It’s a beautiful day, the plans are set, and the work is waiting—sixty feet up. While working at heights presents inherent risks, the more insidious danger can often lie in assuming the equipment we entrust our lives to is as ready for the day as we are.

Most harness failures start small. A loose thread here, a buckle that doesn’t quite lock there. Left unchecked, these tiny issues can turn an otherwise routine workday into a life-altering, potentially fatal event. That’s why OSHA requires fall protection equipment to be inspected before each use. The good news? A systematic, hands-on inspection only takes a few minutes to reveal most potential safety issues before anyone leaves the ground. 

Below, we walk you through the essentials of inspecting fall safety harnesses to help ensure you and your team go home safely at the end of the day. 

Create the Right Environment for Inspection

Before you begin, set yourself up for success. Don't rush an inspection in a poorly lit corner of a truck bed or a noisy gang box area. Take the harness to a well-lit space where you can lay it out flat without distractions. Remove your work gloves so you can properly feel for subtle damages like stiff fibers, burrs on metal, or pulled stitches. Inspecting fall safety harnesses isn’t just about looking for damage; it’s a tactile investigation and you need your fingertips to catch what your eyes might miss. 

Dedicating a specific time and place for this critical ritual reinforces its importance and helps ensure nothing gets overlooked.

Check the Labels and Tags

Think of labels as the harness’s passport. They prove where it came from, when it was made, and whether it meets safety standards. If the label is missing, unreadable, or tampered with, the harness is automatically out of service. No exceptions. 

Labels are typically sewn into the back or shoulder straps, near the dorsal D-ring or chest area. You should be able to clearly read the manufacturer’s name, the date of manufacture, the model or part number, and the markings indicating it meets ANSI/ASSE Z359 standards.

Check the Impact Indicator

Modern full-body harnesses are required to have a built-in fall or impact indicator. These indicators are typically folded and stitched sections of webbing (often located near the dorsal D-ring) that are designed to tear or deploy, providing a clear visual signal that the harness has been subjected to the force of a fall.

If the indicator shows signs of deployment (frayed stitching, torn webbing, or a visible “activated” marker), the harness has already done its job and must be retired immediately. 

Inspect the Webbing and Stitching 

Hold the harness by the back D-ring, letting it hang freely to get a clear, untangled view. Pinch the webbing between your thumb and forefinger, bending it in a "U" shape to reveal any fine cuts, broken fibers, or frayed edges. Look for:

• Burns: Hard, shiny spots from weld spatter or friction.
• Chemical Damage: Stiff, brittle, or discolored patches, or strong chemical smells. 
• UV Degradation: Fading colors and brittle fibers from sun exposure.

Pay special attention to high-wear zones where buckles or D-rings rub. A harness that looks fine overall can still be compromised at these stress points. 

Test the Hardware

Every piece of hardware, including D-rings, buckles, grommets, adjusters, strap keepers, and other critical connection points is a potential weak link. Check: 

• D-Rings: No cracks, pits, or sharp edges. Should pivot freely. 
• Buckles: Must connect securely and release only when intended. On straps with tongue buckles, check whether any of the grommet holes are stretched or elongated
• Adjusters: Should grip webbing tightly under force.

Tug hard on every connection. If it slips or feels loose, it’s best to set the safety harness aside. 

Out of Service Means Out of Reach: End-of-Life Protocols for Fall Safety Harnesses

A questionable harness is a dangerous harness. OSHA and ANSI standards are clear: if a harness shows signs of wear that could affect performance, it must be removed from service immediately. If you find any questionable damage during inspection, follow the rule of thumb: when in doubt, throw it out. Don’t stash compromised gear in a corner or leave it hanging on a rack — if it’s out of service, it needs to be out of reach. To prevent accidental reuse, they should be rendered unusable: cut the straps on harnesses, remove or destroy the hooks on lanyards, and clearly tag them as “Do Not Use.”

If you have any questions or concerns, your safety equipment suppliers are valuable sources of information. The most trustworthy providers don’t just sell gear — they stand behind it, vet it thoroughly, and help you make informed decisions that keep your crew safe.