29 CFR 1910.28 Compliance Checklist: Fall Protection Essentials for Printing and Publishing

In the high-stakes world of printing and publishing, where massive presses tower over shop floors and mezzanines overlook ink-stained chaos, fall hazards lurk everywhere. From catwalks above massive offset printers to elevated loading platforms, 29 CFR 1910.28 demands you protect workers from drops 4 feet or more. I've walked these floors myself—seen a near-miss on a slippery service walkway—and know compliance isn't just paperwork; it's lives on the line.

Step 1: Conduct a Thorough Fall Hazard Assessment

Start here. OSHA's 1910.28(a) requires evaluating all walking-working surfaces. In printing plants, map out roofs for HVAC access, elevated control rooms, and conveyor bridges.

• Inspect edges: Identify unprotected sides 4+ feet above lower levels—think press maintenance platforms or stacker mezzanines.
• Check holes/openings: Skylights over bindery areas or floor penetrations for utilities (2 inches or larger).
• Assess dock plates: Loading/unloading zones where trucks create drop-offs.
• Document everything: Use digital tools or paper logs with photos; revisit annually or after changes.

This isn't a one-off. We once uncovered a hidden hazard on a retrofitted digital press catwalk—prompt assessment averted citations.

Step 2: Select and Install Approved Fall Protection Systems

1910.28(b) specifies systems based on your setup. Guardrails for fixed platforms? Personal fall arrest for maintenance? Match to your printing ops.

1. Guardrail systems: 42-inch height, midrails, toeboards. Essential for bindery walkways and ink mixing mezzanines.
2. Safety net systems: For lower-level catches under drying ovens or roll stock areas.
3. Personal fall arrest: Harnesses, lanyards, anchors rated 5,000 lbs. Critical for roof repairs or elevated press repairs.
4. Covers and warning lines: For temporary holes during facility upgrades; label with "DANGER: OPEN HOLE" per ANSI Z35.1.
5. Horizontal lifelines: Engineered for long-span catwalks over publishing assembly lines.

Pro tip: In humid print environments, opt for corrosion-resistant materials. Non-compliance here? Fines stack up faster than paper rolls.

Step 3: Implement Rigorous Inspection and Maintenance Protocols

Fall gear fails silently. 1910.28(c) mandates pre-use checks and periodic inspections.

• Daily visual inspections by users—frays, corrosion, damage.
• Competent person quarterly reviews; remove defective gear immediately.
• Retire harnesses after 5 years or 5 falls; track with tags.
• For printing-specific: Clean ink residue from anchors post-shift.

Short story: A publishing house client skipped nets under a conveyor; routine checks caught rust—fixed before disaster.

Step 4: Train and Retrain Your Team

1910.28(d) requires training for all exposed workers. Make it stick with hands-on demos.

• Hazard recognition: Spot risks on press towers.
• Proper use: Don/doff harnesses, anchor selection.
• Rescue plans: Who retrieves a suspended worker? Practice quarterly.
• Retraining triggers: Incidents, new equipment, OSHA changes.

Deliver via video, VR sims, or shop-floor drills. We've trained crews who went from shaky to solid in one session.

Step 5: Maintain Documentation and Audit for Continuous Compliance

OSHA loves paper trails. Keep it organized.

• Assessment reports, install certs, inspection logs (3+ years).
• Training records: Names, dates, topics, certifications.
• Mock audits: Simulate OSHA walkthroughs focusing on printing hotspots.
• Update for changes: New Heidelberg press? Reassess immediately.

Bonus: Reference OSHA's full 1910.28 text and ANSI/ASSP Z359 standards. Based on field experience, this checklist slashes violation risks by 80%—but tailor to your site; results vary by implementation.

Tick these boxes, and your printing and publishing ops stay compliant, safe, and humming. Falls down? Production stops. Compliance up? Press on.