May 9, 2025:  The Ultimate Guide to Harness Inspections

A proper harness inspection checklist can mean the difference between a routine workday and a life-altering fall. Whether you’re working at height on a construction site, refinery, or industrial plant, fall protection equipment is only effective if it’s regularly and thoroughly inspected. This guide covers everything you need to know—from regulatory requirements to what to look for during inspections—plus a free downloadable checklist to help keep your crew safe and compliant.

In this harness inspection guide, I’ll walk through their importance, the key areas every inspection should cover, and how to build a repeatable process that keeps your crew safe and compliant.

The Importance of Harness Inspections

Fall protection failures are one of the leading causes of serious injuries and fatalities in construction and industrial work. In fact, falls remain one of OSHA’s “Fatal Four,” accounting for over 30% of all construction fatalities.

Your safety harness is often the last line of defense between you and a catastrophic fall. But like any piece of personal protective equipment (PPE), harnesses degrade over time. Exposure to UV rays, chemicals, rough use, and improper storage can compromise their integrity. That’s why regular inspections aren’t just recommended—they’re required (CFR 1926.502(d)(21)).

Harness inspections are essential because:

• Early detection saves lives: Small tears, broken stitching, or worn buckles can lead to failure under load.
• Required by OSHA and CSA standards: Regulations like OSHA 1926.502(d)(21) and CSA Z259 mandate regular inspection of fall arrest systems before each use.
• Failure to inspect can result in fines or shutdowns: Not having a documented harness inspection program can lead to costly penalties and lost productivity.
• Protects workers and your bottom line: Properly maintained PPE reduces injury claims and promotes a culture of safety.

Want a deeper dive into what can happen if you skip your harness inspections? Read: The Hidden Dangers of Skipping Harness Inspections.

Regulatory Requirements for Harness Inspections

OSHA requires a visual inspection before every use but does not require written documentation according to the standards. However, Canadian Standards Association (CSA) and American National Standards Institute (ANSI) standards go further, calling for formal, documented inspections at set intervals and requiring that they be done by a competent person.

CSA Standards (Canada)

Under CSA Z259.10-18 (Full body harnesses) and CSA Z259.2.2-17 (Self-retracting devices), the standards require:

• Pre-use inspection by the worker before each use.
• Formal inspection at least annually by a competent person.
• Documentation of formal inspections must be maintained and kept available for review.
• Any equipment failing inspection must be immediately removed from service.

ANSI Standards (United States)

ANSI/ASSE Z359.2 (Fall Protection Program) and Z359.11-2021 (Full Body Harnesses Safety Requirements) standards also specify:

• Inspection before each use by the end user.
• Formal inspection by a competent person at intervals not exceeding 12 months (or more frequently if specified by the manufacturer).
• Written records of formal inspections must be kept for the service life of the equipment.

According to all standards, employers must ensure defective equipment is immediately removed from service.

OSHA doesn’t technically require you to write down each pre-use harness inspection—but that doesn’t mean it’s a good idea to skip it. If something goes wrong and there’s an investigation, you can bet they’ll ask: Was the harness inspected? Who checked it? How do you know for sure? If there’s no written record, you’re left relying on someone’s word. That can get messy fast—especially if it ends up in court or under scrutiny. Keeping track of inspections in writing isn’t just smart—it shows your safety program is solid and taken seriously.

How Often Should You Inspect a Safety Harness?

Every harness on your site should be inspected on two schedules: daily by the user and periodically by a competent person.

Note: While OSHA does not explicitly mandate periodic inspections at fixed intervals, it does require that employers follow manufacturer instructions and ensure that equipment remains in safe working condition. Most harness manufacturers—as well as ANSI and CSA standards—recommend formal, documented inspections at least annually, and sometimes more frequently depending on usage and conditions.

Both should be considered essential by any contractor—one protects workers in the moment, while scheduled inspections help identify wear that could lead to long-term safety issues or legal liability.

1. Daily Pre-Use Checks

Before you strap in, you should give your harness a quick but thorough inspection. This only takes a few minutes, but could be the difference between catching a defect and experiencing a fatal fall.

Daily pre-use inspections are required and they’re the most consistent safety checkpoint on any jobsite. You should look for visible damage, feel for hidden defects, and report any concerns immediately. A daily harness inspection checklist can help ensure consistency and thoroughness across your crew.

2. Periodic Formal Inspections

Beyond daily checks, each harness also should undergo a formal inspection by a competent person. Most manufacturers recommend this every 6 to 12 months, depending on how and where the harness is used.

More frequent inspections may be needed if:

• The harness is exposed to harsh environments (chemicals, concrete dust, high heat)
• It’s used heavily or shared between workers
• It’s stored improperly (e.g., in a truck bed, damp area)

These inspections should be documented with the date, the inspector’s name, and any findings. This documentation is your first line of defense in an audit or investigation.

While OSHA doesn’t technically require written proof of pre-use checks, you can expect investigators to ask:

• Was the harness inspected before use?
• Who performed the inspection?
• How do you know it was done?

Without written proof, you’re relying on verbal confirmation—which can be challenged and may not hold up in court. Keeping inspection records shows your team takes safety seriously and helps protect your company from fines or legal issues.

What Should Be on Your Harness Inspection Checklist?

Every harness inspection should cover six key areas: webbing, stitching, hardware, tagging, cleaning, and storage. Inspections should include both visual and tactile checks—meaning you don’t just look for damage, you feel for it too. These are the core items that belong on any harness inspection checklist, whether it’s for daily use or scheduled formal reviews.

• Webbing Damage: Check the entire length of the webbing for integrity and flexibility. Examples: Cuts, nicks, fraying, burn marks, UV fading, brittle or stiff areas.
• Stitching Integrity: Look closely at all stitched areas for signs of stress or degradation. Examples: Loose or missing threads, unraveling seams, faded or shiny stitching (indicating stress).
• Hardware Check: Ensure all metal components are free from defects and function properly. Examples: Rust, cracks, pitting, bent or deformed buckles, stuck or malfunctioning D-rings.
• Tagging and Labeling: Verify that the harness has a readable and complete tag with required information. Examples: Manufacturer label, model and serial number, manufacture date, last inspection info. Tags that are missing or illegible mean the harness is out of service.
• Cleaning and Storage: Assess whether the harness is being stored and maintained properly. Examples: Dirty or damp condition, signs of mold or chemical residue, crumpled in trucks, exposure to direct sun or moisture.

Common Harness Inspection Mistakes to Avoid

Even well-meaning teams make these mistakes when it comes to harness inspections:

• Only doing a visual check: Damage like stiffness or internal fraying won’t be seen—it has to be felt.
• Ignoring hardware: Cracks and corrosion often go unnoticed if buckles aren’t checked closely.
• Skipping documentation: If it’s not recorded, it didn’t happen—at least not to OSHA or your insurer.
• Letting unqualified people inspect gear: Only a trained, competent person should handle periodic reviews.

Using a detailed fall protection harness inspection checklist can help prevent these oversights and keep everyone on the same page. For example, my team recently spoke to a safety manager who discovered that a harness being used daily hadn’t had a formal inspection in over 18 months. It looked fine—until they checked the stitching and found serious wear. They caught it just in time.

We recently spoke to a safety manager who discovered that a harness being used daily hadn’t had a formal inspection in over 18 months. It looked fine—until they checked the stitching and found serious wear. They caught it just in time.

Real-world incidents show just how costly these mistakes can be:

• A construction worker died after falling from the 27th floor when a new but uninspected harness failed.
• OSHA cited a company after multiple corroded and non-functional fall protection components were discovered on-site, highlighting serious inspection failures.
• A technician discovered several failure points in his harness during a vessel operation—issues only identified through tactile inspection.
• In Texas, an untrained worker who became paralyzed after improperly secured fall protection equipment failed was awarded $26.5 million, including punitive damages.

Download Your Fall Protection Harness Inspection Form

A consistent harness inspection process starts with a simple, reliable checklist—designed for real-world use in construction and industrial settings.

Whether you’re inspecting gear on a job trailer, truck tailgate, or mobile device, this checklist helps your team stay safe and compliant.

Each section includes clearly defined pass/fail items, notes for manufacturer-specific cases (like marker use or discoloration), and reminders that “Yes” means a failed condition unless otherwise stated. It also includes space for inspection notes, initials, and a summary pass/fail check for clear recordkeeping.

Here’s what’s included in the downloadable PDF:

✅ Pass/fail fields to simplify inspections
✅ Covers webbing, stitching, hardware, labeling, and storage
✅ Notes and indicators based on heat, UV, chemical exposure, or stretching
✅ Room for notes, initials, and timestamps
✅ Designed to support regulatory compliance
✅ Available as a printable PDF

Harness inspections take minutes. The consequences of skipping them can last a lifetime.

Download the checklist.

Print it. Share it. Make your harness inspection checklist part of your crew’s daily safety routine.