OSHA Guardrail & Handrail Requirements

Nominal Height & Variances for Guardrail Systems

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OSHA's guardrail height requirements include a variance of plus or minus 3 inches. Guardrail systems that are not at least 42 inches high can be cited as a technical violation.

Must Withstand 200 Pounds

All guardrail systems must be able to hold at least 200 pounds of pressure pushing out and down on the railing. Downward pressure should not bend railing past 39 inches above its walking-working surface. To test this, apply an appropriate force within 2 inches of the railing's top edge.

Must Be Smooth

Guardrail system surfaces must be smooth. Smooth surfaces help protect personnel from injuries and prevent job-site hazards.

Must Be 1/4 Inch

The minimum thickness for guardrails, midrails and vertical members is 1/4 inch in diameter.

No Overhanging Rails

The ends of top rails and midrails of a guardrail system must not extend past the final post. The only exception to this rule is where the overhang does not present a projection hazard.

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Midrails, Panels & Equivalents

OSHA regulations permit midrails, screens, meshes and vertical members in guardrail systems. These members must be able to hold at least 150 pounds of outward and downward pressure, and openings between members must not exceed 19 inches.

• Midrails - installed between the top edge and walking-working surface no more than 19 inches apart
• Screens and meshes - cover the entire opening between the top edge and walking-working surface
• Intermediate vertical members - installed no more than 19 inches apart
• Other equivalent intermediate members - installed with no opening more than 19 inches wide
• Steel and plastic banding - not allowed as top rails or midrails

One of the more popular fall protection questions we receive relates to OSHA requirements for safety railing and guardrail systems. Determined inquiring minds can consult OSHA 1910 (General Industry) or OSHA 1926 (Construction), but this can be a laborious process. In the interest of time, here is OSHA’s official stance on guardrail:

OSHA 1910.23 Guardrail/Safety Railing Requirements for General Industry

• 1910.23(e)(1) – A standard railing shall consist of top rail, intermediate rail, and posts, and shall have a vertical height of 42 inches nominal from upper surface of top rail to floor, platform, runway, or ramp level. The top rail shall be smooth-surfaced throughout the length of the railing. The intermediate rail shall be approximately halfway between the top rail and the floor, platform, runway, or ramp. The ends of the rails shall not overhang the terminal posts except where such overhang does not constitute a projection hazard.
• 1910.23(e)(3)(ii) – For pipe railings, posts and top and intermediate railings shall be at least 1 1/2 inches nominal diameter with posts spaced not more than 8 feet on centers.
• 1910.23(e)(3)(iv) – The anchoring of posts and framing of members for railings of all types shall be of such construction that the completed structure shall be capable of withstanding a load of at least 200 pounds applied in any direction at any point on the top rail.

OSHA 1926.502 Guardrail /Safety Railing Requirements for Construction

• 1926.502(b) – “Guardrail systems.” Guardrail systems and their use shall comply with the following provisions:
• 1926.502(b)(1) – Top edge height of top rails, or equivalent guardrail system members, shall be 42 inches (1.1 m) plus or minus 3 inches (8 cm) above the walking/working level. When conditions warrant, the height of the top edge may exceed the 45-inch height, provided the guardrail system meets all other criteria of this paragraph.
• 1926.502(b)(2) - Midrails, screens, mesh, intermediate vertical members, or equivalent intermediate structural members shall be installed between the top edge of the guardrail system and the walking/working surface when there is no wall or parapet wall at least 21 inches (53 cm) high.
• 1926.502(b)(2)(i) - Midrails, when used, shall be installed at a height midway between the top edge of the guardrail system and the walking/working level.
• 1926.502(b)(3) - Guardrail systems shall be capable of withstanding, without failure, a force of at least 200 pounds (890 N) applied within 2 inches (5.1 cm) of the top edge, in any outward or downward direction, at any point along the top edge.
• 1926.502(b)(4) - When the 200 pound (890 N) test load specified in paragraph (b)(3) of this section is applied in a downward direction, the top edge of the guardrail shall not deflect to a height less than 39 inches (1.0 m) above the walking/working level. Guardrail system components selected and constructed in accordance with the Appendix B to subpart M of this part will be deemed to meet this requirement.
• 1926.502(b)(5) - Midrails, screens, mesh, intermediate vertical members, solid panels, and equivalent structural members shall be capable of withstanding, without failure, a force of at least 150 pounds (666 N) applied in any downward or outward direction at any point along the mid rail or other member.

If you read the language carefully, you’ll notice a good deal of similarity between guardrail standards for general industry and construction. With both standards, OSHA deems guardrail compliant under the following conditions:

• Vertical height of 42 inches
• Mid rail height of 21 inches
• Top rails capable of withstanding 200 pounds of pressure from any direction
• Mid rails capable of withstanding 150 pounds of pressure from any direction
• Rail and post diameters of 1-1/2” or more.

The true difference between these standards is not strength or rail height requirements, but the working height requiring use of fall protection equipment. For general industry applications, unprotected leading edges at heights of 4 feet or more require the use of guardrail or some other form of fall protection. For construction applications, the height threshold is 6 feet.

What Do OSHA Regulations Say About Roof Pitch and Guardrail Use?

In case you are wondering when/if OSHA ever specifies when guardrail is an acceptable form of fall protection, you will not find a regulation or letter of interpretation addressing this issue. The determination of the precise pitch threshold where guardrail should give way to some other form of fall protection is a question best left to a safety engineer. That said, common sense suggests the use of guardrail to arrest falls on steeper roofs is a scary prospect. Working with a reputable fall protection company ensures installation of a safety system (e.g., guardrail, horizontal lifeline, etc.) that is best suited for the pitch of your roof.

Remember, select a guardrail or safety railing system that is both appropriate for the pitch of the roof and meets or exceeds all OSHA standards. If you are interested in buying or learning more about OSHA compliant guardrail to protect the leading edges of your roof, we suggest visiting our ecommerce-enabled website at www.PortableGuardRail.com for more information.

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