Inspecting Fall Protection Gear Toolbox Talk

Fall protection equipment is often the last line of defense against a serious or fatal fall. Harnesses, lanyards, self-retracting lifelines, connectors, and anchor devices must be inspected before each use to ensure they will perform as designed. Even minor damage can compromise the equipment's ability to protect a worker during a fall.

This toolbox talk reviews how to inspect fall protection gear, recognize signs of damage, and remove unsafe equipment from service.

Why This Matters

• Damaged fall protection equipment may fail during a fall.
• Daily inspections help identify wear before it becomes a serious hazard.
• Proper inspections reduce the risk of equipment failure and worker injury.
• Equipment exposed to chemicals, heat, UV light, or impact may no longer be safe.
• Workers share responsibility for ensuring their equipment is safe before every use.

Common Hazards

• Frayed, cut, burned, or excessively worn webbing.
• Damaged stitching or loose seams on harnesses and lanyards.
• Cracked, bent, corroded, or deformed hooks, buckles, or D-rings.
• Self-retracting lifelines that do not extend, retract, or lock properly.
• Missing labels or inspection records where required.
• Equipment contaminated with paint, chemicals, oil, or concrete.
• Using equipment that has already arrested a fall.
• Improper storage causing unnecessary wear or damage.

Safety Checklist

Before Work Begins

• Inspect every component of the fall protection system before each use.
• Check webbing for cuts, tears, burns, abrasions, mold, or excessive wear.
• Inspect stitching for broken, loose, or pulled threads.
• Examine buckles, D-rings, carabiners, and hooks for cracks, corrosion, distortion, and proper operation.
• Test self-retracting lifelines to ensure they extend, retract, and lock correctly.
• Verify inspection labels remain legible and required periodic inspections have been completed.
• Remove damaged or questionable equipment from service immediately.

During Work

• Protect equipment from sharp edges, heat, chemicals, welding sparks, and moving machinery.
• Avoid tying knots in lanyards or modifying any component.
• Report any damage discovered during the shift.
• Do not share or exchange equipment without confirming it has been inspected.
• Store equipment properly when not in use to prevent unnecessary damage.
• Replace any equipment that has been subjected to a fall, following company procedures and manufacturer requirements.

Crew Talking Points

• Has everyone completed a pre-use inspection of their fall protection gear?
• What signs of damage require equipment to be removed from service?
• Who performs the required documented inspections on this site?
• How should damaged equipment be tagged and reported?
• Where should fall protection gear be stored after use?
• Speak up immediately if you are unsure whether any equipment is safe to use.

Stop Work If

• Your harness, lanyard, connector, or lifeline shows signs of damage.
• Any component has been involved in a fall and has not been removed from service.
• Connectors do not lock properly or hardware is cracked, bent, or corroded.
• Required inspection labels are missing or unreadable where applicable.
• You cannot verify that the equipment is appropriate for the task.
• You have any doubt about the condition or reliability of the fall protection system.

Final Reminder

Inspect your fall protection gear before every use. If you find damage, excessive wear, missing components, or anything that raises concern, remove the equipment from service immediately and replace it before working at height.