Quick Answer
Workers must inspect fall protection equipment before every use and at least annually as part of a competent-person review. A complete inspection covers harness webbing and stitching, hardware, lanyards, shock absorbers, connectors, self-retracting lifelines (SRLs), and anchor points. Equipment with cuts, fraying, corrosion, distortion, deployed shock packs, or missing labels must be removed from service immediately.

You can download the complete Fall Protection Equipment Inspection Checklist (PDF) here.

Why Do Fall Protection Inspections Matter?
Fall protection is one of the most regulated areas in construction, and for good reason. Falls remain the leading cause of workplace fatalities, and every year the top OSHA violation is simply “failure to provide adequate fall protection.” The second-most common citation is “failure to train workers in fall hazards,” followed closely by violations involving inadequate inspection and maintenance of fall arrest gear.

Most equipment failures are not dramatic or sudden. They start with subtle changes in the gear: a fray along the webbing edge, a sticky snaphook gate, a shock pack that looks slightly elongated, or an SRL that retracts more slowly than yesterday. These details can be easy to miss, especially when crews are under pressure to get to work quickly. Daily inspections catch these issues before they become life-threatening.

Inspections are about building predictable habits. When workers know exactly what to check and supervisors have a consistent record of inspection results, fall protection programs become significantly more reliable.

What Counts as Fall Protection Equipment?
Fall protection equipment includes all components used to prevent falls or minimize the impact of a fall. OSHA 1926 Subpart M, ANSI Z359, and CSA Z259 define the requirements for these systems, and each piece of equipment has its own inspection needs.

The most common equipment includes full-body harnesses, energy-absorbing lanyards, positioning lanyards, SRLs, horizontal lifeline systems, anchors, connectors, and rescue gear. Each piece operates under different stresses, which means each must be inspected differently.

Although workers often think of fall arrest gear as “one system,” each component is a potential failure point. An inspection must treat each as a separate unit, with its own signs of wear and hazard indicators.

When Does Fall Protection Equipment Have to be Inspected?
Fall protection equipment requires inspection at multiple intervals, and these intervals are not interchangeable.

Workers must inspect their gear before each use. This is the most important inspection because it captures new damage that occurs between shifts. Daily pre-use checks should be quick but thorough, and every worker must know what they are looking for.

Equipment must also be inspected after any exposure to a damaging environment, such as welding sparks, sharp edges, corrosive materials, or extreme heat and cold. Gear that has been involved in a fall arrest must be removed from service immediately, even if it looks intact, because internal damage can render it unreliable.

Finally, a competent person must conduct a formal inspection at least once per year. Some manufacturers require more frequent intervals, especially for SRLs and rescue equipment. These inspections must be documented and stored for compliance review.

How to Inspect a Full-Body Harness
Harnesses fail more often than workers expect because they experience continuous handling and movement. Every harness must be inspected from top to bottom.

A harness inspection begins with the webbing. Workers should assume that any stitching or fiber damage compromises strength. Cuts, frays, broken fibers, and areas of abrasion are obvious hazards, but so are heat glazing, chemical contamination, and stiff or brittle patches caused by UV exposure or improper storage. Webbing with discoloration, stains, or hardened areas must be evaluated critically.

Stitching plays a structural role in the harness, and any inconsistency is cause for concern. Workers should check bar tacks, load-bearing seams, and anchor points for loose threads, pulled stitches, or uneven patterns. Stitch repairs done outside the manufacturer—no matter how well-intentioned—disqualify the harness immediately.

Hardware is another potential failure point. D-rings must be free of distortion and must rotate smoothly. Chest and leg buckles should latch securely without sticking, and grommets must not show stretching, tearing, or elongation. All metal components must be free of rust, cracks, or sharp edges.

Finally, labels must be intact and clearly readable. Missing or illegible labels mean the harness cannot be verified as compliant and must be removed from service.

How to Inspect Lanyards
Lanyards are exposed to different conditions than harnesses, especially abrasion from edges and contact with surfaces during work. A proper inspection begins with the webbing or rope.

Workers should run the entire length of the lanyard between their hands, feeling for cuts, broken fibers, hard spots, swelling, or discoloration. Rope lanyards must be checked for soft spots, glazing, or strand separation. Cable lanyards require inspection for frayed wires, kinks, birdcaging, or rust.

Shock absorbers (often called shock packs) must remain sealed and intact. If the pack shows signs of deployment, such as torn stitching or extended length, the lanyard must be discarded immediately. Even minor fraying around the shock pack stitching indicates potential load history.

Connectors must close and lock automatically. Gates should snap shut with a clear, audible action. Any hesitation, binding, or misalignment is an immediate hazard. Workers should test connector operation cleanly and firmly, without force.

How to Inspect Positioning Lanyards
Although positioning lanyards are not designed for fall arrest, they still support workers in high-risk environments. Rope positioning lanyards must show no signs of glazing, contamination, or strand failure. Cable positioning lanyards require careful inspection for broken wires and kinks. Mechanical adjusters must travel smoothly and lock securely. Pads or sleeves used to protect the lanyard must remain intact.

How to Inspect a Self-Retracting Lifeline (SRL)
SRLs contain internal mechanisms that arrest falls quickly. Because they rely on springs, drums, and braking systems, they require a more technical inspection.

The housing must first be inspected for cracks, dents, or evidence of being dropped. Missing screws or loosened fasteners are signs that the internal components may have shifted or been compromised.

The lifeline material must then be inspected based on its type. Webbing SRLs require the same checks as harness webbing: cuts, frays, burns, and contamination. Cable SRLs must show no birdcaging, broken wires, corrosion, or abrasion. Rope SRLs must be free of glazing, swelling, or stiffness.

Retraction must be tested carefully. The lifeline should retract smoothly and completely without lag or hesitation. A slow or incomplete retraction often indicates internal wear. Workers must then perform a sharp tug test to verify that the braking mechanism engages instantly. If the brake catches late or inconsistently, the SRL cannot be trusted.

Finally, the SRL must have an intact, readable label and must not show signs of previous load engagement unless returned from a certified repair facility.

How to Inspect an Anchor Point
Anchors must be strong enough to support 5,000 pounds per worker or must be part of an engineered fall protection system. Workers must verify anchor load ratings and ensure that any temporary or transportable anchors are used strictly according to manufacturer instructions.

A structural inspection includes checking for loose fasteners, cracked welds, corrosion, distortion, or any change to the anchor’s physical shape. Eye bolts, D-rings, and anchor plates must be free of bending, pitting, or elongation. Any movement in an anchor that should be rigid warrants immediate evaluation by a qualified person.

Horizontal lifeline systems require additional checks. Workers must confirm that the tension is correct, the shock absorber remains intact, and the cable or webbing shows no signs of wear. End anchors must be secured firmly to structural load points.

What Are Common Fall Protection Equipment Failures?
The most common failures involve deployed shock packs that were never reported, connectors that no longer auto-lock, and SRLs that fail either their retraction or brake tests. Harnesses often fail inspection due to missing or unreadable labels, especially after repeated washdowns or extended exposure to UV.

Another common hazard involves workers using improvised anchors, such as pipes, rebar, or scaffolding components not designed for fall protection. Improvised anchors frequently bend or detach under load.

SRLs damaged by side loading—where the cable rubs against a sharp edge—often develop birdcaging or broken wire strands. These defects can go unnoticed unless workers intentionally run the cable through their hands during inspection.

When Must Equipment Be Removed From Service?
Equipment must be removed from service when it shows any sign of structural damage, including cut or burned webbing, chemical exposure, loose or missing stitching, bent or cracked hardware, malfunctioning connectors, or failed SRL brake tests. Missing or illegible labels are also grounds for removal because they prevent proper verification of inspection history.

Gear that has arrested a fall must never be reused. Even if it shows no external damage, the internal structure may have been compromised by arrest forces.

How Long Does Fall Protection Equipment Last?
Fall protection equipment does not have a universal lifespan. Manufacturers design gear to last under normal working conditions, but factors such as UV exposure, chemical contamination, and storage environment cause accelerated aging. Many harnesses and lanyards last between five and ten years when stored correctly and used with care. SRLs may require recertification as often as every one or two years depending on the manufacturer.

What is Proper Storage and Care of Fall Protection Equipment?
Proper storage significantly extends the life of fall protection equipment. Gear should be stored in a cool, dry environment away from direct sunlight. Harnesses should not be hung from nails or sharp objects that can deform the webbing. Lanyards should be coiled neatly and kept away from solvents, oils, and welding equipment. SRLs should be stored upright or flat as recommended by the manufacturer and kept free of debris that may enter the housing.

What are the Most Common OSHA Fall Protection Citations?
OSHA’s top fall protection citations include: 

• failure to provide fall protection
• failure to train workers, failure to inspect equipment 
• improper use of SRLs and lanyards 
• failure to use approved anchor points 

These citations often correspond directly with missed inspection items.

Download the Fall Protection Equipment Inspection Checklist (PDF)

This comprehensive checklist covers all components described in this guide and is designed for daily pre-use inspections, toolbox talks, onboarding new workers, and formal competent-person audits.

👉 Download the Fall Protection Equipment Inspection Checklist (PDF)

Frequently Asked Questions

Q: How often must fall protection equipment be inspected?
A: Before each use and annually by a competent person.

Q: Can workers use equipment with missing labels?
A: No. Missing or illegible labels disqualify the equipment.

Q: Do SRLs require recertification?
A: Many manufacturers recommend recertification every 12–24 months.

Q: Can fall protection equipment be repaired?
A: Only by the manufacturer or an authorized service provider.

Q: Does cold weather affect fall protection gear?
A: Yes. Webbing can stiffen and SRLs may retract more slowly.