The Human Factor: Safety on Mast-Climbing Platforms

Words: Vera Autushka

Mast-climbing platforms are efficient and inherently safe technology that allows people to work safely at significant heights. Despite numerous safety features, accidents still sometimes happen—not because the platforms fail, but often because humans do.

Accidents with mast-climbing platforms rarely stem from mechanical failure. Instead, they arise from lapses in judgment, oversight during installation, or insufficient respect for safety protocols. Understanding these risks, and how to mitigate them, is not just prudent but essential.

What Can Go Wrong?
At the core of mast-climbing platform safety are three central risks: falling, structural failure, and improper use.

Falling remains the most prevalent danger—whether it’s workers losing their balance or tools and materials plummeting to the ground. These incidents are often preventable through proper training and the use of protective equipment, such as fall-arrest systems, guardrails, and personal protective equipment.

Then there’s the risk of structural failure, which can occur when platforms are improperly installed or overloaded. In many cases, this is not a failure of the machine but of those who operate or assemble it.
Environmental factors add another layer of complexity. High winds, unstable building surfaces, or compromised anchor points during restoration work can lead to disaster. Such incidents, tragic in their outcomes, are often the result of small, compounding errors that accumulate over time.

Ergonomics Meets Engineering
Mast-climbing work platforms are engineered with safety in mind. Guardrails, adjustable working heights, and anti-overload systems all work together to reduce risk. Additionally, the platforms are ergonomically designed to minimize work-related illnesses and injuries by preventing workers from performing tasks in awkward positions, such as excessive bending when laying brick.

The engineering doesn’t stop there. Modern platforms feature emergency braking systems that activate in the event of a free fall, inclinometers that detect and prevent unsafe tilts, and alarms to alert operators to any unexpected issues. These mechanisms reflect a commitment to not only safeguard workers but to anticipate human error.

Yet, even with these advancements, safety begins and ends with the people who operate and manage the equipment.

The Role of Training
Francois Villeneuve, VP of Engineering at Fraco, recounts a sobering example of the importance of training and thorough inspections. Two workers, short on time and short on bolts, decided to temporarily secure a mast during installation. Their plan was to return after lunch to complete the job properly. But they didn’t. The next step in their rushed timeline saw a platform hoisted onto a mast that was dangerously under-secured. The tragic outcome serves as a stark reminder: Rushing and incomplete tasks can lead to irreversible consequences.

Villeneuve emphasizes that proper training is a cornerstone of platform safety. Installation and operator training can span several days, covering theoretical knowledge and hands-on practice. The goal is simple: To ensure that every person involved knows not only how to operate the equipment but also how to recognize and respond to potential hazards.

Daily Inspections and Maintenance
Safety is a daily commitment. Before each shift, operators must perform a comprehensive visual inspection of the platform. Are the mast bolts tight? Are the hydraulic systems functioning properly? Is the surrounding environment stable and free of hazards?

These daily checks are supplemented by periodic maintenance and non-destructive testing (NDT) to assess the integrity of critical components like the mast, motor, and anchorage points. Neglecting these inspections, or cutting corners, invites risks that could otherwise be avoided.

The Danger of Improvisation
Construction sites are dynamic environments, and workers often face the temptation to adapt platforms to unique architectural challenges. While creativity is a hallmark of the trade, unapproved modifications can lead to disaster.

Villeneuve warns of the dangers of "risky ingenuity." He recalls instances where workers altered anchorage points to avoid obstacles, inadvertently destabilizing the platform. Custom configurations for unconventional designs are developed exclusively by engineers and rigorously tested to ensure they meet safety standards. Improvisation is not an option.

Technology as an Ally
The future of mast-climbing platform safety lies in technology. Load sensors, remote diagnostics, and artificial intelligence are making their way into the industry. For example, systems now exist that can detect unbalanced loads or unauthorized modifications, sending real-time alerts to operators and supervisors.

These innovations aim to catch issues before they escalate, but they don’t replace the human element. Training, diligence, and respect for safety protocols remain irreplaceable.

A Culture of Safety
When asked for their top three safety rules, Villeneuve and Shanon Beekman, Fraco’s Training and Development Manager, gave remarkably aligned answers.

Villeneuve’s advice:

Prioritize training—no untrained workers should ever operate a platform.
Never rush—attention to detail saves lives.
Respect load capacities and proper load distribution.

Beekman adds:

Familiarize yourself with the platform’s user manual.
Always undergo proper training for the specific platform in use.
Stay vigilant—observe your surroundings and speak up about potential hazards.

Mast-climbing platforms are marvels of modern construction engineering, combining efficiency and safety. Yet, as Villeneuve and Beekman stress, the ultimate responsibility lies with those who install, operate, and maintain these machines.

With proper training, a commitment to daily and periodic inspections, and respect for both equipment and environment, the risks associated with mast-climbing platforms can be mitigated. Technology will continue to evolve, making platforms safer, but the human factor remains the most critical component of any safety protocol.

In the end, it’s simple: Don’t cheat. Don’t rush. Don’t overload. And always respect safety guides.

The Human Factor: Safety on Mast-Climbing Platforms

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