Harness and lanyard rules: 8 checks before the shift

Key takeaways

• Inspect the system prior to each use and remove defective components from service.
• After impact loading, wait until a competent person finds it undamaged and suitable for reuse.
• Use 3,000 pounds only when free fall is limited to 2 feet or less, and 5,000 pounds for the other class.
• Do not use a body belt in a personal fall arrest system.

Pre-use inspection mandate

According to Legal Information Institute, personal fall arrest systems shall be inspected prior to each use for wear, damage and other deterioration. This requirement applies to the entire assembly, including the harness and lanyard. If the inspection reveals any defect, the component shall be removed from service.

A separate rule addresses components that have already caught a fall. According to GovRegs, personal fall arrest systems and components subjected to impact loading shall be immediately removed from service. These items shall not be used again for employee protection until inspected and determined by a competent person to be undamaged and suitable for reuse. The impact loading event triggers this specific removal rule. A competent person must perform the inspection to make the determination of suitability. If it is undamaged, it may return to service.

Inspect harnesses and lanyards before the next shift using the checklist in the reference table. See Log lifting sling inspections: 6 checks before the lift.

Harness and lanyard strength rules

The Washington State Legislature specifies that all components of full body harness systems, where strength is not otherwise defined, must support a minimum fall impact load of five thousand pounds (22.2 kN) applied at the lanyard point of connection Washington State Legislature. This requirement applies specifically to full body harness systems whose strength is not explicitly stated elsewhere in the regulation.

For self-retracting lifelines and lanyards, the California Department of Industrial Relations states that devices which automatically limit free fall distance to 2 feet or less must sustain a minimum tensile load of 3,000 pounds California Department of Industrial Relations. This load is applied to the device while the lifeline or lanyard is in the fully extended position. The regulation covers self-retracting lifelines and lanyards that meet the specific free fall distance limitation.

The California Department of Industrial Relations further requires that self-retracting lifelines and lanyards which do not limit free fall distance to 2 feet or less, ripstitch lanyards, and tearing and deforming lanyards shall be capable of sustaining a minimum tensile load of 5,000 pounds applied to the device with the lifeline or lanyard in the fully extended position California Department of Industrial Relations.

GovRegs outlines a similar requirement for self-retracting lifelines and lanyards that automatically limit free fall distance to 2 feet (0.61 m) or less, stating they must sustain a minimum tensile load of 3,000 pounds (13.3 kN) GovRegs. This tensile load is applied to the device with the lifeline or lanyard in the fully extended position. The source identifies this rule under 29 CFR 1926.502, which covers fall protection systems criteria and practices.

Lanyard tensile limits

Self-retracting lifelines and lanyards that do not limit free fall distance to 2 feet or less, along with ripstitch lanyards and tearing and deforming lanyards, must sustain a minimum tensile load of 5,000 pounds applied to the device with the lifeline or lanyard in the fully extended position, according to California Department of Industrial Relations. The same requirement appears in federal regulations, which specify that these devices shall be capable of sustaining a minimum tensile load of 5,000 pounds (22.2 kN) applied to the device with the lifeline or lanyard in the fully extended position, according to GovRegs. When verifying components before the shift, confirm that the lanyard or self-retracting lifeline is rated for this 5,000-pound tensile load in its fully extended state. This check applies specifically to devices that do not limit free fall distance to 2 feet or less, as well as ripstitch and tearing/deforming types. If a lanyard is marked with a lower tensile capacity or lacks the required rating for the fully extended position, remove it from service. The 22.2 kN figure provides the metric equivalent, according to GovRegs. Ensure your pre-use inspection log records the specific tensile load rating found on the device label to match the 5,000-pound minimum requirement.

Horizontal lifeline supervision

Horizontal lifelines must be designed, installed, and used under the supervision of a qualified person, as part of a complete personal fall arrest system, according to GovRegs. The regulation specifies that this system must maintain a safety factor of at least two, according to GovRegs. This requirement applies to the entire lifecycle of the lifeline, from its initial design through its installation and active use on the site, according to GovRegs.

When coordinating your site’s fall protection plan, ensure that a qualified person is present and overseeing the setup of any horizontal lifeline. You cannot simply install these lines without this specific level of supervision, according to GovRegs.

Body belt restrictions

Body belts face strict limitations regarding their application in fall protection systems. According to GovRegs, effective January 1, 1998, body belts are not acceptable as part of a personal fall arrest system. The restriction applies to the specific configuration of the equipment used for arresting a fall, distinguishing it from other types of fall protection gear.

While body belts are banned for fall arrest, they retain a limited role in other safety configurations. According to the California Department of Industrial Relations, body belts used in conjunction with fall restraint systems or positioning devices shall limit the maximum arresting force on an employee to 900 pounds. The 900-pound force limit is a critical parameter for these specific restraint or positioning applications.

Material rules

The material composition of your webbing is a fixed requirement, not a preference. Ropes and straps used in lanyards, lifelines, and the strength components of body belts and body harnesses must be made from synthetic fibers, according to Legal Information Institute. This rule applies to the strength components of both body belts and body harnesses, as stated by the Legal Information Institute. The California Department of Industrial Relations specifies the same requirement for synthetic fibers in these components, according to California Department of Industrial Relations. However, the California Department of Industrial Relations notes an exception when these components are used in conjunction with hot work, where the lanyard may be exposed to damage from heat or flame, according to California Department of Industrial Relations.

When checking your gear before the shift, verify that the webbing is synthetic unless you are working in a hot work environment where heat or flame exposure is a factor. See Hot-work handoff: 6 checks before the crew welds. The California Department of Industrial Relations explicitly allows for non-synthetic fibers only when the lanyard is used in conjunction with hot work where it may be exposed to damage from heat or flame. For all other tasks, the webbing must be synthetic.

Hoist area movement restrictions

When your crew works at hoist areas, the rigging of their personal fall arrest system controls how far they can move. According to California Department of Industrial Relations, the system must be rigged to allow the employee's movement only as far as the edge of the working level or working area. This restriction applies specifically when the system is used at hoist areas.

Federal standards align on this spatial limit for walking and working surfaces. According to Legal Information Institute, when a personal fall arrest system is used at hoist areas, it shall be rigged to allow the movement of the employee only as far as the edge of the walking/working surface. This requirement appears in 29 CFR § 1926.502, which outlines fall protection systems criteria and practices.

Illustrative example

A lifeline that limits free fall to 2 feet or less is checked at 3,000 pounds, fully extended. A lanyard that does not limit free fall to 2 feet or less is checked at 5,000 pounds, fully extended. A body belt used with a positioning device is checked at 900 pounds.

Reference table and next steps

The table below summarizes the eight specific rules for personal fall arrest system components. Each row cites the publisher that states the requirement. Use this table to verify your pre-shift checklist.

Next step

Inspect today's personal fall arrest system, match each lanyard to its load class, and remove defective components from service.

What is the minimum fall impact load a full body harness must withstand?

All components of full body harness systems whose strength is not otherwise specified must be capable of supporting a minimum fall impact load of five thousand pounds (22.2 kN) applied at the lanyard point of connection, according to Washington State Legislature.

How far can an employee move when using a personal fall arrest system in a hoist area?

When a personal fall arrest system is used at hoist areas, it shall be rigged to allow the movement of the employee only as far as the edge of the walking/working surface, according to Legal Information Institute.

What material must ropes and straps in lanyards and lifelines be made from?

Ropes and straps (webbing) used in lanyards, lifelines, and strength components of body belts and body harnesses shall be made from synthetic fibers, according to Legal Information Institute.

When must personal fall arrest systems be inspected for wear and damage?

Personal fall arrest systems shall be inspected prior to each use for wear, damage and other deterioration, and defective components shall be removed from service, according to Legal Information Institute.

Are body belts allowed as part of a personal fall arrest system?

Effective January 1, 1998, body belts are not acceptable as part of a personal fall arrest system, according to GovRegs.