pre shift fall protection inspection form

Use a documented pre-shift inspection for every personal fall arrest system before any employee works at height. A compliant PFAS consists of a body harness, anchorage, and connector, with the means of connection including a lanyard, deceleration device, lifeline, or a suitable combination. For residential construction and similar work, fall protection is required when employees are exposed to a drop of 6 feet or more and cannot be protected by other means. Inspect equipment prior to each use, remove damaged components from service immediately, and ensure the system is used under the oversight of a competent person. [5] [7] [1]

Pre-shift inspection form / checklist:

1. Date, shift, work area, task, employee name, competent person/supervisor name
2. Equipment identification for each item: harness ID, lanyard/SRL ID, lifeline ID, anchor/anchor connector ID, connector/carabiner ID, manufacturer, model, serial number, date placed in service
3. Verification that manufacturer instructions are available and the components are approved to work together; do not interchange components unless specifically approved
4. Confirmation that a rescue plan is in place and reviewed before work starts
5. Confirmation that the selected system matches the task: fall arrest, restraint, or positioning, and that workers are trained for the specific setup
6. Inspection result for each component: acceptable / defective / remove from service
7. Corrective action taken for any defect and tag-out documentation
8. Worker signoff and supervisor/competent person verification before exposure to fall hazards

[1] [1] [1] Harness inspection and serviceability criteria:

• Verify a full-body harness is being used; body belts are not acceptable as part of a PFAS
• Inspect webbing for cuts, frays, burns, cracks, pulled fibers, abrasion, chemical contamination, paint, hardened areas, UV damage, or foreign material
• Inspect all stitching for broken, burned, loose, pulled, or missing threads, especially at load-bearing points and hardware attachments
• Inspect buckles, grommets, strap fasteners, and adjusters for cracks, bends, corrosion, deformation, sharp edges, or improper function
• Inspect dorsal and other D-rings for cracks, bends, nicks, gouges, corrosion, discoloration, deformation, or looseness
• Verify labels and markings are present and legible, including manufacturer, model, size, and date/manufacture information
• Check impact indicators if provided by the manufacturer; if deployed or activated, remove from service
• Verify fit before work: chest strap across mid-chest, leg straps snug with about two fingers of space, shoulder straps taut, and dorsal D-ring centered between the shoulder blades
• Remove from service if any load-bearing webbing, stitching, hardware, labels, or impact indicators are damaged, missing, illegible, deformed, or show evidence of prior fall loading

[1] [3] [3] Lanyards, SRLs, rope grabs, and lifelines:

• Inspect lanyards and vertical lifelines for cuts, frays, broken wires, abrasion, burns, knots not approved for use, chemical damage, crushed sections, heat damage, or damaged terminations
• Verify lanyards and vertical lifelines have at least 5,000-pound minimum breaking strength unless using an SRL/lanyard that automatically limits free fall to 2 feet or less, in which case components must sustain the required lower rating specified by OSHA
• Inspect shock absorber packs and energy absorbers for deployment, tearing, elongation, broken covers, or signs of prior loading; if deployed, remove from service
• Inspect SRLs for housing damage, loose fasteners, corrosion, damaged cable/web line, proper retraction, and positive locking under a sharp pull; remove from service if lockup or retraction is abnormal
• When vertical lifelines are used, attach only one employee per lifeline
• Ensure each knot in a lanyard or vertical lifeline has been inspected by a competent person or qualified person before use if knots are part of the system
• For rope grabs, verify compatibility with the lifeline, correct orientation, smooth travel, and positive locking; keep the rope grab high and the connecting lanyard short
• Protect lifelines and lanyards from cuts and abrasion, especially at metal or concrete edges; use edge protection and only equipment designed for edge exposure when applicable
• Do not connect shock-absorbing lanyards to retractable lifelines unless manufacturer approved, and never hook lanyards together unless manufacturer approved

[2] [2] [6] Anchors and anchorage connectors:

• Verify the anchor point was planned before work and is attached to a substantial structural member such as a beam, girder, roof truss, or rafter
• Confirm the anchorage is independent of any anchorage used to suspend employees or platforms
• For personal fall protection, verify the anchorage is capable of supporting at least 5,000 pounds per attached employee, or is designed, installed, and used under qualified supervision to meet the alternative criteria allowed by OSHA
• Inspect anchor devices and anchorage connectors for deformation, cracks, corrosion, wear, damaged welds, bent plates, elongated holes, damaged straps, cut webbing, missing fasteners, or unauthorized field modifications
• Never use pipes, vents, sheetrock screws, or other non-rated improvised points as anchors
• Verify compatibility between the anchorage connector and the lanyard/lifeline and that the connector is appropriate for the task
• Locate the anchorage as high and directly above the worker as practical to reduce free fall and swing fall hazards
• For horizontal lifelines, verify they are designed, installed, and used under the supervision of a qualified person and are part of a complete system with a safety factor of at least two

[1] [2] [1] Connectors, snap hooks, carabiners, and D-rings:

• Inspect connectors for cracks, bends, deformation, corrosion, sharp edges, excessive wear, gate damage, or evidence of side loading
• Verify connectors are drop forged, pressed or formed steel, or equivalent, with corrosion-resistant finish and smooth edges
• Verify D-rings, snap hooks, and carabiners are rated to at least 5,000 pounds tensile strength and proof tested to 3,600 pounds without cracking, breaking, or permanent deformation
• Use only automatic-locking snap hooks and carabiners that require at least two separate consecutive movements to open
• Ensure connectors are compatible and cannot roll out or unintentionally disengage
• Do not connect snap hooks or carabiners directly to webbing, rope, or wire rope, to each other, to a D-ring already occupied by another connector, to a horizontal lifeline, or to any incompatible object unless specifically designed for that connection
• Verify the harness D-ring is the correct attachment point for fall arrest and is larger than the snap hook where applicable

[2] [2] [2] Worker safety verification before working at height:

• Worker has current fall protection training and understands the specific system being used
• Harness is donned correctly, adjusted snugly, and all loose straps are secured
• Correct attachment point is used and the worker is connected before exposure to the edge or opening
• Fall clearance has been verified, including free fall distance, deceleration distance, lanyard/SRL length, harness stretch, worker height, and clearance to lower levels or obstructions
• Swing fall hazards have been assessed and the worker will remain as directly below the anchorage as practical
• Weather and surface conditions are acceptable; postpone work in wet, icy, or slippery conditions if footing or rescue would be compromised
• Tools and materials are managed so they do not damage the system or create trip hazards
• A prompt rescue plan, rescue equipment, and communication method are in place
• The worker confirms no component has been subjected to a prior fall unless recertified by the manufacturer or authorized service entity

[3] [6] [1] Suggested pass/fail serviceability rules:

• PASS: Equipment is the correct type for the task, compatible, within manufacturer limits, properly fitted, fully functional, and shows no damage, deformation, corrosion, missing parts, illegible labels, or evidence of prior fall arrest
• FAIL / REMOVE FROM SERVICE: Any cut, tear, fray, burn, broken stitching, cracked or bent hardware, deployed shock absorber, failed SRL lock or retraction, damaged rope grab, missing label, unauthorized modification, chemical contamination, severe abrasion, or uncertain history
• FAIL / DO NOT USE: Anchor point not rated or not verified, incompatible connectors, non-locking snap hook, shared vertical lifeline, horizontal lifeline lacking qualified design, or no rescue plan / no competent oversight

[1] [2] [2] A practical pre-shift form can use three signoff columns for each item: Inspect, Accept/Reject, and Corrected/Tagged Out, followed by a final authorization line stating: "I verified the fall protection system is appropriate for the task, all components passed inspection, the anchorage and clearance are adequate, the worker is trained, and rescue arrangements are in place before work at height begins." This approach supports OSHA-aligned verification of equipment condition, compatibility, anchorage strength, and worker readiness before exposure. [4] [1]