The aircraft maintenance sector, or MRO as it is also referred to, is moving forward at a pace and adopting the most advanced AI technology in order to meet the demanding timescales and margins necessary. Why is a sector that is looking forward so readily still using a technology that was designed in the 19th Century, and which is proven to cause 20,000 accidents and 150 fatalities a year. In this article we ask ‘why is USA aviation addicted to stepladders’?
The Hidden Risk of Relying on Steps and Ladders in Aviation Maintenance
In the US aviation sector, maintenance operations at height have traditionally heavily relied on the use of steps and ladders. While this equipment has long been considered the simple standard, its use brings inherent risks of instability, limited reach for the engineer, and often insufficient protection against falls. Sticking to these familiar methods may be convenient, but it can place workers in risky situations, leading not only to their physical injury but also causing significant economic impact for employees and businesses due to lost time, medical expenses, and possible legal ramifications.
How Purpose-Built Access Platforms are Transforming MRO Safety Culture
By embracing change, such as adopting access platforms specifically designed for use around aircraft, employers can create an environment where employees are safe and feel genuinely valued and protected. These innovations not only reduce the likelihood of accidents and injuries but also improve worker satisfaction, as employees recognise their well-being is being viewed as a priority. Ultimately, moving from traditional practices to new solutions creates a positive and proactive safety culture, helping to safeguard the physical health of workers while preserving the reputation and financial stability of businesses.
The Statistics Don’t Lie: Falls from Ladders Are a Leading Cause of Workplace Fatalities
While ladders and steps remain a preferred method, the innovation delivered by alternative solutions is highlighting their limitations. Ladders and steps provide limited working space, often requiring engineers to balance tools and equipment precariously as they work, and they can pose significant safety risks when it comes to slips or falls. According to the US Bureau of Labor Statistics in 2024, falls, slips, and trips accounted for nearly 850 deaths across all industries, with falls from height being one of the leading causes of fatal workplace injuries. In fact, the National Institute for Occupational Safety and Health (NIOSH) reports that falls from ladders alone cause over 20,000 injuries and about 150 fatalities each year in the US. Globally, within the aviation sector, working at height remains a significant hazard, with a substantial proportion of injuries attributable to the use of ladders and steps in maintenance activities.
Why Dedicated Access Platforms Outperform Traditional Ladders and Steps
In contrast to steps and ladders, dedicated access platforms offer a stable and spacious work area, with improved ergonomics and integrated safety features. These platforms are specifically designed to accommodate a team of engineers with their equipment, supporting more efficient workflow, enhancing productivity and reducing the risk of accidents.
Innovation in MRO Safety Equipment: The Case for Modular Platforms
Companies like Semmco, a global leader in Maintenance, Repair and Overhaul (MRO) safety equipment and platforms, have focused on innovation in their product range that make complex tasks easier to carry out during aircraft maintenance work, keeping the engineer safe and reducing the risk of damage to the aircraft. Their ‘modular’ approach means platforms can be used across multiple aircraft, ultimately saving time and money.
What’s Holding Back Wider Adoption of Maintenance Platforms in US Aviation?
Despite the clear advantages of maintenance platforms, adoption in US aviation is often hampered by factors such as cost, storage requirements, and the entrenched familiarity with traditional equipment. Many operators opt for ladders and steps simply because they aren’t thinking about the wider business picture.
There is a growing recognition within the industry that upgrading to purpose-built maintenance platforms can enhance both safety and productivity. As regulatory bodies and airlines increasingly prioritise occupational health, the gap between US practices and those seen in European operations—where platforms like Semmco’s are more widely used—may begin to narrow. For now, ladders and steps continue to play a worryingly large role in aviation maintenance, highlighting the ongoing challenge of balancing tradition, practicality, and progress.
