Inspecting Fall Protection Equipment

Slips Trips Falls
English (NZ)

The Problem

Falls are the leading cause of fatalities in construction and related industries. One of the primary reasons fall-related injuries occur is the failure to properly inspect fall protection equipment. Faulty harnesses, lanyards, or connectors can fail when needed most—leading to serious injury or death. Today, we’ll discuss how to inspect your fall protection gear to ensure it’s safe and compliant with WorkSafe New Zealand requirements.

Identify the Hazards

  • Damaged Harnesses: Cuts, frays, or tears in webbing compromise the strength and safety of the harness.

  • Faulty Hardware: Rust, cracks, or deformation in D-rings, buckles, or hooks can result in equipment failure.

  • Improperly Stored Equipment: Exposure to moisture, UV light, chemicals, or extreme temperatures weakens materials over time.

  • Lack of Inspection: Using uninspected equipment increases the likelihood of failure during a fall.

Safety Practices and Preventative Measures

Inspect the Harness

  • Check webbing for cuts, frays, abrasions, burns, or other signs of damage.
  • Stretch webbing to reveal any hidden flaws.
  • Inspect stitching to ensure no loose, torn, or broken threads are present.

Inspect Hardware

  • Look for corrosion, cracks, or deformation in D-rings, buckles, adjusters, and connectors.
  • Confirm snap hooks and karabiners are functioning correctly and that locking mechanisms operate properly.
  • Never use hardware that is bent, stiff, or difficult to engage/disengage.

Inspect Lanyards and Connectors

  • Examine shock absorbers for signs of deployment or damage.
  • Check for fraying, cuts, or exposed internal fibres.
  • Ensure lanyards and connectors are clean, undamaged, and free from corrosion.

Proper Storage

  • Store gear in a dry, cool place out of direct sunlight and away from chemicals.
  • Hang harnesses to keep their shape and prevent damage from compression or tangling.

Tag and Remove Defective Equipment

  • If equipment is damaged, tag it as “DO NOT USE” immediately.
  • Report all defects to your supervisor for replacement or inspection by a competent person.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

A worker recently fell from height while wearing a harness with hidden damage in the lanyard. The equipment had not been inspected before use. During the fall, the lanyard failed, resulting in serious injuries. This incident could have been avoided with a proper inspection routine.

Employee Responsibilities

  • Inspect all fall protection equipment before every use.

  • Follow correct storage procedures to maintain equipment condition.

  • Report any damaged or suspect gear immediately.

  • Do not use any equipment that hasn’t been inspected or is showing signs of wear.

Employer Responsibilities

  • Provide fall protection equipment that complies with AS/NZS 1891 standards.

  • Ensure employees are trained on inspection, use, and maintenance of fall protection systems.

  • Replace or repair faulty equipment promptly.

  • Establish and enforce a regular inspection and maintenance programme.

Discussion & Questions

  • "What common faults have you come across when inspecting harnesses or lanyards?"
  • "Do you feel confident inspecting your gear, or would further training be helpful?"

Encourage workers to share experiences or ask for clarification on inspection practices.

Commitment/Action Plan

Let’s commit to inspecting all harnesses, lanyards, and connectors before every use. Take 5 minutes at the start of each shift to check your gear—your life could depend on it.

Wrap-Up

Falls from height can be catastrophic, but they are preventable when we use the right equipment and inspect it regularly. Thank you for taking fall protection seriously and helping ensure our site remains safe for everyone.

Standards Overview

WorkSafe NZ requires that:

  • All personal fall arrest equipment must comply with AS/NZS 1891.
  • Equipment must be inspected before use and undergo regular formal inspections by a competent person.
  • Defective equipment must be withdrawn from service immediately and either repaired by a qualified professional or replaced.

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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Last Updated:
April 28, 2025