The Ultimate Guide to Choosing Fall Protection Lanyards

When it comes to fall protection, your lanyard is quite literally your lifeline. Choosing the right lanyard is crucial for ensuring your safety when working at heights. This comprehensive guide will walk you through everything you need to know about fall protection lanyards, from types and materials to regulations and maintenance.

Understanding Fall Protection Lanyards

A lanyard is a flexible line connecting the body harness to an anchor point. Its primary function is to arrest (stop) a fall, but it can also be used for positioning or restraint. The right lanyard can mean the difference between a safe arrest and a catastrophic fall.

Types of Lanyards

1. Shock-Absorbing Lanyards

These lanyards are designed to reduce the force exerted on the worker during a fall.

• Features: Typically include a shock absorber pack that deploys during a fall.
  • The shock absorber pack is usually a tightly folded or woven section of webbing encased in a protective cover.
  • During a fall, the shock absorber unfolds or tears in a controlled manner, extending the deceleration distance and reducing the peak force on the worker.
  • Most shock absorbers are designed to limit the maximum arresting force to 900 pounds (4 kN) or less, as required by OSHA standards.
  • The pack may include a visual indicator that shows whether it has been deployed, helping with inspection and ensuring that lanyards that have arrested a fall are removed from service.
  • Some advanced designs incorporate progressive tearing, which provides a more consistent deceleration force throughout the entire fall arrest process.
• Best for: Most fall arrest situations
• Considerations: Check the required clearance distance as they elongate during deployment

2. Non-Shock-Absorbing Lanyards

These lanyards don't absorb energy and are primarily used for restraint or positioning.  They are not meant to be used for falls, only for restraint.  They play a crucial role in certain work scenarios but have specific limitations.

• Features: No shock absorption mechanism
  • Typically made of strong, durable materials like nylon or polyester webbing, or wire rope for specific applications.
  • Available in various lengths, usually ranging from 3 to 6 feet.
  • May include adjustable features for versatility in different work positions.
  • Often equipped with double-locking snap hooks or carabiners at each end for secure connections.
• Best for: Restraint systems or positioning (not for fall arrest)
  • Restraint: Used to prevent a worker from reaching a fall hazard zone. The lanyard length is calculated to keep the worker away from the edge or opening.
  • Positioning: Allows a worker to be supported on an elevated vertical surface and work with both hands free. Common in tasks like rebar tying or utility pole work.
  • Fixed-length travel restriction: In some controlled environments where the fall distance is very limited and calculated.
• Considerations: Must not be used in situations where a free fall is possible
  • OSHA prohibits the use of non-shock-absorbing lanyards for fall arrest purposes.
  • If there's any possibility of a free fall, a shock-absorbing lanyard or self-retracting lifeline must be used instead.
  • When used for positioning, a backup fall arrest system is typically required.
  • The user must understand the difference between fall restraint and fall arrest to ensure proper application.
  • Regular inspection is crucial, as any damage to a non-shock-absorbing lanyard can compromise its strength entirely.

3. Adjustable Lanyards

Adjustable lanyards offer versatility by allowing workers to modify the length of the lanyard for different work positions or environments. This adaptability makes them valuable in various industrial and construction settings.

• Features: Adjustable length mechanism
  • Typically feature a friction buckle or rope adjuster that allows for easy length modification.
  • Available in both shock-absorbing and non-shock-absorbing variants.
  • Length adjustment range usually varies from about 4 to 8 feet, though some models offer wider ranges.
  • Often made with durable materials like polyester or nylon webbing, or rope for specific applications.
  • May include additional features like wear indicators or protective sleeves over the adjustment mechanism.
• Best for: Varied work environments where different lanyard lengths are needed
  • Ideal for work on scaffolding or structures with varying anchor point heights.
  • Useful in fall restraint systems where the distance to the fall hazard may change.
  • Beneficial in positioning systems where workers need to adjust their work location frequently.
  • Valuable for maintenance tasks that require reaching different areas without changing equipment.
  • Can be used effectively in confined space entry and rescue operations.
• Considerations: Ensure the adjustment mechanism is secure and easy to use
  • Users must be properly trained in adjusting the lanyard to maintain safe working distances.
  • Regular inspection of the adjustment mechanism is crucial to ensure it doesn't slip under load.
  • Be aware of the minimum length requirements - most adjustable lanyards have a minimum length that shouldn't be shortened.
  • Consider the potential for misuse - workers might be tempted to adjust the lanyard to an unsafe length to reach a work area.
  • For fall arrest applications, ensure the lanyard includes a shock absorber and that fall clearance is recalculated for different lanyard lengths.
  • Some adjustment mechanisms may be difficult to operate with gloved hands - consider this for cold weather or certain industrial environments.

4. Twin-Leg Lanyards (Y-Lanyards)

Twin-leg lanyards, also known as Y-lanyards or 100% tie-off lanyards, are designed to provide continuous fall protection while moving between anchor points. They offer a significant safety advantage in certain work environments.

• Features: Two lanyard legs connected to a single point on the harness
  • Typically feature a central attachment point that connects to the dorsal D-ring of a full-body harness.
  • Each leg usually includes its own shock absorber, or there may be a single shock absorber at the central connection point.
  • Available in various lengths, typically ranging from 3 to 6 feet per leg.
  • Often equipped with large hook openings (scaffold hooks) at the connecting ends for easy attachment to anchor points.
  • May include features like wear indicators, impact indicators, or protective sleeves over the energy absorbers.
• Best for: Workers who need to move frequently between anchor points
  • Ideal for steel erection and other construction activities requiring frequent repositioning.
  • Useful in tower climbing, where workers move vertically and need constant attachment.
  • Beneficial in situations where workers need to transfer between elevated work platforms.
  • Effective for maintenance tasks on large machinery or structures with multiple anchor points.
  • Valuable in scenarios where a single anchor point may not always be available or suitable.
• Considerations: Proper use requires training to ensure one leg is always connected
  • Users must be trained in the "leap-frog" technique: always connect the second leg before disconnecting the first.
  • Be aware of potential swing fall hazards when moving horizontally.
  • Ensure adequate fall clearance, considering that twin-leg lanyards are often slightly longer than single-leg versions.
  • Avoid connecting both legs to the same anchor point unless specifically designed and approved for such use.
  • Be cautious of increased trip hazards, especially when one leg is not connected.
  • Consider the additional weight of a twin-leg lanyard, which may be a factor in some work environments.
  • Ensure compatibility with the harness – some older harnesses may not be rated for the potential forces of a twin-leg lanyard.

Twin-leg lanyards provide a versatile solution for maintaining 100% tie-off in dynamic work environments. However, their effectiveness relies heavily on proper use and training. Workers must understand the correct techniques for moving between anchor points and be aware of the specific considerations associated with these lanyards.

Material Considerations

Lanyards can be made from various materials, each with its own strengths and weaknesses:

1. Nylon: Durable and resistant to abrasion, but can degrade with prolonged UV exposure
2. Polyester: Less elastic than nylon, good UV resistance, but less abrasion-resistant
3. Kevlar: Excellent heat resistance, ideal for welding or high-heat environments
4. Wire Rope: Used in sharp edge environments where synthetic materials might be cut

Length and Fall Clearance

The length of your lanyard directly affects your fall clearance requirements:

• Standard lanyards are typically 6 feet long
• Shorter lanyards (3-4 feet) are available for situations with less fall clearance
• Remember to account for the deployed length of shock-absorbing lanyards in your clearance calculations

Connectors and Compatibility

Ensure your lanyard is compatible with your other fall protection equipment:

• Check that the connectors (usually snap hooks or carabiners) are compatible with your harness D-rings and anchor points
• Verify that the connectors meet the required strength ratings (typically 5,000 lbs or 22 kN)

Regulatory Compliance

In the United States, fall protection lanyards must comply with OSHA regulations and ANSI standards:

• OSHA 1926.502: Sets requirements for fall protection systems
• ANSI Z359.13: Provides performance requirements for personal energy absorbers and lanyards

Always check your local regulations as requirements may vary by region or industry.

Special Considerations

Sharp Edges

If you're working around sharp edges, standard lanyards may not be sufficient:

• Look for lanyards specifically rated for sharp edge environments
• These may have additional webbing reinforcement or wire rope cores

Arc Flash Protection

For electrical workers, arc flash-rated lanyards are essential:

• These lanyards are made with materials that can withstand high temperatures
• They're often made with Kevlar or other heat-resistant fibers

Leading Edge

When working near a leading edge (an unprotected side or edge), special considerations apply:

• Use lanyards specifically designed and tested for leading edge applications
• These often have additional abrasion resistance and may include an integral shock absorber

Proper Use and Training

Even the best lanyard is only effective if used correctly:

• Ensure all users are properly trained in lanyard selection, inspection, and use
• Never exceed the lanyard's weight capacity (typically 130-310 lbs including tools and equipment)
• Understand how to calculate fall clearance for your specific lanyard

Inspection and Maintenance

Regular inspection is crucial for lanyard safety:

• Inspect your lanyard before each use
• Look for signs of wear, abrasion, cuts, or chemical damage
• Check that stitching is intact and connectors function properly
• Remove from service immediately if any damage is found or if the lanyard has been involved in a fall

Conclusion

Choosing the right fall protection lanyard is a critical decision that can have life-or-death consequences. By understanding the types of lanyards available, the materials they're made from, and the specific requirements of your work environment, you can make an informed choice that ensures your safety at heights.

Your life is on the line – make sure your lanyard is up to the task.