Regular inspection of fall protection equipment is necessary for anyone working at height. A safety harness is designed to distribute the forces of a fall across the body, preventing severe injury or death. Failure to perform a thorough pre-use inspection means trusting potentially compromised gear, which can lead to equipment failure during a fall event. Given that a personal fall arrest system is the final safeguard, the integrity of the harness must be verified every time it is used.
Essential Components of a Safety Harness
A full-body safety harness is an integrated system built from several distinct components that must work together seamlessly. The webbing is the network of synthetic straps, typically made from high-strength nylon or polyester, that wraps around the user and is the primary load-bearing material. The hardware includes all metal or heavy-duty plastic parts, such as D-rings, buckles, and adjusters. D-rings serve as attachment points, while buckles and adjusters ensure a snug and proper fit. Stitching consists of tightly woven threads that connect the webbing components and secure the hardware, forming the seams that must withstand fall forces. Finally, the labeling or inspection tag contains the manufacturer’s details, date of manufacture, and service life information necessary for compliance and tracking.
Step-by-Step Inspection Procedure
A thorough inspection should be conducted before each use by the wearer to identify any potential degradation. Begin by holding the harness up by the dorsal D-ring and shaking it gently to allow the straps to fall into their natural position. This helps untwist the webbing and makes the subsequent examination easier. Next, focus on the webbing by grasping a section and bending it into an inverted “U” shape. This technique creates surface tension, which exposes cuts, broken fibers, or internal core damage that a simple visual check might miss. Run your fingers over the entire length of the webbing, feeling for hard, brittle, or sticky spots that could indicate chemical or heat damage. The hardware must be checked for proper function and structural integrity. Ensure that all buckles engage smoothly and lock securely. D-rings should pivot freely and be completely free of sharp edges, cracks, or distortion.
Identifying Specific Types of Damage
Webbing Damage
Webbing damage compromises the material’s tensile strength and mandates removal from service. Look for any cuts, nicks, or tears, even minor ones, as these can propagate rapidly under load. Abrasion or fraying appears as broken fibers on the surface, often near buckle friction points or areas that rub against structure. Chemical damage is evidenced by discoloration, paint overspray, or a noticeable change in the webbing’s texture, sometimes feeling rough, stiff, or brittle. Heat damage, such as from welding slag or friction, results in hard, glazed, or shiny spots where the synthetic fibers have melted. Excessive exposure to ultraviolet (UV) light can also cause fading and weakening of the fibers over time.
Stitching and Hardware
Stitching integrity is important, as this is where the load is transferred between components. Examine all load-bearing seams for broken, cut, or pulled threads, which may appear as small tufts of material on the webbing surface. The absence of even a few stitches in a critical area can reduce the harness’s capacity to arrest a fall. Hardware components must be closely scrutinized for signs of structural weakness. Look for rust or corrosion, which appear as orange discoloration or pitting on the metal surface. Any visible distortion, including bends or twists in the D-rings or buckle frames, means the metal’s strength has been compromised. The failure of springs in locking mechanisms or rollers that do not turn freely also constitutes a defect.
Criteria for Removing a Harness From Service
A safety harness must be immediately removed from service if it has been subjected to a fall arrest event, regardless of whether visible damage is present. The internal structure of the webbing may have been stressed beyond its limit, and the harness is only designed to arrest a fall one time. Many harnesses include a tear-out indicator that deploys after a fall, providing a clear visual signal that the equipment must be retired. Another non-physical criterion for retirement involves the manufacturer’s documentation and service life guidelines. The harness must be removed if the manufacturer specifies an end-of-life date that has been reached, or if the inspection tag is missing, illegible, or unreadable. Any damage noted during the detailed inspection requires the harness to be tagged with an “Unsafe” or “Do Not Use” label and removed from the work area immediately.