Permanent fall protection systems for training structure
Italy
Fall protection systems for a multi-level training tower up to 30 meters
The project involved the permanent safety of a training tower used for the operational training of a major public body involved in rescue and emergency management.
The structure, located in the province of Bergamo, represents one of the most advanced technical training facilities: built on 5 operational levels and over 30 meters high, designed for complex exercises that include work at height, rope maneuvers, and rescue operations.
The training tower is used for daily training in highly complex situations, where precision, speed, and coordination are essential. For example:
- Recovery of injured persons with a stretcher in vertical shafts up to 10 meters high and about 2 meters wide, such as wells or elevator shafts;
- Access and intervention operations in confined spaces;
- Maneuvers on the roof up to 30 meters in height;
- Rescue activities that require the simultaneous presence of multiple operators.
The goal? In this context, it was necessary to install fall arrest systems capable of ensuring the safety of a facility designed to train people to deal with risk.
Main issues
Solutions adopted
- Training exercises up to 30 meters with risk of falls from height
- Training simulations in narrow and complex passages
- Multi-level structure
- Need for freedom of movement for rescue operations
- Detailed risk analysis
- Design of fall arrest devices
- Ensuring maximum freedom of movement for operators
- Reducing hooking/unhooking operations
- Continuous protection on all operational levels
- Installation of systems integrated with the structure
Critical safety issues identified
The project required the development of customised fall protection systems, starting from a careful risk analysis and listening to the operational needs of the site. The analysis highlighted several critical issues:
1. Work at height up to 30 meters
The training exercises involve technical maneuvers and movement of equipment at height, with risks of falls from height. It was therefore essential to ensure fall arrest protection along all operational areas, without interrupting the continuity of training activities.
2. Rescue simulations in confined spaces
One of the most distinctive features of the training tower is the presence of vertical shafts designed to simulate complex rescue scenarios. During training exercises, operators must descend or ascend in confined spaces, move stretchers and equipment, or operate with multiple teams simultaneously. In these conditions, fall protection systems must not hinder movements or increase the complexity of maneuvers.
3. Multi-level operational structure
The training tower is developed on multiple floors. Each floor of the structure has different characteristics, making a flexible and highly customized design approach essential.
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What solutions did the structure require?
To meet the structure’s operational needs, Genesi Protection designed and installed fall protection systems, engineered to work in synergy:
On each of the 5 levels of the structure, a rigid fall arrest rail AluxCrab was installed, compliant with EN 795:2012 Type D, CEN/TS 16415:2013 Type D and UNI 11578:2015. The system allows the trolley to run continuously without the need for hooking and unhooking actions, even in the presence of curves and changes in direction. This allows operators to move along the entire path, reducing operational times and increasing the level of safety during training exercises.
On the various levels of the structure and on the roof, flexible Exagon lifelines were installed, compliant with EN 795:2012 Type C, CEN/TS 16415:2013 and UNI 11578:2015. The lifelines provide fall arrest protection in both horizontal and vertical configurations. The system is designed to dissipate energy in event of a fall, reducing the loads transmitted to the structure.
On the roof, on corrugated metal sheet, AP36 anchor points were installed, designed for high performance in environments exposed to stress.
To complete the installed systems, ALU12 anchor points were installed on the walls, used as a secure connection point for transitions between levels and specific technical operations.
The results of the project
The main benefits for the structure are:
- Complete protection of the 5 operational levels.
- Safety systems that can be used simultaneously by multiple operators, optimizing time.
- Solutions integrated into the structure permanently, reducing the need to install and remove temporary protections.
- Freedom of movement for operators during training exercises.
Are your structure safe?
Securing complex structures requires technical expertise, knowledge of regulations, and custom-designed solutions.
If you manage industrial buildings, plants, or infrastructures that involve work at height, Genesi Protection supports you in the design and installation of reliable and compliant fall protection systems.
Contact us for a technical consultation: we will analyze your structure and identify the most suitable fall protection systems for your operational needs.
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