The short answer
Four activities account for most serious incidents in heavy erection: work at height, lifting, hot work and confined space entry. Each has a control set that works, and each fails the same way — when schedule pressure makes the control feel optional.
Erection work concentrates risk: heavy loads moving at height, hot work near combustibles, confined spaces inside equipment. The controls are well known. Incidents happen when they are treated as paperwork.
Work at height
- Full-body harness with double lanyard, anchored above the shoulder
- Fall arrestor blocks where a lanyard cannot maintain anchorage
- Edge protection and covered openings, checked each shift
- A rescue plan in place before anyone goes up — a suspended worker has minutes
Lifting operations
Every critical lift needs a written plan: verified load weight, crane configuration and radius, ground bearing capacity, rigging arrangement and an appointed person in charge. Tools and tackles need valid third-party test certificates and a pre-use check.
Hot work
| Control | Why it exists |
|---|---|
| Permit with defined validity | Forces a re-check when conditions change |
| Combustible clearance or shielding | Sparks travel much further than expected |
| Fire watch during and after | Most fires start after work stops |
| Gas test in hydrocarbon areas | Non-negotiable in live plants |
Confined space
Entry into drums, ducts and vessels needs isolation, gas testing, continuous ventilation, an attendant outside and a rescue arrangement. The attendant is not a formality — self-rescue from a confined space is often impossible.
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