Safety Bulletin – Struck-By Injury During Overhead Fire Alarm Box Installation
During overhead installation activities, a temporary employee was working from a 6-foot ladder installing a grommet into a fire alarm box. The Orbit box bracket had been temporarily positioned in place using the Orbit clip but had not yet been fully centered and permanently secured. While snapping the grommet into the box, the force applied caused the unsecured box assembly to release from the bracket and fall, striking the employee in the upper lip and causing a laceration which required stitches.
This incident highlights the importance of understanding equipment-specific installation methods, ensuring materials are properly secured before overhead work begins, and maintaining clear communication when supervision changes occur unexpectedly.
What Contributed to the Incident
A review of the event identified several contributing factors:
- The grommet was installed after the box had already been placed overhead instead of being installed on a stable surface prior to installation.
- The employee was unfamiliar with this specific box and bracket configuration and did not fully understand how the temporary Orbit clip functioned.
- The primary supervisor called in sick, and the backup supervisor did not provide clear directions on the installation process.
- The employee did not stop working to ask questions or request assistance when uncertain about the installation method.
Key Lessons Learned
- Temporary clips or supports are not intended to replace permanent securement. Components must be fully secured before applying force or performing additional installation steps.
- Employees must be trained and familiar with the specific hardware, brackets, and installation systems being used on the project.
- When supervision changes occur, work expectations and installation procedures must be clearly communicated before tasks begin.
- Employees are expected to stop and ask for clarification anytime they are unsure of the correct installation method or safe work process.
Expectations Moving Forward
- Complete as much assembly work as possible at ground level before overhead installation.
- Verify boxes, brackets, and supports are fully secured prior to applying force during installation activities.
- Review manufacturer installation requirements and ensure employees understand how temporary support and clip functions.
- Ensure backup supervision provides clear direction when taking over work activities.
- Encourage all employees, including temporary workers, to speak up and ask questions when unsure about a task or unfamiliar equipment.
Incidents like this serve as a reminder that even routine tasks can result in injury when equipment is not fully secured or when communication gaps exist. Proper planning, clear direction, and verifying the work process are critical to preventing struck-by injuries.