Welder Falls 19 Stories
From High Rise Building

In February 1996, a welder with 20 years experience as an iron worker died after he and his metal cage fell from a high rise building, where he and a co-worker were welding tube girts. Each welder was supported separately in metal cages, each suspended by a ½ inch thick steel cable. Each had their portable welding rigs on separate floors of the building. The victim had his welding lead coming to his work area from above, while his friend has his lead coming from below. (Des Moines Register Diagram)

The high amperage cable above the victim’s cage was in poor condition, and had a damaged and exposed area where the insulation was torn off. Because of the wind, this bare wire came into direct contact with the steel support cable, and in a shower of sparks the welding lead arced to the steel cable, melting both of them in two, sending the cage and the welder to the ground 19 stories below.

The man inside the cage was wearing a fall protective body harness, rope lanyard, and nylon lifeline attached to a point above his work position. However when the cage fell, it snagged and broke his lanyard, which was in poor condition. His lanyard was attached to the left D-ring of his belt harness, not to the proper attachment point in the midline of his back. He was also not using the leg straps of his body harness, but they were folded upon themselves and taped together.

1. Welding leads should always come from below suspended platforms or cages—never from above!

—Welding leads are frequently damaged on heavy construction sites and high rise jobs.

—Electric welding leads are potentially hazardous and must be kept separate from supporting cables.

2. Welders must inspect welding leads prior to and during work for signs of damage and/or exposed wire.

—Exposed welding leads may start fires and are a significant safety hazard. Handle them carefully!

3. Employers should regularly inspect the condition of safety equipment, and ensure it is worn correctly.

—Old lanyards and lifelines have significantly reduced capacity due to deterioration from UV radiation, oils, welding sparks, and abrasion. Old gear must be identified and replaced.

4. Workers should ensure that fall protective gear is in acceptable condition and worn properly.

—The incorrect attachment point for the man's lanyard may have prevented him from clearing the cage opening when the cage fell. Also, the man was issued a new lanyard, but was not using it.

—The deliberately taped up leg straps indicate a casual approach to fall protection.