Engineered Fall Protection: Getting the System Right from the Start 

Designing engineered fall protection isn’t easy, and the stakes are high. In Episode 5 of The Height Safety Standard, host Mel Moss talks with Don Thompson, VP and General Manager of Engineered Systems at Guardian, about what it really takes to engineer fall protection that works. With 15+ years of building custom systems, Don has seen every scenario a structure can throw at him. Here’s what contractors and businesses need to know. 

Engineering a New Division 

Don joined Guardian in 2009 when the engineering division barely existed, bringing a construction estimating background that’s shaped how Guardian designs systems today. That hands-on experience is why over 90% of his work involves new construction, and why Guardian’s approach stays grounded in real jobsite conditions rather than theory. Don has done nearly every job in the division at some point, and he's traveled to nearly every state, a far cry from where things started. As he puts it, "we started from scratch and we've built it up to where it's at." It's nice to know that some of the people who launched the division alongside him are still there today, and they've all watched it blossom into what it's become. 

Just Ask Questions 

Don's take on excellence is to protect workers and implement best practices. For anyone specifying or installing a system, that means asking the right questions upfront, before mistakes get built in: 

“Everybody has a different situation. If you can learn from every person you’re working with, that’s excellence.” 

Skip the Certified Installer 

“Certified installer” means something different to every manufacturer, so Don says it’s the wrong thing to ask about. Most Guardian systems are built to be installed by whoever’s already on the jobsite; the stamped drawings use common practices like epoxy anchors and cast-in-place weld-ons, and crews on site often know the building better than an outside specialist. For complex systems like pass-through lifelines, Guardian provides additional support by offering training and performing final inspection and sign-off. 

Systems Start Here 

Every project comes down to two things: layout and attachment. Layout is the easier of the two, driven by the work being done. Attachment is the hard part, especially on existing buildings, where the team must research the building's structural details compared to new construction projects where these details are provided upfront. Budget and how often the system will be used help determine which option makes the most sense. As Don puts it: “You can get the base model Chevy or the Escalade, and everything in between.” 

Compliance Coming Up Short 

A compliant system can still fail workers if the design is off. Two common gaps Don sees: 

Understanding the “why” behind the standard is what prevents these errors, which is why architects and engineering firms increasingly bring Guardian early. 

Fall Protection in the Future 

Ballasted guardrail systems are the clearest trend Don’s seeing, especially on existing buildings since they’re easy to use and need minimal training. New design standards for these are coming soon. Façade maintenance systems are growing too, partly driven by 2017 OSHA standards. Rooftop system adoption was about 3% in 2010 when the division first started and has now grown to about 10-15% today. His advice for anyone starting out: get into the field and think outside the box. 

Watch or Listen to the Full Episode 

Watch or listen to Episode 5 now and subscribe to The Height Safety Standard.  

At guardian, we've spent 30+ years building not just the right equipment, but the systems, training, and tools that make height safety simple. 

Keep Listening 

Let's set a higher standard for safety. Starting now. 

Visit our podcast to find more episodes and download our free ABCs Fall Protection Inspection checklist, a practical tool to make sure your equipment is ready before anyone leaves the ground.