Learn from user cases: Checkpoints to assess safety and durability

Introduction

This article explains key points for accident prevention and work efficiency improvement, targeting managers and safety personnel at sites where stepladders and ladders are used daily, such as in manufacturing, construction, and logistics. At these sites, serious accidents like falls and equipment breakage can occur due to incorrect usage, age-related deterioration, or selecting products unsuitable for the intended application. Here, we will delve into the importance of safety and durability evaluation based on actual accident case studies and clarify the checkpoints to be confirmed during implementation, aiming to prevent accidents and improve work efficiency.

Market and Accident Status

Domestic and International Statistical Data

In Japan, according to a survey by NITE (National Institute of Technology and Evaluation), there were 162 accidents related to “ladders and stepladders” in the five years from 2017 to 2021, with about half of them caused by misuse or carelessness. According to the Ministry of Health, Labour and Welfare’s industrial accident statistics, about 86% of disasters originating from stepladders are falls, and many cases leading to serious injuries such as bone fractures have been reported.

Meanwhile, in Vietnam, although safety standards for equipment for working at heights are stipulated by the Law on Occupational Safety and Health and TCVN standards, there are cases where older equipment and non-compliant products are still in use on-site. When procuring locally, it is important to confirm whether the products comply with international standards (JIS, EN, ANSI, etc.).

Accident Characteristics and Trends

From the statistics, accidents involving the elderly are conspicuous, with those aged 60 and over accounting for more than 40% of the total. As for the type of occurrence, falls account for 86%, and as a result, fractures make up about two-thirds of the total, a serious situation. These figures strongly indicate the necessity of correct usage methods, appropriate product selection, and continuous inspection and education.

Data Box

Learning from User Case Studies: Accident Causes and Improvement Measures

Misuse and Carelessness

Common misuses seen on-site include straddling the top plate of a stepladder, leaning the body far out sideways from the climbing surface, or setting it up on sloping or unstable ground. Hasegawa’s collection of near-miss case studies also reports multiple instances where such actions are typical factors leading to falls and loss of balance. For example, there was a case where a worker lost balance and fell at the moment they were on one foot while straddling the top plate during wall work, and another case where a worker was working sideways on a stepladder while holding a heavy load, causing the stepladder to tip over.

Product Deterioration and Unsuitability for Purpose

One cause of accidents is the corrosion of aluminum parts and loosening of joints due to outdoor storage, leading to steps coming off. There are also cases where lightweight household stepladders were used in high-load environments such as factories and construction sites, leading to breakage and falls due to insufficient durability. These are typical examples caused by a mismatch between the usage environment and product specifications.

Improvement Measures and Immediate Action Points

To prevent such accidents, it is important to check the condition of the steps, stiles, and fasteners before each use and to immediately stop using the equipment if corrosion or deformation is found. Storage should be in a place that avoids direct sunlight and rain. Depending on the purpose of use, select commercial-grade products, FRP models, or models with safety mechanisms like outriggers. Furthermore, it is effective to thoroughly communicate correct usage posture and prohibited actions through regular safety education.

Checkpoints for Evaluating Durability and Safety at Introduction

Product Specification Confirmation Items

Before introduction, it is necessary to check basic performance details such as the product’s material, maximum load capacity, corrosion resistance, and anti-slip performance. In particular, for outdoor work or at sites where chemical substances may be scattered, highly durable materials such as aluminum alloy or FRP (Fiber Reinforced Plastic) are recommended. Also, conformity markings to standards such as JIS, SG, and A-mark are important indicators that guarantee safety.

Compatibility with the Usage Environment

The optimal specifications for stepladders and ladders differ depending on the usage environment. Weather resistance is required for outdoor use, lightness and floor protection for indoor use, chemical resistance for chemical environments, and FRP products with insulation performance for electrical work. Neglecting to match site conditions with product specifications increases the risk of reduced durability and serious accidents.

Maintenance Plan

To maintain durability and safety over the long term, it is essential to have a system that clarifies the regular inspection cycle and detects loosening, corrosion, and wear of steps and joints at an early stage. Also, confirming the availability of replacement parts and the manufacturer’s support system before introduction will minimize downtime during long-term operation.

Hasegawa’s Reliability and Implementation Case Studies

Quality Control and Safety Training

At Hasegawa, all products undergo strict quality inspections before factory shipment and are manufactured under ISO-certified process control. Furthermore, even after on-site introduction, the company provides safety training sessions for users and on-site safety diagnostic services to support improvements in usage methods and the identification of hazardous areas. This realizes an improvement in the safety of the entire usage environment, not just the product performance.

Implementation Case Study (Before→After)

At a certain manufacturing site, after replacing previously used non-standard stepladders with Hasegawa’s commercial models, near-miss reports related to stepladders decreased by 70% in one year. In addition, improved anti-slip performance and weight reduction improved work efficiency by about 15%, and parts replacement and repair costs were also significantly reduced. These figures concretely show the effects brought about by the combination of appropriate product selection and safety education.

Conclusion

This article has explained, with statistical data and user case studies, that an approach from both product selection and operational management is essential to ensure the safety and durability of ladders and stepladders. Many accidents are caused by misuse or inappropriate product selection, and daily inspections using a checklist and confirmation of appropriate product standards are the keys to accident prevention. Thorough internal communication and education to entrench a safety culture is the first step to achieving both efficiency and peace of mind on-site. For detailed specifications and case studies, please also refer to Hasegawa’s official materials and videos.