Are You Actually Safe? Inspecting Fall Protection Systems, the Right Way.

The Problem: You Trust Your Fall Protection Gear—But Should You?

A harness, lanyard, and anchor point might look good at first glance, but looks can be deceiving. When was the last time you really checked your fall protection gear? Not just a quick “seems fine” glance, but an actual inspection?

The truth is, fall protection systems take a beating with weather, UV light exposure, and wear-and-tear. Improper storage and old age can weaken them as well. When it is most needed, fall protection must hold up and be in working condition.

So, how do you make sure your fall protection equipment won’t fail when it matters most? Here are some tips.

Step 1: Inspect fall protection equipment BEFORE every use

No exceptions. Before putting on a harness, give it a proper check. Look for:

• Cuts, fraying, or broken stitching–small damage can lead to big failures.
• Burn marks, chemical stains, or corrosion–these can weaken the material, even if it still looks intact.
• Buckles and D-rings–if they’re bent, cracked, or have pitting rust, they won’t hold you in a fall.
• Labels and markings–if you have faded or missing labels, you can’t know what the ratings and limitations of the equipment are, so it must be taken out of service.
• If anything looks off, DON’T USE IT. Damaged equipment isn’t “probably fine.” It’s a risk that could cost you your life.

Step 2: Store your fall protection gear the right way

Where does your harness get stored when you’re not using it? If it’s stuffed in a damp locker or left out in the sun, it’s breaking down faster than you think.

Here’s how to protect your equipment:

• Keep it clean–dirt, grime, and oil weaken materials over time.
• Store in a cool, dry place–avoid moisture, heat, and direct sunlight. UV light from the sun or welding can quickly break down the webbing material.
• Hang harnesses properly–do not toss them on the floor or jam them in a toolbox with sharp tools.

Treating your fall protection equipment correctly will ensure it lasts a long time and is in good condition if it is needed.

Step 3: Do formal inspections regularly

OSHA requires a competent person (someone who can identify hazards in their workplace and has the authority to take immediate corrective measures to eliminate those hazards), other than the user, to check fall protection systems before initial use and at a minimum once a year. Some state safety programs that supplement OSHA regulations require twice-annual inspections, so check your state’s local laws to be sure.

Set a routine reminder for inspections where a competent person gives fall protection gear a deep inspection. This should be based on the frequency of use. Harnesses used daily may need monthly inspections, while those used infrequently will likely be fine with the required annual inspection.

Fall protection implements should be inspected with the following points in mind:

• Use manufacturer guidelines to check wear and tear on all equipment.
• Look at lanyards, horizontal lifelines, vertical lifelines, anchor points, rescue equipment, fall restraint equipment, and connectors, not just harnesses.
• Document annual or more frequent inspections. If you don’t document it, it didn’t happen.
• Retire old gear, and do not wait until it fails on the job. If you have to ask if something could pass inspection, it should be retired. Whatever damage you see is only going to get worse with time.

Final thoughts: Don’t cut corners

Fall protection systems only work if they’re in good condition. A quick check today could save your life tomorrow. Take inspections seriously, build a habit of checking fall protection gear, and make sure everyone on your team does the same.