The Asia-Pacific region, with its tropical climate and high solar irradiance, offers an ideal setting for large-scale solar energy production. Countries like India, Australia, Singapore, Malaysia, and Vietnam are making significant strides in expanding their solar energy capacity through ambitious targets and strategic investments.
Singapore, despite its limited land area, has embraced innovative solar solutions such as floating solar farms, including the 60 MWp Tengeh Reservoir project, which helps maximize space utilization. The government has also set a target to deploy at least 2 GWp of solar energy by 2030.
Malaysia is rapidly scaling up its solar energy sector through initiatives like the Large Scale Solar (LSS) program, which has attracted private investments and driven the development of large solar farms. The country is also home to several solar manufacturing companies, positioning itself as a key player in the regional supply chain.
Vietnam has experienced a solar energy boom, with aggressive feed-in-tariff incentives driving rapid growth. In 2020 alone, the country installed over 9 GW of rooftop solar, making it one of the fastest-growing solar markets in Southeast Asia.
However, as solar energy adoption expands, so do the risks associated with installation and maintenance. Workers are frequently exposed to working-at-height hazards, necessitating proper safety measures such as fall protection systems, secure walkways, and modular access platforms to ensure a safe and sustainable solar energy future.
Falls From Heights
Falls from heights remain one of the leading causes of occupational injuries and fatalities worldwide, and the solar energy sector is no exception. Workers installing and maintaining solar systems are particularly vulnerable to fall hazards, which can lead to severe consequences if proper safety measures are not in place.
Common Fall Hazards in Solar Installation and Maintenance:
Roof Falls: Solar installers often work on sloped, slippery, or unstable roofs, increasing the risk of falls. Uneven surfaces, loose materials, and adverse weather conditions can further compromise worker safety.
Falls from Heights: Installing solar panels on high-rise buildings or elevated structures exposes workers to significant fall risks. Without proper fall arrest systems, the danger of slipping, misstepping, or losing balance is heightened.
Fragile Roof Falls: Older roofs, asbestos sheeting, or skylights may not be structurally capable of supporting a worker's weight. Stepping on these surfaces without adequate precautions can lead to falls through the roof, causing serious injury or fatality.
"It is essential to prioritize safety by following established protocols and guidelines to prevent work-at-height accidents and protect workers."
The consequences of a fall during solar system installation can be catastrophic, not only for the worker but for the overall project. The risks involved make safety protocols and precautions crucial in preventing these incidents.
Potential Consequences of a Fall During Solar System Installation:
Injuries: Falls from heights can cause serious injuries such as broken bones, head trauma, spinal cord damage, and internal injuries. These injuries can be life-threatening and often require immediate medical intervention.
Fatalities: In severe cases, a fall from height may lead to death, particularly if the worker falls from a significant height or in an uncontrolled manner.
Installation Delays: A fall can halt the installation process, causing significant delays in completing the solar system installation. These delays can be costly for both the installer and the customer, disrupting project timelines.
Equipment Damage: If a fall results in damage to the solar equipment, it can increase the cost of the installation. Repair or replacement of damaged equipment adds to the financial burden of the project, as well as additional time for repairs.
Legal Issues: In the event of an injury, there may be legal ramifications related to workers' compensation, liability, and insurance claims. Proper documentation and adherence to safety regulations are essential in reducing the risk of legal disputes.
Reduced Productivity: An injured worker may be unable to continue the job, leading to reduced productivity and further delays in the project. If the injury requires extended time off, it may also place pressure on the team, impacting other ongoing projects.
To prevent falls during solar system installation, it is important to follow proper work-at-height safety procedures, use appropriate personal protective equipment, and ensure that all equipment is in good working order. Proper training for solar system installers can also help reduce the risk of falls and other accidents.
A compliant fall protection system provides a safe working environment by reducing the risk of falls from heights. It helps workers confidently perform their tasks, knowing they are protected against the risk of falling.
Compliance with fall protection regulations is also important for employers to avoid legal and financial consequences. Occupational health and safety regulations require employers to provide a safe work environment and to implement suitable fall protection measures when working at heights.
"Compliance with fall protection regulations isn't just about avoiding penalties, it's about saving lives"
Fall Protection Methods
The Hierarchy of Control is an effective tool for managing risks in the workplace, including fall protection. It is a set of measures that are implemented in a specific order to eliminate or minimize risks.
Collective Fall Protection (Guardrails and Guarded Platforms)
Collective fall protection is a system designed with the intention to prevent workers from reaching a fall hazard. Unlike personal fall protection, which is designed to protect an individual worker, collective fall protection is designed to protect multiple workers at once.
There are several types of collective fall protection systems, including Lifeline, guardrails and guarded platforms.
Rooftop Guardrails
Rooftop guardrails are barriers that are installed around the perimeter of a work area to prevent falls and are an important safety feature that can prevent falls from rooftops, terraces, and other elevated areas.
Rooftop guardrails must comply with various International standards to ensure their effectiveness and safety. Some of the standards that rooftop guardrails need to comply with include:
EN 14122: This European standard specifies the design and construction requirements for guardrails that serve as a permanent means of access to machinery or elevated areas. It includes guidelines on the minimum height of guardrails, the spacing of the posts, and the load-bearing capacity of the system to ensure that workers are adequately protected.
EN 13374: Applicable to temporary guardrail systems used during construction and maintenance, this standard specifies the design, testing, and evaluation requirements for temporary edge protection. The standard covers a variety of safety concerns, including stability, strength, and resistance to environmental conditions, ensuring the system provides adequate fall protection during temporary work on rooftops or buildings.
BS 13700: This British standard provides comprehensive requirements for the design, installation, inspection, and maintenance of fall protection systems, including guardrails. It outlines procedures for regular inspections and maintenance schedules to ensure that systems remain in good working condition over time.
Additional Standards in the Asia-Pacific Region:
AS/NZS 1891.4:2018 (Australia/New Zealand): This standard specifies the requirements for fall arrest systems, including guardrails, in Australia and New Zealand. It addresses the design, selection, installation, and maintenance of guardrails and other fall protection equipment, ensuring compliance with local workplace safety regulations.
Work Health and Safety Regulation (WHSR) 2011 (Australia): Under the Australian WHS Regulations, fall protection systems such as guardrails must be designed, constructed, and maintained in accordance with the relevant codes and standards to provide a safe working environment. This regulation applies to all workplaces, including rooftop installations.
ISO 14122 (International): The International Organization for Standardization (ISO) provides guidelines for the safety of machinery, including fall protection systems such as guardrails. ISO 14122 specifies design and operational requirements for fixed means of access, such as guardrails, ladders, and stairways, ensuring safety for workers using these systems in industrial settings.
Singapore’s Workplace Safety and Health Act (WSH Act): In Singapore, the WSH Act outlines the responsibilities of employers to ensure that safe working environments are maintained. The code of practice requires employers to implement appropriate fall prevention measures, including guardrails, on rooftops or elevated surfaces. Compliance with local standards, such as those issued by the Singapore Standards Council, is mandatory.
Malaysia's Department of Occupational Safety and Health (DOSH) Standards: Malaysia follows guidelines set by DOSH for safety and fall protection systems, including rooftop guardrails. The regulations ensure that guardrails are structurally sound and compliant with national safety standards to protect workers from falls. These standards are aligned with international best practices, ensuring worker safety during rooftop work.
Japan’s Industrial Safety and Health Act (ISHA): Japan's ISHA mandates that employers provide fall protection measures for workers engaged in elevated work, including the installation of appropriate guardrails. The standards outlined under this act are aligned with international safety standards but are specifically tailored to Japan’s work environments and safety protocols.
Rooftop guardrails must comply with various international standards, such as EN 14122, EN 13374, BS 13700, and relevant local regulations in the Asia-Pacific region to ensure their effectiveness and worker safety. Adhering to these standards guarantees that the guardrails will meet both the necessary structural integrity and safety requirements, protecting workers from potential fall hazards during rooftop and elevated work. Additionally, compliance with local regulations, like those in Australia, Singapore, and Malaysia, further ensures that companies maintain a safe working environment and minimize legal and financial risks.
Guarded Platforms
Guarded platforms are elevated structures that are designed to provide a safe and secure working surface for workers who need to perform tasks at height. They are equipped with guardrails or other forms of edge protection to prevent falls and protect workers from injury.
Guarded platforms should comply with several international standards to ensure their safety and effectiveness. One of the most relevant standards for guarded platforms followed in the Asia Pacific region is:
EN 14122-2: This standard provides guidelines for designing and building fixed access routes, including platforms and walkways. It covers aspects such as load-bearing capacity, slip resistance, and guardrail height.
There are several types of guarded platforms that can be used for solar maintenance. The type of guarded platform that is best suited for a particular job will depend on several factors, including the height of the solar panels, the layout of the installation, and the specific maintenance tasks that need to be performed.
Fixed platforms: Fixed platforms are permanent structures that are attached to the building or structure that supports the solar panels. They are typically made of steel or aluminum and are designed to provide a stable, slip-resistant working surface. Fixed platforms are often used in larger installations where regular maintenance is required.
Mobile platforms: Mobile platforms are designed to be moved from one location to another as needed. They are often used in smaller installations or for one-off maintenance tasks. Mobile platforms can be made of aluminum or steel and can be equipped with wheels or casters for easy movement.
Rooftop Walkways: Rooftop walkways are installed to mitigate working-at-height hazards related to uneven surfaces, obstructions, and steep slopes on a rooftop. It provides a clear pathway for workers to move around and provides secure access to rooftop equipment, such as HVAC systems, solar panels, and other installations.
Stepovers: Stepovers are similar to walkways, but are designed to provide access over obstacles such as pipes, ducts, or other rooftop equipment. They are typically made of the same materials as walkways and can be customized to fit the specific needs of the installation.
Fragile Roof Protection
Fragile roof fall protection refers to measures taken to prevent workers from falling through or off of a fragile roof during Solar Installation or maintenance work. Fragile roofs are those that are not designed to support heavy loads or foot traffic.
Skylight covers: Skylight covers are physical barriers that are designed to prevent people or objects from falling through skylights. These can be secured over the skylight to prevent accidental falls. EN 1873 specifies the requirements for the design and testing of skylight protectors to ensure that they provide adequate protection against falls. The standard covers various aspects of skylight safety covers, including their dimensions, strength, durability, and resistance to weather conditions.
Collective Protection is a preferred method of protection as they have the benefits of not being reliant on correct usage, minimal training requirements, and a compliant collective protection system will need very little maintenance when installed by a competent and certified installer.
Making sure that the collective protection used at the worksite is compliant with international standards that are followed in the particular region is very important. This will not only protect the workers from a serious fall hazard, but also protects the employer from legal consequences that may follow if an unfortunate accident occurs.
"Every worker deserves to come home safely at the end of the day, and every employer has a responsibility to ensure that happens"
Personal Fall Protection Systems
Where collective protection does not apply, personal fall protection systems could be applicable.
Horizontal lifeline
Anchorages
Personal Protective Equipment (PPE)
Horizontal Lifelines
A Horizontal lifeline is a safety system that is installed horizontally and provides a secure anchor point for a worker's safety harness. It typically consists of a cable or rope that is secured to two anchor points and provides a continuous attachment point for a worker's personal fall arrest system.
When installing or maintaining solar panels, workers may need to move around the roof, which increases the risk of falling. By using a horizontal lifeline system, workers can attach themselves to the lifeline and move along the roof safely, reducing the risk of falls and other accidents.
It is important that the system is designed, installed, and used under the supervision of a qualified person as part of a complete personal fall arrest system with at least a safety factor of two. They should also be regularly inspected and maintained to ensure their safety and effectiveness.
Horizontal Lifelines must be compliant with the following international standards:
EN795 2012 – European Standards for Personal fall protection equipment - anchor devices.
OSHA Code 1910.140(c) (11-22) – American Standards for Personal Fall Protection Systems.
CEN TS 16415:2013 – American Standards for Personal Fall Protection Equipment.
ANSI Z359 – Standards for personal energy absorbers and energy-absorbing lanyards.
Deadweight Anchor
The Deadweight Anchor is the key part of any system. Designers must utilise their experience and competency when choosing an anchor used for Fall Protection and Rope Access methods. As part of the company and designers’ due diligence, the test methods must be incorporated in to specific O&M manuals. These type of testing methods will differ from project to project and product to product.
Other factors to take into consideration are:
What is the task to be undertaken by the user?
What is the work method?
What is the frequency/duration of the work?
Type of site (e.g. Industrial plant, commercial property)
Structure suitability
Free fall distance
The designer also needs to consider what the system will be used for:
Anchors for fall restraint - How far from the fall hazard will the anchor be installed?
Anchors for fall arrest - Is the system positioned at least 6.75m away from any potential landing area?
Anchors for rope access and work positioning - two eyebolts per anchor point will be required.
Installation should comply with the recommendations of BS EN 795 and BS 7883.
Ideally, installation should be carried out by a qualified engineer who is able to ensure that the building’s structure is of sufficient capacity to be able to sustain the likely loads imposed when the anchorage point is in use.
Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) is essential for fall protection when installing and maintaining solar panels. As working at heights increases the risk of falls and the potential for serious injury or even death, PPE is a critical tool that can help protect workers from these work-at-height hazards.
There are many reasons why PPE is important for fall protection when installing and maintaining solar panels.
Prevents falls: PPE such as safety harnesses, lanyards, and anchor points can help prevent falls from occurring in the first place. Workers can secure themselves to anchor points on the roof or structure using a safety harness and lanyard, which can prevent them from falling off the roof.
Reduces the impact of falls: In the event of a fall, PPE can reduce the impact of the fall and minimize the potential for serious injury or death. A safety harness can absorb the shock of a fall and prevent the worker from hitting the ground or other objects.
Increases worker confidence: Knowing that they are wearing the appropriate PPE can increase worker confidence and reduce anxiety when working at heights. This can lead to improved productivity and quality of work. However, training must be provided to all users in selecting and using the right PPE for the task they perform.
Compliance with safety regulations: Many regulatory bodies require the use of PPE when working at heights. Ensuring that workers are wearing the appropriate PPE can help companies comply with these regulations and avoid penalties.
"Using Personal Protective Equipment (PPE) when working at height is not just a recommendation, it is a necessity"
Overall, it is essential to provide workers with adequate training, supervision, appropriate Collective Protection and Personal Protective Equipment to reduce the working at height hazards associated with solar panel installation and maintenance. Regular inspection and maintenance of equipment and systems can also help identify and address potential hazards before they become a problem.
Even though the fundamentals are similar, fall protection standards can vary across different countries and regions. While there are some common principles and best practices for fall protection that are widely accepted, the specific standards and regulations governing fall protection can differ based on factors such as local laws and industry-specific requirements.
It is important to research or consult an industry expert to understand the specific fall protection standards that apply to your industry and location to ensure compliance and promote worker safety.
By following proper safety protocols, solar systems can continue to provide a safe and sustainable energy source for years to come.
Contact one of our safety experts.
Kee Safety has been in the fall protection industry for over 80 years and has built a reputation as a leading provider of safety solutions. We work closely with our clients to understand their unique needs and provide customized solutions to meet their specific requirements. You can contact one of our Safety Experts for any of your Fall Protection requirements.
