Elevated storage areas are common in warehouses and distribution centers, especially in the building materials industry where space optimization is essential. But these raised platforms, mezzanines, and racking systems also come with serious fall hazards. If your facility is due for an OSHA or internal safety inspection focused on fall protection, being well-prepared can help you avoid violations, fines, and—more importantly—accidents.
Here’s how to get your facility inspection-ready and demonstrate full compliance with fall protection standards.
- Understand the Applicable Standards
Start by reviewing OSHA’s general industry fall protection regulations (29 CFR 1910 Subpart D). For elevated storage areas, key requirements include:
Guardrails at edges 4 feet or higher
Midrails and toe boards where needed
Fall arrest systems in areas without guardrails
Safe access points (ladders, stairs, gates)
Be sure to also check any state-specific regulations or industry best practices that may go beyond the federal baseline.
- Inspect All Guardrails and Edge Protections
Before any inspection, walk through all elevated storage areas and physically inspect:
Guardrails for structural integrity and proper height (at least 42 inches)
Midrails and toe boards for gaps or missing sections
Swing gates or safety chains at access points for functionality
Anchorage points for any personal fall arrest systems
If anything looks loose, worn, or improvised—repair or replace it before the inspection.
- Verify Proper Signage and Warnings
Inspectors will expect to see clear, visible warnings around fall hazards, especially in areas with:
Temporary platforms
Restricted-access zones
Equipment requiring tie-off
Install or refresh signs that identify fall hazard zones, PPE requirements, and access restrictions.
- Review Fall Protection Equipment
If your facility uses harnesses, lanyards, or self-retracting lifelines (SRLs), make sure they’re:
Inspected regularly and within date
Stored correctly (dry, clean, out of direct sunlight)
Assigned to trained individuals only
Clearly labeled and matched with compatible anchor points
Inspectors may check for frayed harnesses, damaged lanyards, or missing inspection tags.
- Audit Employee Training and Certifications
Your team must be trained on fall hazards and the proper use of fall protection systems. Before an inspection:
Review training logs and ensure they’re up to date
Make sure new hires and temporary workers are included
Refresh documentation for annual or refresher training sessions
If an inspector asks, employees should be able to describe the fall protection procedures in their work area.
- Evaluate Access Points and Ladders
Fall hazards often begin before workers even reach the elevated area. Make sure:
Fixed ladders are OSHA-compliant and securely mounted
Stairways have handrails and anti-slip treads
Workers are not using makeshift access methods like stacked pallets or unsecured ladders
Secure all access points and restrict unauthorized entry with gates or clear signage.
- Practice Emergency Response and Rescue Plans
A fall protection inspection may include questions about your emergency procedures. Prepare by:
Reviewing your written fall rescue plan
Verifying that designated rescue personnel are trained
Making sure rescue equipment is available, accessible, and functional
Running mock drills or tabletop exercises for your team
Being able to show a thought-out and practiced rescue plan speaks volumes to an inspector.
- Conduct a Mock Inspection
Before the official inspection, run your own internal audit using a fall protection checklist. Involve your safety officer or an outside consultant to:
Identify blind spots
Document compliance efforts
Make corrective actions before inspection day
A mock inspection helps you see your facility through the eyes of a regulator—and resolve issues proactively.
Final Thoughts
Preparing for a fall protection inspection isn’t just about checking boxes—it’s about creating a safe, compliant workplace that protects your people. In the building materials industry, where elevated storage is the norm, staying ahead of inspections ensures your facility operates without disruption and keeps your team out of harm’s way.
Take a proactive approach now, and inspections will become just another day on the job—instead of a major disruption.
