When Should Fall Protection Equipment Be Inspected?

So, when should fall protection equipment be inspected? The answer might seem straightforward, but there’s a lot more to it than just “whenever you feel like it” or “once a year.” Whether you’re a site supervisor, safety officer, or worker, knowing how often to inspect this equipment can mean the difference between life and death.

1. The Importance of Regular Inspection

Fall protection equipment serves as the last line of defense when working at heights. If that equipment fails, the consequences can be fatal. Safety harnesses, lanyards, anchors, and other protective gear must be in optimal condition to function properly. But wear and tear, exposure to the elements, and improper use can degrade these items over time. Regular inspections ensure that they remain in top shape.

Here’s why regular inspections matter:

• Prevent catastrophic failure: Worn or damaged equipment can fail unexpectedly.
• Comply with regulations: OSHA and other safety organizations have strict requirements regarding fall protection gear.
• Ensure worker confidence: Employees are more likely to work safely when they trust their equipment.

2. Frequency of Inspections

When exactly should you be inspecting fall protection equipment? Let’s break it down into three main categories:

a) Pre-use Inspections

Every time fall protection equipment is used, it must be inspected. Workers should inspect their gear before every shift. This inspection focuses on obvious issues like frayed straps, broken buckles, or damaged lanyards. A quick visual and tactile check can prevent accidents before they happen.

Key things to check during a pre-use inspection include:

• Cuts, tears, or fraying on straps
• Broken or cracked buckles
• Missing components
• Discoloration (which could indicate chemical damage)

This inspection should only take a few minutes but can save lives.

b) Annual or Periodic Inspections by a Competent Person

At least once a year, fall protection equipment must undergo a more thorough inspection by a competent person. A “competent person,” as defined by OSHA, is someone who has the training and knowledge to recognize hazards and take corrective measures. These inspections are far more detailed than pre-use checks and involve a closer examination of the materials, stitching, and mechanical parts.

For equipment that sees heavy use, such as in industries like construction or oil and gas, some organizations recommend these inspections be conducted more frequently than once a year—sometimes as often as every six months.

During these inspections, the competent person will:

• Inspect the stitching and connections for signs of wear.
• Check the mechanical components for rust, deformation, or other issues.
• Ensure the gear complies with manufacturer guidelines and regulations.

c) Post-Incident Inspections

If fall protection equipment is subjected to a fall or other significant impact, it must be removed from service and thoroughly inspected. This is non-negotiable. Even if the equipment appears to be undamaged, internal stress could have weakened it. This inspection ensures that the gear is still safe to use or needs to be replaced.

In cases where equipment has absorbed a fall, it is often advisable to discard it, even if no visible damage is present.

3. Common Causes of Equipment Failure

Inspecting equipment isn’t just about ticking boxes—it’s about identifying potential points of failure. Let’s dive into the most common causes of fall protection equipment degradation:

• Environmental factors: Exposure to UV light, chemicals, dirt, or moisture can weaken straps and hardware.
• Improper storage: Storing equipment in damp or high-temperature environments accelerates deterioration.
• Misuse: Using fall protection equipment for tasks it wasn’t designed for (such as using a lanyard to tow materials) can damage it.
• Normal wear and tear: Even under ideal conditions, equipment will degrade over time simply from regular use.

4. Visual Inspection vs. Tactile Inspection

One of the keys to effective inspections is understanding that visual checks alone aren’t enough. Fall protection equipment also needs to be physically handled to check for hidden issues. This is where tactile inspection comes into play.

For example, feeling along the length of a harness or lanyard can reveal cuts or abrasions that aren’t immediately visible. Similarly, running your fingers over buckles can help detect cracks or irregularities that a simple glance might miss.

5. OSHA and Industry Standards

Let’s talk about the rules. The Occupational Safety and Health Administration (OSHA) sets stringent guidelines for fall protection. According to OSHA 1926.502(d)(21), all fall protection equipment must be inspected regularly and removed from service if found to be defective.

But OSHA isn’t the only authority here. Equipment manufacturers also provide specific inspection guidelines, and failing to adhere to these could not only lead to accidents but also invalidate warranties or liability claims.

Here are a few of the most widely followed standards:

• OSHA 1926.502(d)(21): Regular inspection of fall protection systems.
• ANSI Z359.2: Specifications for the comprehensive management of fall protection programs.
• CSA Z259: Canadian standards for fall protection.

Each of these provides guidance on how often equipment should be inspected and what specific procedures should be followed.

6. What to Do if Equipment Fails Inspection

So, what happens if a piece of equipment doesn’t pass an inspection? The answer is simple: Remove it from service immediately.

Do not attempt to repair the equipment yourself unless you are a certified technician and authorized by the manufacturer to do so. Most companies will opt to replace faulty equipment to ensure continued worker safety. The cost of a new harness or lanyard is nothing compared to the cost of a life.

7. The Role of Training

Regular inspections are essential, but they only work if workers are trained to perform them correctly. Training should be a part of every safety program, and it should cover not just how to use fall protection gear but also how to inspect it properly.

Some points that training programs should include:

• Identifying common signs of wear and damage
• Proper storage techniques to extend the life of the equipment
• How to conduct both visual and tactile inspections
• Understanding manufacturer guidelines for each specific piece of equipment

Regular refresher courses should also be part of the program, as procedures and technologies evolve.

8. Recordkeeping: An Often Overlooked Aspect

Another critical aspect of inspecting fall protection equipment is documenting inspections. Every time an inspection occurs, whether it’s a daily pre-use check or an annual review by a competent person, it should be logged. This not only helps track the history of each piece of equipment but also ensures compliance with regulations.

These logs should include:

• Date of inspection
• Name of the person conducting the inspection
• Condition of the equipment
• Any actions taken (e.g., equipment removed from service)

In large organizations, this can be managed through digital tracking systems, ensuring that nothing slips through the cracks.

9. The Financial Impact of Neglecting Inspections

Failing to inspect fall protection equipment regularly doesn’t just pose safety risks—it can also have a financial impact. OSHA fines for non-compliance can be hefty, ranging from thousands to tens of thousands of dollars per violation. Additionally, workplace accidents involving fall protection failures often result in expensive lawsuits, medical bills, and increased insurance premiums.

From a purely financial perspective, it’s far cheaper to invest in regular inspections than to deal with the fallout from an accident.

10. Innovations in Fall Protection Inspections

In recent years, technology has started to play a role in the inspection of fall protection equipment. For example, RFID (Radio Frequency Identification) tags are now being embedded in harnesses and lanyards. These tags can be scanned to quickly access the equipment’s inspection history, helping to ensure nothing is missed.

There are also apps designed to help workers and safety officers perform and log inspections more efficiently. These digital tools streamline the process, reducing the risk of human error and ensuring that inspections happen on schedule.

Conclusion

Regular inspection of fall protection equipment isn’t just a box to tick—it’s a critical safety measure that protects lives. By following OSHA guidelines, conducting thorough pre-use and annual inspections, and staying up-to-date with the latest technology, companies can create a safer working environment and prevent unnecessary accidents.

Whether you’re responsible for managing a team or simply looking out for your own safety, make inspections a priority. After all, when you’re 30 feet in the air, you want to be sure that your equipment will catch you if you fall.