Harnesses and Lanyards
The Problem
Falls are the leading cause of fatalities in the construction industry, accounting for around 30% of all workplace deaths. Many of these incidents happen because workers either don’t use fall protection equipment correctly or use damaged gear. Today, we’ll focus on harnesses and lanyards—critical tools for fall protection—and how to use and maintain them properly to stay safe.
Identify the Hazards
- Improper Fit: A harness that doesn’t fit properly may not protect you during a fall and could cause further injury.
- Damaged Equipment: Frayed lanyards, worn webbing, or corroded buckles compromise safety.
- Incorrect Use: Using the wrong type of lanyard or failing to connect to an approved anchor point increases the risk of failure.
- Lack of Inspections: Skipping regular checks can allow serious faults to go unnoticed until it’s too late.
Safety Practices and Preventative Measures
To mitigate these risks, always follow these safety practices:
Selecting the Right Equipment
- Use a harness designed to suit your body size and weight.
- Choose the correct type of lanyard for your task (e.g. energy-absorbing lanyards for fall arrest).
Inspecting Your Equipment
- Harness: Check for frayed, cut, or worn webbing. Inspect buckles for rust, cracks, and functionality.
- Lanyard: Look for damage such as broken stitching or exposed fibres. Ensure snap hooks and connectors are undamaged and lock correctly.
- Remove defective equipment from service immediately and report it.
Proper Fitting
- Adjust the harness snugly—it should fit close to the body without restricting movement.
- Ensure the D-ring sits in the centre of your back between the shoulder blades.
Using the Equipment Safely
- Always attach your lanyard to a certified anchor point rated to withstand at least 15kN (approx. 5,000 pounds).
- Keep the anchor point above head height to reduce free-fall distance.
- Never tie off to scaffolding rails, handrails, or other non-certified anchor points.
Storage and Maintenance
- Store harnesses and lanyards in a dry, clean place away from UV exposure, moisture, and chemicals.
- Avoid exposing gear to sharp edges or heat sources.
Real-Life Case or Scenario
E.g. A worker recently fell 4.5 metres from a roof when their harness failed during a slip. Post-incident investigation revealed the webbing had multiple tears that had gone unnoticed. This tragic incident could have been prevented by conducting a proper inspection. Regular checks save lives—don’t take shortcuts
Employee Responsibilities
- Inspect your harness and lanyard before every use.
- Report and tag any damaged equipment immediately.
- Use fall protection equipment correctly, and connect only to certified anchor points.
- Always wear and adjust your harness properly.
Employer Responsibilities
- Provide certified fall protection systems that meet AS/NZS 1891 standards.
- Ensure all fall protection equipment is regularly inspected and maintained.
- Train workers on the proper use, adjustment, and inspection of harnesses and lanyards.
- Provide certified anchor points at all work-at-height locations.
Discussion & Questions
- “Have you ever come across a damaged harness or lanyard? What was done about it?”
- “What are the challenges you face when working with harnesses and lanyards?”
Encourage team members to share their experiences or raise any concerns.
Commitment/Action Plan
Let’s commit to inspecting our fall protection gear before every shift. Take five minutes to ensure your harness fits well and your lanyard is safe to use. Make safety personal—because a few minutes of prevention could save your life.
Wrap-Up
Fall protection equipment works—when it’s in good condition and used properly. Don’t take chances with your safety. A harness that fits well, is correctly worn, and thoroughly inspected can be the difference between life and death. Thanks for doing your part to keep the site safe.
Standards Overview
Under the Health and Safety at Work (General Risk and Workplace Management) Regulations 2016 and WorkSafe NZ guidance:
- Workers must use fall protection where there is a risk of falling from a height.
- Harnesses and lanyards must meet AS/NZS 1891 standards and be inspected regularly.
- Employers must ensure fall arrest systems are properly maintained and workers are trained in their correct use.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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