with a risk of falling over 2 metres. Have compliant gear ready, for example AS 1657 edge protection, AS/NZS 1891 fall arrest equipment, a rescue kit, an inspection register, and a clear comms plan.

Step-by-step implementation on WA sites

1. Embed the plan in the SWMS and pre-start, follow the hierarchy of control, prioritise scaffolds or edge protection over harnesses.

2. Assign clear owners, nominate a competent person and a rescue lead, add spotters, and verify training and EWP licences.

3. Complete pre-use inspections, tag gear, sign the heights register, and schedule competent inspections at least every 6 months.

4. Trial the task, walk access, verify anchors and ratings, confirm fall clearance and swing-fall, stage the rescue kit, and time a drill.

5. Monitor in real time, keep comms up, use a short checklist at breaks, and stop work if conditions change.

6. Capture feedback, log hazards and near misses, update the plan and SWMS, brief the crew, and archive revisions.

Expected outcomes are clear responsibilities, controlled access until controls are verified, and a crew that can describe the rescue steps for their task. Trial runs usually surface practical fixes, for example a Perth roofing team identified swing-fall at a valley and swapped lanyards for temporary edge protection and revised anchors. You should see cleaner sign-offs, fewer delays, and defects found before use. Keep momentum with brief toolbox talks, and ensure workers maintain current nationally recognised Work Safely at Heights training delivered by an RTO.

Troubleshooting and Additional Tips

Step 1: Tackle equipment failure and non-compliance

Prerequisites: your hazard assessment and current Working at Heights plan. Materials: inspection checklists aligned to AS/NZS 1891.4, tag-out system, training records, and a rescue kit.Action: run pre-use checks before every shift and a competent-person inspection at least every 6 months, as outlined in AS/NZS 1891.4. Remove from service any harness with damaged webbing, distorted hardware, or missing labels; retire frayed lanyards and SRLs that fail function tests. Ensure fixed and single-point anchors are installed and maintained to AS/NZS 5532, and verify guardrails and platforms comply with AS 1657. Control non-compliance with short toolbox refreshers, spot checks, and a simple stop-work rule. Expected outcome: fewer gear failures, better uptake of controls, and evidence you met duties under the WHS Act 2020 (WA) and WHS (General) Regulations 2022.

Step 2: Build alternatives for unforeseen challenges

Prerequisites: a live risk register and authority to pause work. Materials: access to temporary edge protection, EWPs, or scaffolds, plus a documented rescue plan.Action: when conditions change, do a dynamic risk assessment on the spot. If anchors are not viable, switch to guardrails or an EWP with restraint. If weather spikes risk, reschedule. Practice your rescue plan so a suspended worker can be reached quickly, and stage the rescue kit at the workface. Expected outcome: safe continuity of work without cutting corners.

Step 3: Keep the plan and training fresh

Prerequisites: version-controlled documents and feedback from workers. Materials: updated procedures, photos from site, and recent incident learnings.Action: review the working at heights fall protection plan at least annually, after any incident, or when new equipment arrives. Deliver refreshers that reflect AS/NZS 1891 updates and site changes, and verify competence, not just attendance. Expected outcome: training and procedures that match real risks.

Step 4: Nail your documentation and audit trail

Prerequisites: clear filing system, physical or digital. Materials: SWMS for high risk construction work with a fall risk over 2 metres, inspection logs, permits, and rescue drill records.Action: keep signed training registers, equipment inspection reports, corrective actions, and review dates. Store photos of installed anchors and certifications. Expected outcome: records that satisfy WorkSafe WA inspectors and make continuous improvement easy.

Conclusion

If you remember one thing, make it this: a working at heights fall protection plan in Western Australia must be site specific, built on a solid hazard assessment, and aligned with the Work Health and Safety Act 2020 (WA) and the Work Health and Safety (General) Regulations 2022, including the hierarchy of control for falls. Choose controls that eliminate or isolate the risk first, then use compliant personal fall arrest systems that meet AS/NZS 1891 and anchor requirements aligned with AS/NZS 5532 when higher level controls are not practicable. Document emergency and rescue procedures before anyone leaves the ground, and make sure every worker is trained and competent for the exact equipment and tasks. Safe Work Australia consistently identifies falls from height as a leading cause of worker fatalities, so a well executed plan directly reduces the most severe incidents. Keep it simple, visible, and used every day, not just filed away.

Continual improvement is where good plans become great. Set a rhythm that works: 1) pre-start checks every shift, 2) formal detailed inspections at least every six months by a competent person in line with AS/NZS 1891.4, and 3) annual reviews of your plan or sooner after any change, incident, or near miss, as required under the WHS Regulations. For example, when a Perth roof job shifts from full edge protection to temporary lifelines, update your clearance calculations, confirm anchors to AS/NZS 5532, and run a toolbox rescue drill. The payoff is fewer incidents, faster rescues, and confident crews. Need help sharpening skills and meeting WA expectations? Book Nationally Recognised training with Safety Heights and Rescue Training to lock in safe habits and keep your team going home healthy.