Personal Fall Arrest Systems: Selection, Inspection, and Fit

Why Personal Fall Arrest Systems Matter

Falls are the leading cause of fatalities in construction. A personal fall arrest system (PFAS) stops a worker's fall before the worker strikes a lower level. On a roof, that system is often the last — and only — barrier between a slip and a fatal outcome. OSHA's fall protection standards require that workers on roofs six feet or more above a lower level be protected, and a PFAS is one of the accepted means. A PFAS works only if every component is in good condition, properly connected, and correctly worn. This lesson covers how to inspect, remove from service, and don each component.

The Three Components of a PFAS

Full-body harness. The harness distributes fall-arrest forces across the thighs, pelvis, chest, and shoulders. It is the only body-worn device acceptable for fall arrest — body belts are not permitted as the sole means of fall arrest. The dorsal (back) D-ring, positioned between the shoulder blades, is the required attachment point for fall arrest.

Connecting device. A shock-absorbing lanyard or a self-retracting lifeline (SRL) links the harness to the anchor. A shock-absorbing lanyard contains a tear-webbing pack that deploys during a fall, reducing the arrest force on the body to no more than 1,800 pounds — the OSHA limit. An SRL spools out as you move and locks instantly when a fall begins, limiting free-fall distance. Six-foot lanyards are common, but always calculate the total fall clearance needed before selecting lanyard length.

Anchorage. A PFAS must be connected to an anchorage capable of supporting the forces of a fall. Anchorage selection is covered in a separate lesson; today the focus is the harness and connecting devices.

Inspection: General Rules

Inspect every PFAS component before each use. Manufacturers provide specific inspection sequences in their product guides — follow them exactly. OSHA requires that equipment be removed from service when it shows any of the discard criteria below, and after any fall event (even if no damage is visible).

Never use equipment that has arrested a fall until a competent person has inspected and cleared it. When in doubt, tag it out.

Inspection Criteria: What to Look For

Webbing. Run the webbing slowly through your fingers, feeling both faces and all edges. Remove from service if you find: cuts, abrasions that expose fiber, fraying, broken stitching at load-bearing seams, chemical damage (stiffness, discoloration, brittleness), burns, or heat damage (glazing, melting).

Hardware — D-rings, buckles, and snap hooks. Inspect all metal components visually and by feel. Remove from service if you find: deformation (bent, warped, or cracked metal), corrosion that pits the surface, sharp edges that could cut webbing, or snap hooks whose keeper gates do not open and close freely and lock positively. A snap hook keeper must spring shut and resist accidental opening — this is the auto-locking function. Gate deflection or failure to lock is an immediate discard.

Shock pack (on lanyards). The tear-webbing pack is housed in a protective sleeve. Look for a deployed (expanded or open) sleeve, which means the pack has been activated in a fall. Also look for cuts, burns, or chemical staining on the sleeve. A deployed pack must be removed from service — it cannot be reset.

Self-retracting lifeline. Check the housing for cracks or damage. Pull out several feet of lifeline and release it — it should retract smoothly. Tug the line sharply to confirm the locking mechanism engages. Inspect the connecting snap hook using the same criteria as above. Check for corrosion, damage to the swivel, and that the manufacturer's inspection label is present and legible.

Labels. Every component must have a legible manufacturer's label showing at minimum the product model, manufacturing date, and applicable standards. A missing or illegible label is a discard criterion because you cannot verify the equipment's specifications or service history.

Removing Equipment from Service

When a defect is found, attach a red out-of-service tag to the component immediately, note the defect on the inspection log, and set it aside so it cannot be used by another worker. Never attempt field repairs on PFAS webbing or hardware. Only the manufacturer or an authorized service center may evaluate equipment for re-use after a fall.

Donning a Full-Body Harness: Step-by-Step

1. Hold the harness by the dorsal D-ring and shake it out so all straps hang free and untangled.

2. Slip both arms through the shoulder straps, as you would a backpack.

3. Secure the chest strap buckle and position the strap at mid-sternum — not at the throat and not at the abdomen.

4. Reach between your legs and pull the leg straps forward; connect and secure each leg loop buckle. Leg loops should be snug enough that you can slide two fingers underneath — not so loose they could slip off.

5. Adjust all straps so no webbing is twisted. Twist-free webbing distributes force correctly.

6. Ensure all tongue buckles are fully engaged — the tongue must pass through the buckle frame and the excess strap must be captured in its keeper.

7. Confirm the dorsal D-ring sits between your shoulder blades and is accessible — not shifted to the side.

The 12-Point Peer Fit Check

After donning, a second person checks all 12 fit points on the standardized checklist. No single point can be skipped. The instructor signs off only after all 12 points are marked correct. This two-person verification mirrors the buddy-check culture required on professional job sites.

Safety Reminders

• Never use a PFAS as a positioning or restraint system unless it is specifically rated and configured for that use.
• Store harnesses away from direct sunlight, chemicals, and sharp objects.
• Follow the manufacturer's stated service life — most synthetic-webbing harnesses have a defined retirement date regardless of appearance.
• A PFAS does not prevent a fall; it arrests one. Whenever possible, eliminate the fall hazard first.