11 Sep Rebar Safety – Impalement Protection

Rebar Safety – Impalement Protection

Rebar impalement protection is required whenever employees could fall onto or otherwise be exposed to protruding reinforcing steel or similar projections. Exposed rebar can cause cuts and punctures, but the greatest danger is a worker falling onto an unprotected bar and suffering a serious or fatal impalement injury.

Recognize the Hazard

Reinforcing steel is common around foundations, walls, columns, slabs, and other concrete construction. Hazards can exist when rebar:

• Projects vertically from floors, foundations, or excavations.
• Extends horizontally into access or work areas.
• Is located below employees performing elevated work.
• Is present below grade or inside excavations and basements.
• Is positioned where employees could trip or fall onto it.
• Creates sharp projections along normal access routes.

Do not assume rebar is safe simply because it is short, located below grade, or appears unlikely to be contacted.

OSHA Impalement Protection

OSHA requires employees working at any level where they could fall onto or into protruding reinforcing steel to be protected against the hazard of impalement.

Protection may include:

• Guarding or covering exposed reinforcing steel.
• Bending or otherwise eliminating exposed projections where appropriate.
• Installing properly designed impalement-protection devices.
• Using guardrails or other fall-protection methods to prevent employees from reaching the hazard.

The method selected must actually eliminate the impalement hazard.

Rebar Caps

Not every plastic rebar cap provides impalement protection.

Mushroom-style or other non-reinforced plastic caps generally provide protection from scratches and minor contact only. They should not be relied upon where a worker could fall onto the rebar.

Where an impalement hazard exists, use a manufactured rebar protection system specifically designed and rated for impalement protection, such as a cap incorporating appropriate reinforcement.

Before relying on a cap:

• Verify that it is intended for impalement protection.
• Follow the manufacturer’s installation instructions.
• Make sure it fits securely on the rebar.
• Inspect it for damage or displacement.
• Replace missing, cracked, damaged, or improperly installed caps immediately.

Never assume that a cap is adequate based only on its appearance.

Troughs and Continuous Covers

Where multiple pieces of rebar are exposed, continuous protective systems may be more practical than individual caps.

Properly designed systems may include:

• Manufactured rebar troughs.
• Wood troughs or covers constructed to provide adequate protection.
• Other engineered guarding systems capable of preventing employee contact with the exposed ends.

Covers and troughs must be sufficiently strong, securely installed, and maintained so they cannot easily shift or become displaced.

Fall Protection and Rebar

Preventing the fall is an important part of rebar impalement protection, but employees must consider both the fall hazard and the impalement hazard.

Where required, use appropriate fall-protection systems such as:

• Guardrail systems.
• Personal fall arrest systems.
• Fall restraint systems.
• Other approved fall-protection methods appropriate for the work.

Do not rely on an ordinary rebar cap as a substitute for required fall protection.

When planning work, consider where an employee could land—not simply the distance to the walking or working surface immediately below.

Working Around Exposed Rebar

Employees working near reinforcing steel should:

• Maintain clear walking and working areas.
• Avoid stepping over exposed rebar whenever safer access is available.
• Never remove protective caps or covers unless authorized.
• Replace displaced protection immediately when qualified and safe to do so.
• Keep materials, cords, hoses, and debris away from rebar areas to reduce trip hazards.
• Use designated access routes.
• Wear appropriate gloves when handling reinforcing steel.
• Wear required eye, head, foot, and other PPE.
• Report unprotected or improperly protected rebar immediately.

If work activities require removing impalement protection, another effective means of protection must be established before employees are exposed.

Inspect the Work Area

Conditions around reinforcing steel can change rapidly as construction progresses. Inspect the area before beginning work and as conditions change.

Look for:

• Missing or displaced caps.
• Caps that are not rated for impalement protection.
• Damaged protective troughs or covers.
• Newly installed or exposed reinforcing steel.
• Trip hazards near exposed rebar.
• Changes in elevation that create a potential fall onto rebar.
• Guardrails or fall-protection systems that have been removed or altered.

Do not work where an uncontrolled rebar impalement hazard exists.

Remember

A small plastic cap does not necessarily provide rebar impalement protection. Where employees could fall onto exposed reinforcing steel, the hazard must be eliminated through appropriate guarding, impalement-rated protection, fall prevention, or another effective protective system.

Prevent the fall, protect the exposed rebar, and never leave an impalement hazard unguarded.