How often should fall protection equipment be inspected?

For OSHA/ANSI-aligned practice, fall protection equipment should be inspected at two levels: before each use by the user and regularly/periodically by a competent person. The documents consistently require pre-use inspection of PFAS/PFRS/PDS components and regular competent-person review, with immediate removal from service when damage, wear, deterioration, or missing/illegible labels could affect strength or function. OSHA 1910.140 defines a competent person as someone able to identify hazards in the system and authorized to take prompt corrective action. [1] [2] [8]

Inspection frequency requirements:

• Harnesses, lanyards, lifelines, anchors, anchorage connectors, rope grabs, snap hooks, carabiners, and other PFAS/PFRS/PDS components: inspect before each use.
• Periodic documented inspection by a competent person: perform on a regular schedule established by the employer/manufacturer; for ANSI compliance in practice, many employers use at least annual competent-person inspections, and more often for severe service, frequent use, or harsh environments.
• After any fall arrest event: remove the entire affected system from service immediately and do not reuse until a competent person determines it is safe; where manufacturer instructions require, destroy or send to an authorized service center.
• After any event that could damage equipment: inspect immediately before return to service.
• Safety nets: inspect at least weekly and after any occurrence that could affect integrity.

[3] [4] [2] What to inspect during pre-use and periodic inspections:

• Harness webbing and stitching: cuts, tears, abrasion, fraying, stretching, burns, mold, mildew, chemical damage, cracked fibers, loose or broken stitching.
• Harness hardware and D-rings: bent, cracked, nicked, gouged, deformed, corroded, or excessively worn parts; verify buckles couple securely.
• Shock absorbers/impact indicators: any sign of deployment, torn pack, exposed red warning indicator, or activated impact indicator means remove from service.
• Lanyards and lifelines: cuts, frayed strands, broken fibers, knots in rope lanyards/lifelines, excessive wear, burns, chemical attack, damaged thimbles/splices, and damaged labels.
• SRLs/SRDs: cuts or frayed strands in the line, housing damage, impact indicator activation, improper retraction/locking, or any condition requiring service per manufacturer; do not field-repair unless specifically authorized.
• Connectors, snap hooks, and carabiners: cracks, corrosion, deformation, gouges, excessive wear; gates must self-close/self-lock where required, open easily, and close/lock firmly; keeper must not open when closed.
• Anchors and anchorage connectors: correct installation per manufacturer, secure attachment to substantial structural member, proper fasteners, no unusual shape, distortion, wear, corrosion, or damage; rings should move freely where designed to do so.
• Labels/markings: manufacturer labels and load/capacity markings must be present and legible.

[1] [1] [2] [7] [6] [5] Removal from service criteria:

• Any component with cuts, tears, fraying, broken stitching, burns, chemical damage, mold/mildew, corrosion, deformation, cracks, gouges, excessive wear, missing parts, or illegible labels that could affect use must be removed from service.
• Any harness, lanyard, SRL/SRD, shock absorber, connector, or anchorage connector that has arrested a fall must be removed from service immediately pending competent-person evaluation; if manufacturer instructions require disposal, destroy it or send it to an authorized service center.
• Any activated impact indicator, deployed shock pack, or visible red warning indicator is removal-from-service evidence.
• Do not use equipment that appears to need repair until examined and cleared by a competent person.
• Do not use defective nets; remove defective safety-net components from service.

[1] [3] [2] [14] [1] Maintenance and storage expectations:

• Follow the manufacturer’s instructions and warnings for inspection intervals, cleaning methods, lubrication if permitted, repair, and retirement criteria.
• Keep equipment clean and dry; store in a cool, clean, dry place out of direct sunlight and protected from crushing, contamination, sharp edges, moisture, and chemicals.
• Do not attempt unauthorized repairs, especially on SRLs/SRDs; use an authorized service center when required.
• Assign unique equipment IDs and maintain inspection/maintenance records as a best practice, especially for periodic competent-person inspections.
• Use only compatible components; substitutions or changes should be evaluated by a competent person before use.

[2] [3] [12] [2] [11] For OSHA compliance, at minimum ensure pre-use inspection of personal fall protection equipment, removal of defective equipment from service, competent-person involvement when equipment is damaged or has been subjected to a fall, and anchorage strength consistent with the applicable standard and system design. For ANSI compliance, follow the specific manufacturer instructions and the applicable ANSI/ASSP Z359 series for inspection procedures, documentation, and retraining/competent-person oversight; where employer policy is silent, a conservative best practice is a documented competent-person inspection at least annually, with more frequent intervals based on use conditions. Also ensure workers are trained in inspection, maintenance, storage, and hazard recognition by a competent person. [9] [10] [13]