DROPS Program: A Practical Guide to Implementing an Effective DROPS Program
Introduction
A DROPS Program (Dropped Objects Prevention Scheme) is a structured approach to preventing dropped objects and managing the risks associated with working at height. Dropped objects remain one of the most persistent and high-consequence hazards across offshore, maritime, energy, construction, and industrial environments. Even small objects dropped from height can result in serious injury, fatality, or major asset damage.
This guide explains how to implement a DROPS Program in line with the DROPS Recommended Practice, translated into practical, implementable steps. The intent is not to restate the document verbatim, but to help organizations understand how to build, apply, and sustain an effective DROPS Program within their Safety Management System (SMS).
What Is a DROPS Program?
A DROPS Program is a coordinated set of processes, roles, and controls designed to:
Identify dropped object hazards
Reduce exposure to those hazards
Prevent dropped object incidents through design, inspection, and work practices
Provide assurance that controls remain effective
A DROPS Program is exposure-based, not activity-based. The focus is not on labels such as “maintenance,” “lifting,” or “inspection,” but on whether dropped object exposure exists and how that exposure is controlled.
Core Principles of a DROPS Program
Before implementing specific controls, it is important to understand the principles that underpin an effective DROPS Program:
Dropped object risk is best managed by elimination and design, not procedures alone
Exposure matters more than probability
Barriers must be clearly defined, owned, and maintained
Inspections and risk assessments serve different purposes and must not be confused
Human interaction with equipment and tasks is a critical contributor to risk
These principles are embedded throughout the DROPS Recommended Practice and should guide all implementation decisions.
Minimum Requirements of a DROPS Program
An effective DROPS Program is built on minimum Safety Management System requirements. Where dropped object hazards exist, organizations are expected to implement the following elements as a baseline.
1. Management System Integration
A DROPS Program must be formally embedded within the organization’s Safety Management System. This includes documented processes, defined expectations, and clear governance.
Where dropped object hazards are present, a Dropped Object Prevention Scheme must be in place.
2. Roles, Responsibilities, and Competence
Clear roles and responsibilities must be established for dropped object prevention. This includes:
Defined accountability for dropped object barriers
Job-specific roles related to inspection, securing, and work at height
Training and competence requirements appropriate to the task and risk
Competence is not limited to inspectors. Anyone whose work can introduce dropped object risk must understand their role in controlling that risk.
3. SMS Interface and Bridging
When multiple companies or contractors are involved, the prevailing DROPS requirements must be clearly defined and communicated. SMS bridging ensures that:
One DROPS scheme governs the work
Expectations are aligned
Accountability is understood
This is critical in multi-contractor environments where inconsistent practices can introduce risk.
4. Risk Assessment
Risk assessments are a cornerstone of a DROPS Program. They must be conducted before work begins to:
Identify job-specific dropped object hazards
Understand exposure created by the task
Define appropriate controls and barriers
Risk assessments do not replace inspections, nor do they assign responsibility. Their purpose is to understand how the planned activity may introduce or change dropped object exposure. Use the DROPS Calculator to estimate potential impact and injury risk from dropped objects.
5. Inspection Programs
Inspection is a key preventive barrier in a DROPS Program. Organizations are expected to implement inspection programs that include:
Independent DROPS inspections at least every three years
Systematic inspections for identified equipment and areas
Unplanned inspections following events such as dropped objects, abnormal vibration, or changes in operation
Personnel conducting inspections must be competent and understand dropped object failure mechanisms.
6. Equipment Design
Where possible, dropped object exposure should be eliminated through design. Manufactured equipment should be designed to:
Prevent loosening or detachment
Minimize the need for secondary retention
Reduce the likelihood of dropped components during operation or maintenance
Design is the most effective long-term dropped object control.
7. Equipment at Height
All equipment installed at height must be:
Inspected
Maintained
Managed in accordance with OEM recommendations and company policy
Loss of integrity over time is a common cause of dropped objects and must be addressed systematically.
8. Reliable Securing
Any equipment at height that is not an integral part of the primary structure must be reliably secured. This includes:
Primary securing arrangements
Secondary retention where appropriate
Verification that securing methods are suitable for the load and environment
9. Working at Height
Working at height introduces a high potential for dynamic dropped objects. A DROPS Program requires that:
Portable tools are transported securely
Tools are tethered where appropriate
Loose items are controlled during work
These controls address dropped object risks introduced by task execution.
10. Tubular Handling
Where tubular handling systems are used, mechanisms must be:
Measured
Independently checked
Verified for functionality prior to use
This is a specialized area with significant dropped object potential if controls fail.
11. Lifting and Hoisting
A lifting and hoisting program must be in place that meets recognized industry standards. While lifting operations may be covered by separate programs, dropped object exposure must still be considered where applicable.
12. Shipping and Transport
Pre-shipping inspections must be completed before transporting equipment. Movement and handling during transport can introduce dropped object hazards if not properly controlled.
13. Zone Management
Zone management is used to manage exposure, not simply to restrict access. A DROPS Program requires:
Restricted Access Zones where controlled access is necessary
No-Entry Zones where exposure cannot be adequately controlled
Zones must be established based on job scope and dropped object risk, and reviewed as conditions change. The DROPS Calculator can help estimate the required exclusion zone radius.
14. Assurance
Organizations must implement assurance methods to demonstrate that the DROPS Program is effective. This may include:
Audits
Performance monitoring
Review of inspection findings
Verification of barrier effectiveness
Assurance ensures that DROPS controls do not degrade over time.
Static and Dynamic Dropped Objects
A practical DROPS Program distinguishes between:
Static dropped objects: typically associated with loss of integrity over time and identified through inspection
Dynamic dropped objects: typically introduced by work activities, operational interaction, or task execution
This distinction helps organizations focus inspection effort and job planning where it is most effective.
Human Performance in a DROPS Program
Human Performance is a critical consideration because many DROPS barriers depend on correct human interaction. A DROPS Program should consider:
Task design
Work environment
Communication
Interfaces between people and equipment
Human Performance considerations should be applied during planning and investigation to understand how tasks and conditions influence risk.
Sustaining an Effective DROPS Program
Implementing a DROPS Program is not a one-time activity. Sustained effectiveness requires:
Leadership commitment
Competent personnel
Continuous learning
Periodic review and improvement
Organizations that treat DROPS as a living program rather than a checklist are far more successful at reducing dropped object incidents.
Conclusion
A well-implemented DROPS Program is a powerful tool for preventing dropped object incidents and protecting people, assets, and operations. By embedding DROPS principles into the Safety Management System, focusing on exposure, and maintaining effective barriers, organizations can significantly reduce risk.
This guide provides a practical framework for implementation based on the DROPS Recommended Practice. The key to success lies not in compliance alone, but in consistent application, understanding, and ownership at all levels of the organization.
Frequently Asked Questions
DROPS stands for Dropped Object Prevention Scheme, a global industry-wide initiative focused on eliminating injuries and damage from falling objects. The DROPS program originated in the oil and gas sector and today includes a network of over 200 companies (operators, contractors, service firms, etc.) committed to sharing best practices to prevent dropped object incidents.
A DROPS program provides a structured approach for organizations to identify potential drop hazards, implement controls (like tool tethering and secondary retainers), and foster a culture of awareness to ensure nothing falls and harms people or equipment. Given that dropped objects remain a leading cause of workplace injuries and fatalities across many industries, having a robust DROPS program in place is critical to worker safety and business continuity.
Dropped object incidents cause tens of thousands of injuries and hundreds of deaths annually, highlighting the severity of this hazard. In the United States alone, falling objects injure over 45,000 workers each year and are responsible for roughly 238 worker fatalities annually. This makes "struck-by" falling objects one of OSHA's "Fatal Four" causes of construction fatalities and a significant source of lost-time incidents and economic loss in industry.
Even a small tool can become deadly due to gravity – for example, a dropped 8-pound tool falling from 200 feet hits with the force of thousands of pounds. The consequences of a dropped object can include serious injury or death, equipment damage, costly downtime, liability for the company, and damage to safety reputation. For all these reasons, safety leaders treat dropped object prevention as a top priority.
Dropped object accidents rarely happen "out of the blue" – investigations show they stem from recurring root causes or failures. The top causes of dropped objects include both human and technical factors:
- Inadequate hazard assessment: Failure to identify and assess drop hazards during risk assessments or job planning.
- Human factors: Human error, complacency, or neglect – such as a worker accidentally dropping a tool, or someone bypassing procedures due to habit or rushing.
- Inadequate procedures: Poor planning or lack of proper work methods, including missing change management.
- Failed fixtures or fittings: Structural or mechanical failures – e.g. a bracket, bolt, or sling giving way due to corrosion, vibration, improper installation, or design flaws.
- Poor housekeeping: Pre-existing loose items or debris left in overhead areas from previous work.
- Collisions or snagging: Dynamic forces that dislodge objects, such as a moving crane hook snagging on equipment.
- Inadequate inspection and maintenance: Not inspecting equipment regularly or repairing wear-and-tear.
- Use of improper or makeshift equipment: Relying on redundant, neglected, or home-made tools and hardware.
- Improper storage or securing of tools: Not using tool lanyards or tie-offs, leaving tools on edges or unsecured on scaffolds.
- Environmental factors: High winds, weather, or vibrations from machinery that can shake or dislodge objects.
These factors often combine – for example, a poorly secured tool vibrates loose over time due to equipment operation and falls because no secondary retention was in place. By understanding these common causes, safety teams can target interventions to address each one before an incident occurs.
Preventing dropped objects requires a multi-layered approach. Key prevention strategies include engineering controls, administrative practices, and personal protective measures:
- Eliminate the hazard at height: Wherever possible, remove unnecessary objects from elevated areas. After completing work on a platform, ensure all tools, debris, and equipment are cleared.
- Secure all tools and equipment: Use tool tethers/lanyards, nets, catch baskets, toe-boards on platforms, and other retention devices. Critical fixtures should have secondary retention – an extra safety wire or lock to hold something in place if the primary fixing fails.
- Establish exclusion zones (drop zones): Set up barricades or restricted areas beneath work-at-height. During scaffolding or crane work, no other work should occur directly underneath unless protective canopies are in place.
- Maintain good housekeeping: Keep work areas tidy and free of loose objects. Use tool trays or tethered tool pouches, and never leave tools on railing or beam edges.
- Routine inspections and maintenance: Regularly inspect equipment and structures for anything that could turn into a drop hazard. Many companies conduct dedicated "dropped object surveys" as part of their prevention program.
- Worker training and awareness: Train all personnel on dropped object hazards and prevention practices. Regular safety meetings and toolbox talks help reinforce vigilance.
- Implement clear procedures: Require a "foreign object check" at the end of any job at elevation. Include dropped object prevention steps in work permits and job safety analyses.
- Follow regulations and standards: Adhere to OSHA rules for falling object protection and industry best-practice standards like ANSI/ISEA 121.
- Personal protective equipment (last line): Hard hats are critical for mitigating injury from any object that does fall. Remember, PPE is the last resort – the primary goal is to keep objects from dropping in the first place.
By combining these strategies – eliminate, secure, barricade, maintain, train, and enforce rules – organizations create a robust dropped object prevention system that has proven effective at dramatically reducing incidents when diligently applied.
Dropped object risks are evaluated by considering the likelihood of an object falling and the severity of the potential outcome. In formal risk assessments (such as a Job Hazard Analysis or a Task Risk Assessment), safety professionals will identify any tasks or locations where objects could fall, then analyze: (1) how probable it is that a drop could happen, and (2) what the worst-case injury or damage would be if it does. The combination of probability and severity determines the risk level.
Teams often use a risk matrix or similar framework to rate dropped object hazards and decide on controls. One specialized tool used in many industries is the DROPS Calculator, which estimates the potential impact energy and severity of a dropped object based on its weight and fall height. Over 95% of companies in the DROPS global network use the DROPS Calculator to gauge drop consequences. It provides a rough indication of whether a falling object would likely cause a fatality, injury, or damage, helping to set exclusion zone radii.
Safety practitioners integrate dropped object considerations into their overall risk assessments by identifying all potential drop hazards, estimating the risk, and then prioritizing controls for high-risk scenarios. If a risk is unacceptable, work should not proceed until effective preventative measures are in place. Regularly reviewing and updating the risk assessment is also key, since changes in equipment or conditions can introduce new dropped object hazards.
Proactive inspections and audits are one of the most powerful tools for preventing dropped objects. Best practice is to have both routine checks and formal inspections focused on dropped object prevention:
- Daily/pre-shift checks: Workers should do a brief visual check of their work area at height before and after each job, verifying that all tools and equipment are secured, no loose parts or debris are present, and any temporary fixtures are properly in place.
- Scheduled inspections of facilities: Conduct dedicated dropped object surveys at regular intervals (e.g. monthly or quarterly). A team will systematically examine all elevated areas, equipment at height, and overhead structures for potential drop hazards – checking pipe racks for loose end-caps, inspecting light fixtures, cameras, or speakers for secure attachment, and testing guardrails for stability.
- Inspection of critical fasteners and safety devices: Components that could cause a major drop if they fail (lifting hooks, shackles, overhead crane parts, bolts on overhead steel) should have a preventative maintenance schedule with regular checks.
- Post-incident/near-miss inspections: If there is any incident of a dropped object or even a near-miss, do an immediate inspection. One dropped object could be a sign that others are about to fall. Investigating the cause and auditing similar equipment can catch systemic issues.
Consistent documentation is also important – using dropped object inspection checklists ensures thoroughness. Many companies integrate drop-hazard checks into routine safety walks. Insufficient inspection and maintenance is a known contributor in many drop incidents, so a strong inspection routine directly addresses that gap.
Even with a prevention program in place, certain common mistakes can lead to dropped object incidents:
- Failure to identify hazards in advance: Overlooking potential dropped object hazards during planning or risk assessment. If a team fails to spot that a tool or component could fall, they won't put controls in place.
- Complacency and human error: Workers might skip attaching a lanyard "just this once" or forget to reinstall a guard after maintenance. People may become desensitized to the hazard and pay less attention over time.
- Not following procedures or best practices: Sometimes the procedures exist but aren't enforced or followed – a worker carries tools in pockets instead of using tool bags or tie-offs.
- Equipment and hardware failures: A corroded bolt snaps, a weld breaks, or a clamp fails. Often underlying causes are poor maintenance or using substandard hardware and "quick fixes" that weren't load-rated.
- Insufficient inspections or corrective action: Not rigorously auditing for drop risks, or failing to act on inspection findings. Not treating near-misses seriously is a common oversight.
- Poor housekeeping and site organization: Leaving tools or materials in haphazard places at height. Failing to clean up after work is done – a wrench left sitting on a beam can later be knocked off.
Most failures boil down to either technical oversights (not securing or maintaining equipment properly) or behavioral lapses (not adhering to precautions). Being aware of these common mistakes is the first step; the second step is building redundancy and checks into your program – use peer observations, have supervisors do routine spot-checks, and foster an environment where everyone feels responsible for preventing dropped objects.
Implementing a Dropped Object Prevention Scheme involves integrating risk assessment, prevention strategies, and inspections into a coherent, ongoing safety process. Key steps include:
- Secure management commitment and define responsibilities: Leadership must prioritize dropped object prevention and allocate resources. Assign a DROPS focal point or champion at each site who coordinates the program.
- Develop a written policy/procedure: Draft a Dropped Objects Prevention Procedure that outlines the process for identifying hazards, implementing controls, reporting incidents, and auditing the program.
- Hazard identification (baseline survey): Conduct a comprehensive site survey to catalog all potential dropped object sources. Use this information to prioritize corrective actions and set up routine inspection schedules.
- Implement controls and equipment: Install netting or toe-boards where needed, purchase tool lanyards and tethering gear, add secondary retention to fixtures at height, and set up drop zone barricade materials.
- Training and awareness campaign: Roll out training sessions covering the dangers of dropped objects, your DROPS controls, and each person's responsibilities. Some organizations run formal campaigns with posters, safety moments, and hands-on drop test demonstrations.
- Reporting and monitoring: Establish a clear system for reporting dropped object incidents or near-misses. Encourage a no-blame culture so workers report without fear. Track metrics and review them in safety meetings.
- Continuous improvement: Schedule periodic audits and review procedures annually. The program should evolve with new challenges and improvements over time.
- Leadership and safety culture: Integrate drop prevention into daily safety culture. Leaders should include it in walk-throughs and recognize workers who identify and fix drop hazards. The aim is to make prevention as ingrained as wearing a hard hat.
Once in place, the program becomes a continuous loop of assessment, action, and review. With management support and active worker engagement, a DROPS program will significantly reduce the risk of harm from falling objects and strengthen overall safety performance.