1. The Harness is Old or Weathered

As your harness ages, the materials can weaken, reducing its effectiveness in protecting you. A harness that is old or weathered can no longer provide the necessary support in the event of a fall.

Signs of Wear: Look for visible signs like frayed or torn fabric, worn-out stitching, or crust buildup on the webbing. If the fabric feels brittle or looks faded from prolonged exposure to sunlight or environmental elements, it’s time for a replacement.

Why It’s a Concern: These signs indicate that the harness’s structural integrity has been compromised, and it may not perform as effectively in preventing injury during a fall.

2. The Hardware is Compromised

The hardware of a safety harness, such as D-rings, buckles, and other metal components, is crucial for securing you in place. If these parts are damaged, they could fail when you need them most.

Signs of Damage: Check for cracks, chips, or dents in metal components. Look for sharp abrasions or signs of rust, which can weaken the hardware over time. If any of the buckles or attachment points are malfunctioning or do not lock securely, they need to be replaced.

Why It’s a Concern: Compromised hardware can fail during a fall, causing the harness to break loose or fail to support you properly. Regular inspections of hardware can help catch these issues early.

3. The Harness Has Taken an Extreme Fall

If your harness has been involved in a fall, even if it appears undamaged, it must be replaced immediately. Both OSHA and ANSI guidelines mandate that any harness involved in a fall should be removed from service.

Why It’s a Concern: The force from a fall can cause micro-damages to the fabric and hardware, which may not be visible but can still affect the harness’s ability to protect you in future incidents. Harnesses that have taken a fall may not be able to withstand another impact, so replacement is essential for your safety.

1. Visual Inspection

Start with a visual check of the entire harness. Look for any obvious signs of damage or wear.

Fabric and Webbing: Examine the webbing for fraying, cuts, burns, or discoloration. Pay close attention to high-stress areas like the shoulder straps, leg straps, and back. If the fabric feels stiff, brittle, or shows any signs of damage, it could indicate that the harness is no longer safe to use.

Stitching: Check all the stitching for signs of unraveling or loose threads. Any stitching that is coming apart or damaged should be a red flag that the harness is compromised.

Labels and Markings: Ensure that all safety labels are still visible and legible. The labels provide crucial information about the harness’s specifications, certifications, and expiration date. If these labels are worn out or missing, it may indicate the harness has been used extensively or improperly stored.

2. Inspect the Hardware

The hardware (D-rings, buckles, connectors, and adjustment points) is critical for ensuring your safety. Properly functioning hardware is vital for maintaining the harness’s integrity during use.

D-rings: Inspect the D-rings for any cracks, dents, or other visible damage. They should not be bent, broken, or rusted. The rings should rotate freely and function as designed.

Buckles and Fasteners: Check that all buckles and fasteners work smoothly. They should lock into place securely and adjust without resistance. If they are difficult to adjust or don't lock properly, they could fail when needed most.

Webbing Connectors and Attachment Points: Ensure all webbing connectors are intact and have no signs of wear. Check the attachment points, such as front, back, and side D-rings, for any damage or bending.

3. Test the Fit

A harness that fits improperly can be uncomfortable and unsafe. Make sure your harness is adjusted correctly for a secure fit.

Straps: Adjust the straps so that the harness fits snugly but isn’t too tight. There should be no excessive slack in the straps, and they should be secure, preventing any movement that could compromise safety.

Shoulder and Leg Loops: Ensure that the shoulder straps and leg loops are comfortable but secure. You should be able to move freely without the harness shifting out of place, but it should fit tightly enough to prevent any gaps.

Proper Positioning: Check that the harness sits correctly on your body, with the attachment points aligned properly. The D-rings should rest in the center of your back, and the harness should distribute weight evenly across your body.

4. Functional Check

After completing the visual inspection, conduct a functional check to make sure that the harness operates as it should.

Test Buckles: Open and close the buckles several times to ensure they are functioning properly. The buckles should click into place without any difficulty, and the webbing should slide smoothly through them.

Check Adjustment Points: Ensure that all adjustment points are easy to tighten and loosen, and that they stay secure once adjusted. They should not slip or become loose under pressure.

Test Attachment Points: Try to move the D-rings and other attachment points to ensure they remain secure. You should not hear any rattling or feel any instability in the attachment points.

5. Look for Signs of Damage from Previous Falls

If your harness has been used in a fall, even if there are no visible signs of damage, it must be replaced. Falls create forces that can weaken the materials and hardware, even if they aren’t immediately apparent.

Warning Signs: If your harness has been subjected to a fall, look for any areas where the webbing may have been stretched or damaged by the force of the impact.

OSHA and ANSI Guidelines: Follow OSHA and ANSI guidelines, which require any harness that has been involved in a fall to be immediately taken out of service and replaced, regardless of visible damage.

6. Record Your Inspections

Keep a record of your safety harness inspections to ensure that they’re happening regularly and any potential issues are tracked.

Inspection Log: Use a checklist or log to document each inspection, noting the date, any issues found, and whether the harness is safe to use or needs replacing. At MTN, we have included a safety harness inspection checklist on our website that can help you identify if the harness is safe for use.

Compliance: Regular documentation of harness inspections can help with compliance to safety regulations and ensure that you're adhering to industry best practices.

Proper Storage

Storing your harness correctly is key to preserving its integrity. Poor storage practices can lead to premature damage, even if the harness is not in use.

Avoid Sunlight and Humidity: Store your harness in a cool, dry place away from direct sunlight. UV rays can degrade the webbing, while excess moisture can lead to mold, mildew, and material degradation.

Storage Position: Always hang the harness in a way that prevents it from being crumpled or compressed. This will help avoid unnecessary wear on the straps and buckles.

Cleaning and Maintenance

Regular cleaning ensures your harness stays in top condition, especially if it's exposed to dirt, sweat, or other contaminants.

How to Clean: Follow the manufacturer’s instructions for cleaning your harness. Typically, harnesses should be hand-washed with mild detergent and air-dried. Avoid machine washing or using harsh chemicals, as they can weaken the fabric.

Maintenance: Check for signs of wear during cleaning, such as fraying or damage to the hardware. Address any issues immediately to prevent further damage.

Avoid Exposure to Harsh Conditions

Exposure to chemicals, UV light, or extreme temperatures can degrade the materials of your harness.

Chemical Exposure: Keep your harness away from harsh chemicals, oils, or solvents that could damage the webbing or buckles.

Temperature: Avoid exposing your harness to extreme temperatures. Excessive heat can weaken materials, while freezing conditions can make the webbing brittle and prone to cracking.

Disposal

Once a harness has reached the end of its useful life, it's crucial to dispose of it safely. Continuing to use a worn-out harness can lead to dangerous situations.

Safe Disposal: Cut the harness into pieces to ensure it can’t be reused by someone else. This prevents anyone from unknowingly using a compromised harness.

Check Manufacturer Guidelines: Some manufacturers offer specific disposal instructions or services for old harnesses, so always check the label or manufacturer’s website.

Recycling Options

Many harnesses are made from materials that can be recycled, though this varies depending on the manufacturer and harness type.

Recycling Programs: Some companies or organizations may offer harness recycling programs. If available, it’s a good idea to take advantage of these services to help keep materials out of landfills.

Environmental Impact: Recycling ensures that the materials from old harnesses are repurposed for other uses, reducing environmental waste and supporting sustainability efforts.