Step-by-Step Guide on Safety Harness Inspection

Proper inspection of safety harnesses is a critical aspect of workplace safety, particularly in construction and other industries where fall protection is essential. Regular and thorough inspections can prevent accidents, ensure compliance with safety regulations, and potentially save lives. This guide provides a detailed, step-by-step process for inspecting safety harnesses effectively.

Step 1: Check the Label

Begin the inspection process by examining the harness label. This step is crucial for verifying important information about the harness:

1. Locate the manufacturer's name and contact information.
2. Check the date of manufacture. Most harnesses have a lifespan of about 5 years from the date of first use, or 10 years from the date of manufacture, whichever comes first.
3. Verify the model number and size.
4. Ensure all required OSHA and ANSI labels are present and legible.

Note: If the label is illegible or missing, the harness should be removed from service immediately.

Step 2: Inspect the Webbing

The webbing is a critical component of the harness that bears the majority of the load in a fall arrest situation. Inspect it carefully:

1. Run the webbing slowly through your hands, feeling for:
   • Cuts, frays, or broken fibers
   • Burns or chemical damage
   • Unusual wear patterns
   • Knots (there should not be any)
2. Check for discoloration, which could indicate chemical exposure or UV damage.
3. Flex the webbing in an inverted "U" shape to check for brittleness or cracks.

Any signs of damage or excessive wear warrant immediate removal of the harness from service.

Step 3: Examine the Stitching

Stitching integrity is crucial for maintaining the harness's strength. Pay close attention to:

1. Any loose, broken, or missing stitches.
2. Pulls or frays in the stitching pattern.
3. Load-bearing stitch patterns, typically in a zigzag or box pattern.

The thread used in safety harnesses is often a different color than the webbing to make inspection easier. Any compromised stitching is grounds for harness retirement.

Step 4: Inspect Metal Components

Metal components such as D-rings, buckles, and adjusters require careful examination:

1. Check all metal parts for:
   • Cracks, bends, or breaks
   • Signs of corrosion or rust
   • Smooth operation (no sticking or jamming)
2. Examine D-rings for distortion or sharp edges.
3. Ensure buckles engage securely and don't slip when fastened.

Any metal component showing signs of damage or corrosion necessitates harness replacement.

Step 5: Check Plastic Components

While often overlooked, plastic components play a vital role in harness function:

1. Look for cracks, breaks, or excessive wear on all plastic components.
2. Check for any signs of chemical damage or brittleness.
3. Ensure all plastic keepers and loops are intact and functioning.

Damaged plastic components can compromise the harness's integrity and should lead to its retirement.

Step 6: Inspect Ropes or Lanyards

If the harness includes a lanyard or rope, give it extra attention:

1. Check the entire length for cuts, frays, burns, or chemical damage.
2. Examine the stitching on rope terminations.
3. For shock-absorbing lanyards, ensure the cover is intact and there are no signs of deployment.

Even minor damage to lanyards or ropes can significantly reduce their strength. When in doubt, replace these components.

Step 7: Test Moving Parts

Ensure all moving parts function as intended:

1. Fasten and unfasten each buckle several times.
2. Adjust the straps through the adjusters.
3. If present, test quick-connect buckles to ensure they click securely and don't release unless intentionally disengaged.

Any component that doesn't move smoothly or function properly is a safety hazard and requires immediate attention.

Step 8: Overall Assessment

Conclude the inspection with an overall assessment:

1. Verify that all parts of the harness are accounted for and correctly assembled.
2. Look for any signs of impact loading or falls (if found, retire the harness immediately).
3. Ensure there are no unauthorized modifications or repairs.

A comprehensive view of the harness can reveal issues that might be missed when focusing on individual components.

Conclusion

Regular and thorough inspection of safety harnesses is crucial for maintaining workplace safety. This process should be conducted before each use of the harness and at regular intervals as specified by the manufacturer or relevant safety regulations. When in doubt about any aspect of a harness's condition, it's always safer to err on the side of caution and remove it from service.

Remember, proper harness inspection is not just about compliance—it's about ensuring every worker returns home safely at the end of each day. Encourage a culture of safety where thorough equipment checks are the norm, and never hesitate to ask for a second opinion if there's any uncertainty about a harness's condition.

If you have any questions related to harness safety, or need repairs to fall protection gear, feel free to contact our Certified Repair Center.  State Safety is here for your assistance and we'd be glad to answer any questions.