Falls remain the leading cause of death in the construction industry, accounting for over one-third of all construction fatalities each year. Fall protection violations are consistently the number one most-cited OSHA standard, with thousands of citations issued annually. Personal fall arrest systems — including harnesses, lanyards, self-retracting lifelines (SRLs), and anchorages — are literally life-saving equipment, but only when they are properly inspected and maintained. OSHA requires inspection before each use, and ANSI Z359 standards call for additional formal inspections by a competent person at least annually. This guide covers the complete inspection requirements and provides a free downloadable checklist.
Free Fall Protection Inspection Checklist
Download our Word document checklist covering pre-use and annual inspections for harnesses, lanyards, SRLs, connectors, and anchorages.
Download Checklist (.docx)Why Fall Protection Inspections Are Required
OSHA 29 CFR 1926.502(d) — Personal Fall Arrest Systems (Construction)
OSHA's construction fall protection standard establishes the baseline requirements for personal fall arrest system (PFAS) inspections:
- 1926.502(d)(21): 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.
- 1926.502(d)(20): Personal fall arrest systems and components subjected to impact loading shall be immediately removed from service and shall not be used again until inspected and determined by a competent person to be undamaged and suitable for reuse.
- 1926.502(d)(15): Anchorages must be capable of supporting at least 5,000 pounds per employee attached, or be designed and used as part of a complete system maintaining a safety factor of at least two.
OSHA 29 CFR 1910.140 — Personal Fall Protection Systems (General Industry)
The general industry standard mirrors construction requirements:
- 1910.140(c)(22): Personal fall arrest systems must be inspected before each use for wear, damage, and other deterioration. Defective components must be removed from service.
- 1910.140(c)(21): Systems subjected to impact loading shall be immediately removed from service and not used again until a competent person inspects and approves reuse.
ANSI Z359 — Fall Protection Code
ANSI/ASSP Z359 standards go beyond OSHA minimums and are widely recognized as the industry best practice:
- Z359.2: Requires a comprehensive managed fall protection program, including formal inspections by a competent person at least annually in addition to pre-use inspections.
- Z359.11: Establishes specific inspection criteria for full body harnesses, including webbing, hardware, labels, and stitching.
- Z359.13: Defines inspection requirements for energy absorbers and shock-absorbing lanyards.
- Z359.14: Covers self-retracting devices (SRLs) including inspection, maintenance, and manufacturer service requirements.
Full Body Harness Inspection
Inspect every harness before each use. A competent person should perform a detailed formal inspection at least annually per ANSI Z359.2.
| Inspection Item | What to Check |
|---|---|
| Webbing (all straps) | No cuts, tears, fraying, abrasion, or burns. No chemical damage, discoloration, or UV degradation. Check shoulder, chest, leg, and sub-pelvic straps. Inspect both sides of all webbing. |
| Stitching | No pulled, cut, broken, or missing stitches. Contrast-color thread visible and intact at all load-bearing connection points. No separation of stitched layers. |
| D-rings (dorsal, sternal, side) | No cracks, distortion, sharp edges, or excessive corrosion. D-ring pivots freely on webbing. No wear or reduction in cross-section greater than 5%. Metal not bent or deformed. |
| Buckles and adjusters | All buckles function properly (tongue, friction, or pass-through type). Buckle tongues seat securely. No distortion, corrosion, or missing components. Adjusters hold position under load. |
| Grommets and rivets | All grommets present and intact. Rivets tight and not pulled through webbing. No deformation or corrosion around attachment points. |
| Labels and markings | Manufacturer label legible with model number, date of manufacture, and capacity. ANSI Z359.11 compliance marking visible. Unique serial number or ID traceable. |
| Indicators (if equipped) | Fall indicator not deployed. Impact indicators intact. If any indicator shows evidence of impact loading, remove harness from service immediately. |
Lanyard and Energy Absorber Inspection
| Inspection Item | What to Check |
|---|---|
| Lanyard webbing or rope | No cuts, burns, abrasion, chemical damage, or excessive wear. Rope core visible through sheath is a failure. Check entire length, including areas near connectors. |
| Snap hooks | Locking type snap hooks required. Gate closes completely, lock engages, and keeper holds gate closed. No distortion, cracks, or corrosion. Gate spring provides adequate pressure. |
| Carabiners | Gate closes and locks properly. No deformation, cracks, or excessive wear at load-bearing surfaces. Auto-locking mechanism functions correctly. |
| Energy absorber (shock pack) | Outer cover intact with no tears or evidence of deployment. Inner pack not separated, stretched, or exposed. If deployed (pack torn open), destroy the lanyard immediately. |
| Thimbles and stitching | Rope thimbles seated properly. Stitching at terminations intact. No pulled or broken stitches. Splice integrity maintained. |
| Labels | Manufacturer, model, capacity, and date of manufacture legible. ANSI Z359.13 compliance marking visible. |
Self-Retracting Lifeline (SRL) Inspection
| Inspection Item | What to Check |
|---|---|
| Housing | No cracks, dents, or deformation in the housing. No loose screws, rivets, or bolts. Swivel attachment at top rotates freely. |
| Lifeline (cable or webbing) | Cable: no kinks, broken strands, bird-caging, or corrosion. Webbing: no cuts, abrasion, or chemical damage. Lifeline extends and retracts smoothly through full length. |
| Braking mechanism | Sharp pull on lifeline engages brake and locks immediately. No hesitation or slipping. Lifeline does not continue to extend after brake engagement. |
| Connector (snap hook) | Locking snap hook gate closes and locks fully. No distortion, corrosion, or damage. Gate spring provides positive closure. |
| Impact indicator | Fall indicator not deployed. If indicator shows evidence of impact loading, remove SRL from service and return to manufacturer or authorized service center. |
| Labels and service date | Manufacturer label legible. ANSI Z359.14 compliance marking visible. If annual service is required by manufacturer, verify current service date. |
Anchorage and Anchor Connector Inspection
| Inspection Item | What to Check |
|---|---|
| Structural integrity | Anchor point shows no cracks, deformation, or loosening from the supporting structure. Bolts or welds intact and not corroded. |
| Capacity rating | Anchorage rated for at least 5,000 pounds per employee (or designed as part of a system with a safety factor of at least 2). Rating label visible. |
| Anchor connector | Beam clamps, roof anchors, or other connectors properly installed per manufacturer instructions. No slippage, corrosion, or missing components. |
| Independence | Anchorage is independent of any anchor used to support or suspend platforms. Not shared with scaffolding, material hoists, or other systems. |
| Location | Anchorage positioned to limit free fall to 6 feet or less. Located to prevent swing falls into lower levels or obstructions. Overhead anchorage preferred. |
Removal from Service Criteria
Immediate Removal Required
- Any component that has been subjected to impact loading from a fall arrest event
- Shock-absorbing lanyard with a deployed (torn open) energy absorber pack
- SRL with a deployed fall indicator or that has arrested a fall
- Webbing with cuts, tears, burns, chemical damage, or fraying that exposes inner fibers
- Hardware with cracks, distortion, corrosion that reduces cross-section, or sharp edges
- Snap hooks or carabiners that do not close and lock completely
- Missing, illegible, or removed manufacturer labels
- Unauthorized modifications, repairs, or alterations
- Equipment that has exceeded the manufacturer's recommended service life
Documentation
- Tag removed equipment as "Do Not Use" and segregate from serviceable equipment
- Document the deficiency, equipment serial number, and date removed from service
- Destroyed equipment should be cut or rendered unusable to prevent accidental reuse
- Maintain inspection records by equipment serial number for the life of the equipment
- For SRLs, contact the manufacturer or authorized service center for post-fall inspection
Best Practices
Equipment Tracking
Assign a unique ID or use the manufacturer's serial number to track each piece of fall protection equipment. Maintain a master inventory with purchase date, manufacturer, model, and inspection history. Inspection software can automate tracking, schedule annual inspections, and generate audit-ready reports by equipment serial number.
Training
OSHA 29 CFR 1926.503 requires employers to train all employees who might be exposed to fall hazards. Training must include the correct procedures for inspecting fall protection systems. Workers should be able to identify common defects and know when to remove equipment from service. Training management software can track who has been trained and when refresher training is due.
Storage and Care
Store fall protection equipment in a cool, dry location away from direct sunlight, chemicals, sharp objects, and extreme temperatures. Hang harnesses to maintain shape and prevent creasing. Do not store wet equipment in sealed bags or containers. Follow manufacturer guidelines for cleaning — typically mild soap and water, air dry only. Proper storage prevents premature degradation and extends equipment service life.
Download the Free Checklist
Get our fall protection inspection checklist in Word format. Customize it for your specific equipment inventory and site requirements.
Download Checklist (.docx)Ecesis EHS Software
Inspections
Digital inspection forms with mobile completion, photo capture, and corrective actions.
Safety Inspections
Workplace safety inspections with automated scheduling and deficiency tracking.
Preventive Maintenance
Schedule annual equipment inspections, SRL service dates, and manufacturer recertifications.
Training
Track fall protection training, competent person certifications, and authorized user qualifications.
Compliance Calendar
Track annual inspection dates, equipment service intervals, and training renewal deadlines.
Task Management
Assign and track corrective actions from defective equipment to replacement or repair.
