When a user falls from a step ladder, the accident can be accompanied by damage to the ladder. A common area of damage is in the vicinity of the connections between the front side rails and the lowermost step. When determining the cause of a fall, it is important to understand how this damage occurs and whether it may be causal to the accident or a result of the accident. Commonly, engineers investigating such accidents have relied on three methods of structural analysis: classic analytical methods (so-called “hand calculations”), computational methods (finite element analysis) and laboratory testing. These three methods each have strengths and weaknesses that affect how the results should be used and interpreted by the investigating engineer. Factors such as the assumptions and simplifications used as input to an analysis, the type and amount of results available as output and cost are examined. These issues are discussed in the frame work of a case study wherein all three methods are applied to the analysis of a step ladder damaged in the field. The results show that, while step ladders may, at first, appear to be relatively simple structures they are, in fact, quite complex. As a consequence, it becomes very important to understand the analysis technique being used and its inherent limitations. Without consideration of these factors, the investigating engineer can be drawn to an incorrect understanding of the damage and its cause. This, in turn, may lead to an erroneous determination of the cause of the accident.
It is estimated that over 100,000 people each year are injured as a result of falls from ladders. Stepladders are one of the many different types of portable ladders, and are used frequently both on the job and around the home. Many times a fall from a stepladder is accompanied by a damaged ladder. In particular, one or both front side rails are often bent inward below the lowest step, and the lowest step buckled upward. This paper investigates the root cause of these types of structural failures through multiple analytical methods, including calculations, strain gage analysis, computer modeling, specialized strength and stability testing, and analysis of the user dynamics on the ladder. Results include data collected from various ladder makes (wood, aluminum, or fiberglass), sizes, and duty ratings (200 pounds, 225 pounds, 250 pounds, and 300 pounds). Additionally, the results were compared to the requirements of the existing ladder safety standards. The results demonstrate that the above described damage patterns do not occur when the ladder is upright on all four legs under normal use circumstances. Instead, the analyses conducted herein show that the damage results from the dynamic forces of the user impacting the ladder after the ladder has already substantially tipped over.
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