WORKING AT HEIGHT
STRUCTURED SUPPORT
When it comes to working at height, designing out risk beats managing it, says Tom Harris, Global Technical Lead at Gripple.
Working at height remains one of the most hazardous activities in building and construction. Despite tighter regulation, training, and advances in access equipment, falls from height still accounted for over a quarter of fatal workplace injuries in 2024/25. For health and safety professionals, this statistic highlights that while managing risk is important, the most effective safety strategies are those that eliminate hazards at their source.
“FALLS FROM HEIGHT ACCOUNTED FOR OVER A QUARTER OF FATAL WORKPLACE INJURIES IN 2024/25.”
Suspension systems play a vital role in modern buildings. They support electrical lighting, HVAC, pipework, and other essential services in hospitals, offices, retail spaces, factories, and schools. But while these systems are essential, the way they are traditionally installed often puts workers at unnecessary risk.
HOW SUSPENSION SYSTEMS CAN CONTRIBUTE TO RISK
In early electrical installations, suspension methods were often simple and offered little in the way of organised cable management. Around the mid-century, cable trays supported by threaded rod and strut were introduced, transforming suspension by providing a safer, more structured support system.
Even today, rod and strut systems remain the go-to solution for many contractors. But installation is far from risk-free. Every piece must be cut to length, often estimated by eye, then drilled, bracketed, and fixed overhead. Cutting typically requires hot works permit, adding another layer of risk and compliance. These tasks mean repeated trips up ladders, lifts, or platforms, increasing time spent at height and the potential for falls, fatigue, and mistakes.
TRADITIONAL METHODS UNDER MODERN PRESSURE
Modern projects operate under unprecedented pressure. Skills shortages, tighter programmes, and higher safety expectations all sit side by side. Teams are expected to work faster, smarter, and more safely.
Traditional threaded rod installations struggle under this pressure. They take time, create waste, and rely heavily on skilled labour. More importantly, they keep people working at height longer than necessary.
DESIGNING RISK OUT OF INSTALLATION
Pre-engineered suspension systems take a different approach. Instead of managing risk once work starts, they remove many of the hazards before installation
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begins. These systems are delivered ready to install, with pre-cut tracks and tool free fittings.
GROUND-LEVEL ADJUSTABILITY
Traditional systems often require repeated trips up ladders or lifts for fine-tuning, increasing exposure to fall hazards. Today’s advanced solutions allow precise adjustments to be made entirely from the ground as many times as needed, dramatically reducing the number of working-at-height interactions.
BETTER ERGONOMICS
Lightweight components also reduce manual handling and physical strain and this benefit becomes even more critical when working at height. Every extra kilogram matters, especially when climbing ladders or using access equipment. Lighter systems mean less effort during installation, fewer trips up and down, and a lower risk of musculoskeletal injuries.
IMPROVED SITE CONTROL
Cleaner installations don’t just look better, they actively improve safety, efficiency, and sustainability. Minimising debris and waste clutter reduces trip hazards and keeps emergency routes clear.
FASTER INSTALLATION, LESS EXPOSURE
Every minute spent working at height carries risk. However, systems that streamline installation reduce time off the ground by up to 85%, easing pressure on teams, and supporting tighter project schedules without compromising safety.
ELIMINATION OF HOT WORKS PERMITS
On-site cutting and welding introduces fire hazards, demands additional permits, and requires supervision. According to the Office for National Statistics (ONS), in 2023/24, welding and cutting accounted for 85% of hot work–related fires recorded in non-domestic buildings and in 10% of those, there was at least one casualty. Prefabricated kits remove these steps entirely, lowering risk, simplifying compliance with safety regulations, keeping sites safer.
ADOPTING FORWARD-THINKING APPROACH
Working at height in construction will always carry risk, but how we manage it is changing. By using installation methods that remove hazards from the process, businesses can protect workers, meet compliance requirements, and deliver safer results. Pre-engineered suspension systems make this possible – reducing time at height, eliminating hot works, and simplifying installation across all sectors.
www.gripple.com
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