After years of climbing free-hand, line specialists at Duke Energy (Charlotte, North Carolina) are learning how to scale wood poles all over again. As part of the utility's focus on safety, all the line specialists must now use 100% fall protection.

Line specialists have died or been seriously injured when they've fallen off a utility pole because of fatigue, contact with a live wire or wood rot. To help protect these workers, Duke Energy is changing the way its line specialists climb poles.

Due to the increasing number of fatalities and accidents reported by utilities nationwide, Duke Energy tested a fall protection device and later rolled it out company-wide three years ago. The company first implemented the fall protection system in the Carolinas, but two years ago, line specialists in Ohio, Kentucky and Indiana also moved to 100% fall protection.

Preventing Falls

Line specialists for Duke Energy can no longer plunge to the ground if they “cut out.” By using a device called the BuckSqueeze, which is manufactured by Buckingham Manufacturing Co. Inc. (Binghamton, New York), line crews can improve the safety of their workers. Rather than falling to the ground, the device catches them and holds them into position. The system reduces the fall distance that can occur from the hazards and help to reduce injuries in the field.

To use the device, a user must snap the belt around the outside of the utility pole with a locking snap hook. The interior nylon belt is then adjusted to fit snuggly against the pole. Should the worker experience a fall, his or her downward weight would then put pressure against the interior strap, cinching the pole and stopping the fall.

Learning Curve

While the device can improve the safety of the line specialists, it takes time for users to master the skill of climbing with the apparatus. For that reason, the utility experienced some pushback from the line specialists during the testing process.

Moving to a 100% fall protection system was a major change for many of the line professionals. Many line specialists have spent decades free-climbing to a location with a safety belt. They were professional and proficient climbers, and didn't see a reason to change their ways. Because they felt comfortable about their climbing skills, they were initially reluctant to adapt to a change in their climbing style.

One reason why the line specialists were reluctant to switch to the 100% fall protection system was because it would slow them down. As they climbed up the pole, they would grasp the strap assembly and lift it up the pole. In the past, they could climb poles hand over hand and not worry about the safety belt slowing them down. But if their climber cut out of the pole for any reason, the line specialists were exposed to the possibility of a fall.

While the system can slow line specialists down, it has helped to improve the safety of the crews, says Todd Irby, a line specialist for Duke Energy, Gastonia, North Carolina.

“It doesn't matter how fast you are doing your job,” he says. “If you cut out and get hurt, your family won't have you anymore. With this device, everyone can go home at the end of each day.”

Technical Training

Before rolling out the fall protection system company-wide, Duke Energy implemented a pilot program. The utility purchased 100 devices for Indiana and another 100 for Ohio and Kentucky. The company then selected 200 line specialists to test the device out in the field.

The vendor first instructed Duke Energy's Technical Training Department on the proper usage of the device before training the line specialists. After the technical trainers were proficient in its use, they brought in line specialists in small groups for both classroom and practical training. They watched an instructional DVD and then spent time in the field practicing on the pole with the device under an instructor's guidance.

The line specialists practiced how to attach to the pole, release the pressure and then work their way up and around the pole. While many of the veterans had decades of experience climbing poles, they had to learn new techniques.

One challenge that they often faced was climbing over obstacles such as transformers and crossarms. In this scenario, they had to use an additional lanyard to place over the piece of equipment. They would then take their device, climb a few feet to where they were clear of the equipment and then take the additional lanyard off. Throughout this process with the additional lanyard they are able to achieve fall protection at all times throughout their ascent and descent.

The line specialists discovered that working with the device took time, practice and patience, and each field worker has his or her climbing technique.

Rolling Out the Device

Duke Energy has now fully implemented the 100% fall protection system company-wide. About 1,200 line specialists are now using the device out in the field. Soon after the pilot program was rolled out, the company implemented the program for the rest of the line personnel. Duke also requires its contractors to use 100% fall protection while working on its system.

While many workers were initially hesitant to use the device, over time, they have begun to appreciate the company's mandatory move to 100% fall protection for all climbing employees. It was a challenge for the line specialists to change their climbing styles, but most of the field employees realized that this change could someday save their life or prevent a serious injury.

The utility still faces some opposition to the device, but for the most part, it is now widely accepted by the line specialists. Duke Energy prides itself on the safety of its employees, and the major driving force behind this decision was to protect its workers out in the field.

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Mark Hoeweler (Mark.hoeweler@duke-energy.com) is the supervisor of the Midwest Technical Training Department for Duke Energy in Cincinnati, Ohio. He has been with the company for 18 years. Before joining the Training Department, he spent 12 years in the field as a cable splicer.

Dale Lykins is a technical training specialist for the Midwest Technical Training Department for Duke Energy in Cincinnati, Ohio. He has been with the company for 21 years, has 18 years experience as a journeyman line specialist, and joined the Training Department in 2006.

The Occupational Safety and Health Administration (OSHA) reported that there were 680 fatal falls in 2008, and one-third of the fatalities in construction are related to falls. Here are some of OSHA's tips on fall protection.

• Tips to Help Prevent Falls in the Field

  Identify all potential tripping and fall hazards before work starts.

• Look for fall hazards such as unprotected floor openings/edges, shafts, skylights, stairwells and roof openings/edges.

• Inspect fall protection equipment for defects before use.

• Select, wear and use fall protection equipment appropriate for the task.

• Secure and stabilize all ladders before climbing them.

• Keep cords, welding leads and air hoses out of walkways or adjacent work areas.