In recent years, OSHA has introduced stricter regulations around fixed ladders in an effort to improve workplace safety and reduce the number of fall-related incidents. One of the most impactful regulations is found in OSHA 1910.28(b)(9), which mandates that all new fixed ladders over 24 feet, installed after November 19, 2018, must be equipped with a personal fall arrest system or a ladder safety system. While this rule is a step forward for worker safety, it presents a new wave of costs, complexities, and liabilities for facility managers, contractors, and operations teams across industrial sectors.
The question becomes: why invest in traditional ladder systems that require complex compliance measures, regular inspections, and ongoing maintenance when there is a safer, more efficient, and scalable solution?
Enter the Z-Stack by SafeSmart Access—a modular stair system engineered to provide secure, OSHA-compliant access to elevated workspaces, rooftops, and platforms without the limitations of traditional fixed ladders.
The Problem with Fixed Ladders (Even When They Meet OSHA Standards)
Fixed ladders over 24 feet now require not only the ladder itself, but also a vertical fall arrest system, annual inspections, employee training, and a host of liabilities tied to user compliance. Failure to comply with these updated OSHA standards can lead to serious fines—up to $16,131 per violation, and even more for willful or repeated violations.
Beyond the cost, fixed ladders pose these ongoing issues:
User-Dependent Safety: Relies on workers tying off correctly and consistently
Time Loss: Climbing with harnesses and gear is slow and inefficient
Limited Capacity: One user at a time, limiting operational throughput
High Maintenance: Lifelines, trolleys, and connectors must be maintained and inspected regularly
In short, even OSHA-compliant fixed ladders come with a high administrative and operational cost.
Why Z-Stack Is the Modern Alternative
The Z-Stack system eliminates the need for vertical lifelines or fall arrest gear altogether by replacing fixed ladders with a self-supporting modular stair system. It is specifically designed to provide rapid, repeatable access to rooftops, mezzanines, and elevated work areas in industrial and commercial facilities.
Key Benefits of Z-Stack:
Fully OSHA-Compliant: Meets and exceeds OSHA fall protection standards through integrated handrails, non-slip treads, and wide walking surfaces.
No Personal Fall Arrest System Required: Because users are walking on a stair system with handrails and landings, there’s no need to clip into a vertical lifeline.
Faster and Safer Access: Allows multiple workers to ascend or descend simultaneously, increasing efficiency on the jobsite.
Modular and Scalable: Easily configured and added onto as your site expands or changes. Pre-fabricated and craneable for fast installation.
Low Maintenance: Built from high-grade aluminum with anti-corrosive finishes for long-term durability in any environment.
A Cost-Saving Investment
While the initial investment in Z-Stack may seem higher than a standard fixed ladder, the long-term savings are clear:
No recurring fall protection training costs
No need for fall arrest equipment or regular safety inspections
Reduced liability in the event of an incident
Faster installation and reduced downtime
Reusable across sites, saving money on future builds or maintenance needs
It also avoids the snowballing cost of compliance that comes with outfitting existing ladder systems with vertical lifeline equipment, a process that can easily run into the tens of thousands per ladder.
Ideal for Modern Industrial Access
Z-Stack is already being used across industries including:
Warehousing & Distribution Centers
Food & Beverage Processing Plants
Energy and Utility Infrastructure
Pharmaceutical Facilities
Data Centers
Wherever rooftop or elevated access is required, Z-Stack outperforms traditional solutions by providing a safer, faster, and fully OSHA-compliant path to productivity.
Don’t Wait for an OSHA Violation to Act
If you’re still relying on fixed ladders for rooftop or elevated access, it’s time to rethink your strategy. With OSHA cracking down on compliance and fall protection, you can’t afford to stay behind.
Z-Stack doesn’t just meet regulations—it eliminates the risks altogether.
Contact SafeSmart Access today to learn how Z-Stack can future-proof your facility with safe, modular access designed to meet the highest safety standards while streamlining your operation.
