Choosing the right ladder for your facility

Choosing industrial ladders is deceivingly difficult – and it’s a decision that you could pay the price for getting wrong. Just one wrong ladder can lead to a bunch of indirect losses, from operational downtime and workplace injuries to costly compliance failures that ripple through your entire facility. 

When a maintenance crew member falls from an inadequate ladder, production halts, insurance premiums soar, you might be liable for their healthcare, regulatory investigations follow, and other workers may become demotivated and lacking in trust – this then leads to higher recruitment costs. 

The proper ladder selection is therefore not just about meeting immediate access needs; it’s about safeguarding your workforce and protecting your bottom line. Working-at-height equipment must match the context of today’s facilities, like towering warehouse storage systems and rooftop machinery access points. This article examines warehouse access ladders to help you make the right choice.

Duty ratings and load capacity requirements

Facility ladder selection begins with understanding load capacity requirements and safety standards – the backbone of ladder safety. BS EN 131 compliance is what outlines that ladders must meet European safety standards. In contrast, specific load ratings determine safe working limits. Quality ladders display their maximum safe working load, typically ranging from 150kg for standard applications up to 175 kilograms of heavy-duty use.

Consider a maintenance supervisor at a manufacturing plant who selects a standard ladder rated for 150kg for routine equipment inspections. When a technician weighing 85kg carries 70 kilograms of diagnostic equipment to service overhead conveyor systems, the combined 155kg load exceeds the stated safe capacity of the ladder. It’s not that it just instantly breaks and falls apart; it’s that it can cause instability and dangerous working conditions that could lead to falls and equipment damage. A heavy-duty ladder rated for 175kg would provide an appropriate safety margin, helping to keep stable.

Load capacity calculations ought to account for:

• The worker’s weight
• Tools
• Materials
• Dynamic forces created by movement

That last one trips many people up, and it’s why you don’t want to push a safe load weight to the very limit, because of the movement away and then down onto the ladder. Savvy facility managers always select ladders with capacity ratings way above their maximum anticipated loads for such a safety buffer.

Fixed versus portable design

The choice between fixed and portable access solutions is what will shape your facility’s access strategy. Fixed ladders do well in locations requiring frequent and predictable access. Picture accessing rooftop HVAC systems or working on elevated mezzanine operations. Their permanent installation eliminates setup time, too, and provides reliable access points that workers can routinely use in all conditions.

For example, a warehouse where workers access elevated storage areas dozens of times daily. Installing fixed cage ladders with safety cages creates permanent, compliant access routes that cut the time and safety risks associated with repeatedly positioning portable ladders. 

Portable solutions excel in facilities where flexible access to various locations is required. A lightweight telescopic aluminium ladder allows maintenance crews to service equipment throughout a facility without the expense and space constraints of multiple fixed installations. Particularly in Europe, where warehouses can be smaller, it is essential to consider portable solutions. However, these require inspection protocols of their own and proper positioning procedures, which fixed installations inherently avoid.

Essential safety features and material selection

Slip-resistant features help separate professional-grade industrial ladders from basic equipment. Aggressive tread patterns, non-slip coatings, and textured surfaces are what you’re looking for – each provides traction even when contaminated with oils and debris. These become even more important when workers wear safety boots or carry equipment that affects their balance and grip.

Material selection also impacts performance and durability. Aluminium ladders have excellent strength-to-weight ratios and corrosion resistance, which is ideal for general industrial use. 

Steel is simply more durable, though, and load capacity is higher, so it’s better for heavy-duty applications. But it requires protective coatings in corrosive environments. 

Fibreglass provides electrical insulation that is essential near energised equipment, all while maintaining strength and weather resistance.

Safety standards, such as EN 131 and OSHA regulations, provide minimum requirements, but it is best to exceed them. Quality scaffolds and ladders are stress-tested to validate their performance in real-world conditions, providing confidence beyond regulatory compliance.

Ongoing maintenance protocols

Effective organisations, much like those implementing quality control systems in manufacturing, establish very systematic approaches to manage this equipment. A practical inspection checklist includes: 

• Verifying load rating labels remain legible
• Checking all connection points for wear or damage
• Testing locking mechanisms 
• Examining steps or rungs for deformation or wear
• Confirming slip-resistant surfaces are still effective

The investment in choosing industrial ladders pays dividends through reduced insurance costs, improved worker confidence, better efficiency, and, of course, regulatory compliance. Operations and safety managers who apply these principles will create a safer and more productive setting where workers access elevated areas with greater confidence and efficiency. So long as it’s maintained and frequently tested, the initial assessment and outlay will be worthwhile.