A full body harness is one of the most critical pieces of fall protection equipment on your jobsite. To perform effectively, it must be in proper working condition every time it is used.
Regular inspections identify signs of wear, damage, or misuse before they compromise safety. This guide walks you through what to check and how to train your crew to inspect harnesses confidently and consistently.
Compliance with OSHA 1926.502 is essential, but the real goal is keeping your team equipped with gear they can trust.
7 Step Full-Body Harness Inspection Checklist
1. Start with the Back D-Ring
Run your fingers around the entire D-Ring to check for:
- Cracks in the metal
- Pitting or corrosion
- Deformation or bending
- Surface roughness or sharp edges
If any damage is found, remove the harness from service.
2. Check the Back Plate
The back plate is the plastic backing where the D-Ring attaches. Examine this component for cracks in the plastic material.
What to Check:
- Hairline cracks in any area of the plate
- Stress marks around attachment points
- Discoloration or brittleness
Hairline cracks may expand under load and compromise the harness. If damaged, remove the harness from service.
3. Inspect Every Inch of Webbing
Webbing inspection requires both visual examination and hands-on evaluation to detect damage that could compromise the harness.
Visual Inspection: Examine all webbing straps systematically. Bend each section of webbing in a U-shape to expose both sides and inspect for:
- Cuts or nicks in the material
- Burns or heat damage (melted, scorched, or darkened areas)
- Frays along edges or through the weave
- Tears of any size
- Broken, loose, or pulled threads in stitching areas
- Discoloration from chemical exposure
- Stiffness or brittleness in the material
Tactile Inspection: Remove your gloves and run your hands along every strap and stitching area. Feel for:
- Rough spots or texture changes that indicate wear
- Stiff or brittle areas that suggest chemical or heat damage
- Soft spots that could indicate internal fiber damage
- Irregularities in thickness or consistency
If the webbing shows any visual damage or feels different from normal working condition, remove the harness from service immediately.
4. Test the Load Indicator
Load indicators are designed to show when a harness has experienced fall forces. Common types include stitched loops that tear apart or colored fabric that becomes visible when deployed. The indicator is typically located on the back of the harness near the dorsal D-Ring.
What to Check:
- Broken or separated stitching in the indicator area
- Torn fabric loops
- Exposed colored warning fabric
- Visible damage to the indicator mechanism
Check your harness manual for the specific type and location of your load indicator if you are unsure what to look for.
If indicators are deployed, remove the harness from service.
5. Check All Labels
Labels must be present and legible to meet OSHA requirements and ensure traceability.
How to Inspect:
- Open the protective covers over labels
- Verify all labels are present and legible
- Confirm you can read manufacturer information, model numbers and dates
If labels are unreadable or missing, remove the harness from service.
6. Test Every Buckle
Every buckle must function properly every time. Check all buckles on your harness: chest strap, leg straps and any waist or positioning straps.
What to Check:
- Buckles connect and release smoothly through multiple cycles
- Buckles adjust properly along the webbing
- Hardware shows no cracks, pitting, deformation, or corrosion
- Grommets are secure and not bent or deformed
- Buckles hold securely when fastened
How to Test: Buckle each connection and pull firmly on the straps. The buckle should hold securely without slipping or releasing. If you can pull the webbing through the buckle when it is locked, the buckle has failed.
If any buckle fails, remove the harness from service.
7. Inspect Tongue and Buckle Leg Straps
If your harness has tongue and buckle leg straps, complete these additional checks.
What to Check:
- All grommets are present and not bent or deformed
- Buckle function operates correctly (refer to step 6 testing procedures)
- Straps hold firm when pulled after buckling
If any components are damaged or non-functional, remove the harness from service.
Need new harnesses after your inspection? Check out Malta Dynamics’ full body harnesses.
When to Remove Your Harness From Service
The cost of replacing a harness is minimal compared to the consequences of equipment failure. Trust your inspection findings. If equipment shows signs of damage, wear, or deterioration that raises safety concerns, remove it from service immediately.
Experienced workers can identify when equipment no longer meets safety standards. When equipment condition is questionable, err on the side of caution and replace it.
When Are Harnesses Unacceptable to Use?
- Deployed load indicators – The harness was in a fall and should not be used again
- Cuts or tears in webbing – No matter how small, cuts weaken the entire system
- Cracks in any hardware – D-Rings, buckles, or grommets with cracks are likely to fail
- Burns or heat damage – Melted, scorched, or discolored materials lose strength
- Chemical damage – Webbing that’s stiff, brittle, or discolored from exposure
- Missing or unreadable labels – Cannot verify the harness meets safety standards
- Broken stitching – Especially at attachment points where loads concentrate
- Bent or deformed hardware – Will not function properly when needed
- Edge wear exceeding 10% – If webbing edges show more than 10% wear, retire the harness. Measure the original width and compare to the worn area.
- Harnesses exceeding 5-year lifespan – The general lifespan of a full-body harness is about 5 years. Retire harnesses after 5 years or per manufacturer recommendations.
Further review OSHA’s requirements for removing a harness from service.
When Are Harnesses Still Good to Use?
- Light surface dirt – Clean it and inspect underneath
- Minor scuffing on hardware – As long as there are no cracks or sharp edges
- Slight fading – Normal UV exposure that doesn’t affect material strength
- Normal wear patterns – Smooth, even wear without cuts or fraying
How Often Should You Inspect Your Harnesses?
Daily Inspections
Inspect your harness before and after every shift per OSHA 1926.502(d)(21).
Competent Person Inspections
In addition to daily checks, you also need:
- At a minimum, a competent person must inspect each harness at least once a year. More frequent inspections—such as every 6 months—are recommended by ANSI.
- If you are working in harsh conditions or your harnesses undergo heavy use, conduct more frequent inspections.
Comprehensive inspections can identify problems your daily checks might miss. A competent person has the knowledge and training to identify serious issues.
Inspection Documentation
Record every training session, daily check and full inspection. Proper documentation provides legal protection and demonstrates regulatory compliance.
In the event of an incident, investigators will require inspection records. Without documentation, there is no proof that inspections were conducted—which can expose your company to legal and financial liability.
Records also help track equipment lifecycle, identify patterns of damage and demonstrate due diligence. They show your commitment to safety and regulatory compliance.
For daily checks, maintain a simple system that workers will consistently follow. Document who inspected the equipment, the date of the inspection, pass/fail results, any problems found and corrective actions taken. Standard logbooks are sufficient for daily documentation.
For formal inspections conducted by a competent person (someone who has the knowledge and authority to identify hazards and take corrective action), the following must be documented:
- Complete equipment identification including serial numbers, model numbers and manufacturer
- Inspector name and qualifications
- Inspection date and detailed findings
- Pass/fail determination with reasoning
- Corrective actions taken
- Next inspection due date
Keep formal inspection records for at least three years after the equipment is retired. Daily logs should be maintained for the lifetime of the harness.
Malta Dynamics Professional Inspections and Training Options
Malta Dynamics provides professional fall protection inspections to ensure your equipment meets safety standards. We design and test the gear we inspect. We know what failure points look like because we have seen them in the field.
Need to train your team? Our experts visit your jobsite and conduct fall protection trainings.
Additionally, our 16-hour competent person training offers the proper training to oversee fall protection programs, identify predictable hazards and implement prompt corrective measures to maintain a safe work environment on construction jobsites.
Inspection Best Practices
A proper inspection routine keeps your crew safe, your project on schedule and your business compliant with regulations.
Make inspection a standard procedure, not an additional task. Train your crew to see it as part of the job. When everyone knows what to look for and takes it seriously, equipment failures are prevented.
The gear that protects workers only functions when properly maintained. Make harness inspection part of your daily routine. It requires only a few minutes and ensures your gear is ready when needed.
When in doubt, replace the equipment. The cost of replacing a harness is minimal compared to the consequences of equipment failure. Every inspection is a step toward maintaining workplace safety.
Trust Malta Dynamics for Your Fall Protection Needs
Malta Dynamics has been protecting workers at height for over three decades. We design, manufacture and personally use all our safety fall protection solutions.
Our harnesses are built for the work you do, tested beyond industry standards and backed by experts who know what it takes to keep you safe.
Ready to upgrade your fall protection?
- Browse our complete selection of full body harnesses built for every jobsite
- Get professional equipment inspections with our fall protection inspection services
- Train your team right with our 16-hour competent person training: This course meets OSHA requirements for those responsible for overseeing fall protection systems.
Not sure where to start? Contact Malta Dynamics today and let our experts help you build a safer jobsite—one harness at a time.
