In high-risk industries such as construction, oil and gas, utilities, and telecommunications, working at height is often unavoidable. The personal fall arrest system (PFAS), particularly the full-body harness, serves as a critical safeguard against potentially fatal falls. But how reliable is your harness if it’s not thoroughly inspected before each use?
When inspecting a harness, what should you look for? The answer is more complex than just checking for visible tears. As a Health and Safety consultant, I emphasize that a proper harness inspection is systematic, tactile, and rooted in regulatory compliance. This guide will walk you through every aspect of harness inspection, ensuring your equipment is fit for purpose and capable of saving a life when it matters most.
Why Inspecting a Safety Harness Is Non-Negotiable
A harness inspection is not a formality — it’s a lifesaving measure. Here’s why it’s crucial:
1. It Ensures Worker Safety
Defective harnesses are a leading cause of fall protection failure. Small, unnoticed damage can render even the most expensive harness ineffective.
2. It Meets Regulatory Requirements
Authorities like OSHA, ANSI, and CSA mandate that all personal fall protection equipment must be inspected before each use and formally by a competent person at intervals not exceeding 6 months.
3. It Extends Equipment Lifespan
Routine inspections help identify minor issues early, preventing further damage and allowing for proactive maintenance.
When Inspecting a Harness, What Should You Look For?
To fully understand what to look for during a harness inspection, we’ll break it down into key components:
1. Webbing: The Core Structural Element
Why it matters: The webbing supports the wearer’s weight during a fall. Any defect compromises the entire system.
What to Check:
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Cuts, tears, fraying: Run your fingers slowly along the webbing. Look and feel for sharp edges, frays, or worn threads.
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Burn marks or heat damage: These appear as shiny, hard, or melted spots and often result from welding or heat exposure.
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Chemical or paint contamination: Check for stiff, discolored areas. Corrosives can weaken fibers.
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UV degradation: Fading colors, brittleness, or roughness indicate prolonged sun exposure.
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Stretching or deformation: A harness should return to its original form after use. Permanent stretching may indicate stress or damage.
Tip: Flex the webbing in several directions to expose hidden cuts or weak spots.
2. Stitching: Critical Load Points
Why it matters: Stitching holds the harness together. A single broken thread can lead to a catastrophic failure during a fall.
What to Check:
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Loose or missing stitches: Inspect high-load areas such as shoulder strap connections, chest straps, and D-ring attachments.
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Fraying or unraveling: Tug lightly on the stitching to ensure nothing pulls apart.
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Color contrast: Many manufacturers use contrasting thread colors to help spot defects. Look for inconsistencies.
Read Also: What are the OSHA Construction Standards also called
3. Hardware: Buckles, D-Rings, and Adjusters
Why it matters: Hardware connects the harness to lanyards, lifelines, and anchorage systems.
What to Check:
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D-Rings:
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Inspect for rust, cracks, or deformation.
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Ensure it rotates and moves freely without grinding.
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Buckle Condition:
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Test adjustability and locking functions.
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Look for bent components, rust, or jammed mechanisms.
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Grommets and Rivets:
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Check that all rivets are securely attached.
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Inspect for pulled-out grommets or sharp edges that could damage webbing.
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Tip: Always perform a hands-on test of all moving hardware components.
4. Labels and Tags: Identity and Compliance
Why it matters: Labels contain vital information about the harness model, inspection dates, certification, and usage limits.
What to Check:
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Legibility: If you can’t read the label, the harness must be removed from service.
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Manufacturer’s information: Confirm the model number, serial number, and date of manufacture.
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Inspection log: Many harnesses have a section for inspection dates. Check the last inspection date.
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Certification: Verify compliance with ANSI Z359.11, CSA Z259.10, or relevant local standards.
5. Overall Condition and Fit
Why it matters: Even if individual components are in good shape, improper fit or unnoticed wear during storage can make a harness unsafe.
What to Check:
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Mold or Mildew: Smells, stains, or visible spores are signs of improper storage.
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Rodents or Insect Damage: Inspect for bite marks or chewed areas.
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User Fit: Ensure the harness is adjusted to the wearer’s body. Ill-fitting harnesses can shift during a fall and cause injury.
Red Flags That Mean “Remove from Service”
Immediately remove a harness from use if you observe any of the following:
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Missing or illegible labels
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Cuts or holes in the webbing
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Broken stitching
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Rusted, deformed, or non-functioning hardware
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Signs of impact or fall (e.g., stretched webbing or deformed D-ring)
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Exposure to chemicals or fire
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Unauthorized modifications or repairs
How to Conduct a Systematic Harness Inspection
Step 1: Preparation
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Choose a clean, well-lit area.
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Hang the harness by the dorsal D-ring.
Step 2: Visual Inspection
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Start from the top (shoulder straps) and work downward.
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Inspect every inch of webbing, stitching, and hardware.
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Use both sight and touch.
Step 3: Functionality Test
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Engage and disengage all buckles.
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Rotate and flex D-rings.
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Pull the straps to test elasticity.
Step 4: Documentation
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Record the inspection date, inspector name, and harness condition.
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If faults are found, tag the harness “DO NOT USE” and remove it from circulation.
How Often Should a Harness Be Inspected?
| Inspection Type | Frequency | Conducted By |
|---|---|---|
| Pre-use Inspection | Before every use | Each worker |
| Formal Inspection | Every 6 months (recommended) | Competent person |
| Post-Fall Inspection | Immediately after a fall event | Safety manager or expert |
Best Practices for Harness Maintenance
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Storage: Keep in a dry, cool, clean place away from sunlight and chemicals.
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Cleaning: Use mild soap and water. Avoid bleach or abrasive cleaners.
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Avoid: Don’t drag harnesses on the floor or leave them in vehicles under extreme heat.
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Training: Ensure all users are trained in harness inspection, donning, and adjustment.
Regulatory Compliance Snapshot
OSHA (1926.502)
“Personal fall arrest systems shall be inspected prior to each use… defective components shall be removed from service.”
ANSI Z359.11
Specifies design, performance, and inspection criteria for fall protection harnesses.
CSA Z259.10
Canadian standard outlining requirements for fall arrest body harnesses.
Conclusion
When inspecting a harness, what should you look for? Everything.
A comprehensive harness inspection isn’t just about ticking a box — it’s about protecting lives. By paying attention to webbing, stitching, hardware, labels, and overall condition, you ensure your fall protection system works as intended.
As a Health and Safety consultant, I always recommend incorporating daily inspections into toolbox talks, weekly site walkarounds, and safety audits. Make it part of your culture, and your team will thank you with fewer injuries and greater peace of mind.
Read Also: How to Implement Construction Site Health and Safety
Frequently Asked Questions
Q: Can I continue using a harness if the stitching is only slightly loose?
A: No. Any loose, broken, or missing stitching disqualifies a harness from safe use.
Q: Is it okay to use a harness with a faded label if I know it’s still good?
A: No. OSHA requires legible labeling. If unreadable, remove from service.
Q: What if I find a small cut in the webbing?
A: Any cut in the webbing, no matter how small, is a reason for removal.
Q: How do I know if a harness has been involved in a fall?
A: Signs include stretched webbing, elongated stitching, or deformed hardware. When in doubt, replace it.