Do Fall Protection Harnesses Expire?

A fall protection harness is a safety harness that connects a worker to a fall protection system. It includes various straps that fit around the thighs, chest, hips, shoulders, and back that help keep workers safer in the event of a fall. The design also helps to keep workers upright to prevent suspension trauma and make it easier to rescue them.

To ensure your harnesses work as intended, you’ll need to inspect them before and after use. Knowing what to check for is essential to prevent life-threatening situations. Keep reading to learn more about the life span of safety harnesses and what signs of wear and tear to look out for.

Life Span of Fall Protection Harnesses

Several factors affect the life span of the harness, including the make and model. Each manufacturer will have specific guidelines on longevity — some even place their life span at up to 10 years. How long you can use a harness will depend on the equipment’s capabilities, the environment you use it in and the manufacturer’s recommendations. 

While there are no specific regulations about the harness’s life span, it’s up to employers to regularly inspect safety harnesses for wear and tear, especially after events that may compromise safety. There are several factors that can contribute to your harnesses’ wear and tear: 

• Snagging on objects can tear the fabric or stitch, causing a weak spot that could fail during a fall. 
• Paint and chemicals that get onto the material can weaken the fabric. It’s important to remove chemicals as soon as possible according to the manufacturer’s guidelines. 
• UV rays can cause deterioration over time, weakening the fabric. When not in use, store your harness away from direct sunlight.
• The metal components, such as the D-ring and buckles, are vulnerable to caustics and acids. When metals come into contact with these substances, cleaning them as soon as possible is essential. 
• Improperly storing the harnesses can also result in wear and tear.

When Do Fall Protection Harnesses Expire?

Fall protection harnesses do expire, but the reality is the date may not be in accordance with the manufacturer’s guidelines. The Occupational Safety and Health Administration (OSHA) and American National Standards Institute (ANSI) safety standards also don’t give specific codes or standards for how long a harness should last. You need to consider the variables that affect your unique working environment. The OSHA will use the manufacturer guidelines as a way to determine whether there has been any violation, for example, if you failed to care for or use the harness correctly.

While the manufacturer may give a recommendation of five years before expiration, they won’t know what chemicals your harness is exposed to and the environmental factors such as sun and pollution exposure. A harness worn daily may not make it five years, whereas if worn once a week or month, it will last much longer. A qualified onsite inspector is the best person to tell you whether your harness is expired.

To help you keep track of the state of your harness, you should mark the date you first used it — not the day it was manufactured. 

The inspector should be a competent person, as defined by the OSHA. This person uses manufacturers’ recommendations and OSHA and ANSI rules as guidelines. There are a lot of helpful indicators and reminders for what to check for in Appendix C of the OSHA standards.

Signs of Wear and Tear: When to Replace Your Harness

You can look out for specific signs that indicate your harness is worn out:

• Physical damages: When the webbing rubs against abrasive surfaces, it can cause damage. When there are multiple frays throughout the webbing, and it has begun to ripple and has an inconsistent thickness, it’s time to replace the harness. Sometimes, the material catches on a surface and causes a tear in the webbing. Some manufacturers state that tears of a specific length are acceptable — however, it is wise to replace a harness once it has any cut or tear in it. 
• Environmental damage: Workers who use equipment for welding or work with hot materials may accidentally burn their harnesses. The melting point of the equipment varies by manufacturer, but for most, it is 200 degrees Fahrenheit. Usually, any burn mark is enough reason to retire a harness. Exposure to the sun will cause the harness to change color over time. If the harness is significantly faded, it will be time to change it. Chemical exposure will also make the harness feel hard and brittle.
• Wear from usage: Frequently wearing the harness will also cause it to degrade over time. Friction on the fabric will cause it to fray. The metal components, such as the D-ring, may have dents and cracks from repeated use.

Maintenance and Checks for Fall Protection Harnesses

The best way to determine whether a harness is safe to use or if you should retire it is to do a thorough inspection. A qualified inspector should check the harness before use. ANSI recommends that you carry out a formal inspection at least every six months. To keep track of the condition of the harnesses, the inspector should document each inspection in a log sheet. While the harness is inspected, it should be out of use, giving the inspector time to check it thoroughly. 

The inspection should follow these steps during their checks: 

1. Inspect webbing and stitching: Check for cuts, fraying, excessive wear, missing or alternate straps, burns, UV damage and chemical and heat exposure. Start at one end of the webbing, hold it with both hands and stretch it 8 inches apart to flex the fabric. This will help you spot defects. 
2. Inspect metal and plastic parts: The buckles should engage and disengage quickly and smoothly. Check for cracks, corrosion, deformities, deep pitting, sharp edges, cuts and chemical or heat exposure. The D-ring should not have any signs of damage. Make sure to check that all of the components are still in place.
3. Inspect load indicators: The load indicators are parts of the webbing that are folded over and securely stitched. If an indicator has a rip or is separating, the harness experienced a fall and is no longer safe to use.
4. Inspect labels: The labels on the harness need to be visible and fully legible.
5. Complete inspection log sheet: Keep documentation of the inspection process that notes the condition codes, assessment sores and additional comments. It’s important to note that a harness fails or passes an inspection — there is no in-between. 

You also need to store your harnesses correctly to ensure their longevity. Keep it away from direct sunlight, moisture and exposure to extreme temperatures. It’s recommended to keep your harnesses either hanging, flat or neatly folded to prevent unnecessary wear. If you hang it, make sure it’s by the D-ring and not the webbing.

The Cost of Not Replacing an Expired Harness

Using a damaged harness increases the risk of failure should an accidental fall occur. None of your workers should wear a harness that has failed an inspection. Make sure to dispose of harnesses that fail the inspection and replace them with new ones. Using harnesses past their expiration can result in severe injuries and even fatalities. The result is devastating to the lives of the workers and their families. The consequences can also be overwhelming for your business. 

Trust Rigid Lifelines With Your Fall Protection Harnesses

When your workers work at height, you need trustworthy safety equipment. Regularly and thoroughly inspecting your harnesses is essential to keep your employees safe. Using damaged equipment can cause it to fail, resulting in devastating consequences. A qualified onsite inspector will help you check your equipment and give you peace of mind that it’s safe to use. Immediately retire any harness that doesn’t meet the required safety standards. Correctly storing your equipment will also help it last longer.

We have extensive experience in engineering and designing safety equipment that complies with OSHA and ANSI regulations. To protect your workers, contact us today for the fall protection solution that suits your needs.