Fall Protection Inspection Checklist
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Why this inspection matters#
Falls to a lower level are the leading cause of construction fatalities — roughly a third of the total in recent BLS Census of Fatal Occupational Injuries years, the single largest cause on the list. Fall protection only works if every link in the system is sound, and damaged components fail at a fraction of their rated load. ANSI Z359 and OSHA 1926.502(d)(21) require personal fall arrest equipment to be inspected prior to each use by the user for wear, damage, and deterioration, with defective components removed from service — and industry practice adds a documented competent-person inspection at least annually.
Two OSHA figures anchor this checklist. Under 1926.502(d)(15), an anchorage for personal fall arrest must support at least 5,000 pounds (22.2 kN) per worker attached, or be engineered and used under a qualified person with a safety factor of at least two. And under 1926.502(d)(20), any system or component subjected to impact loading must be immediately removed from service and not reused until a competent person confirms it is undamaged — in practice, gear that has arrested a fall is retired. OSHA also requires (d)(20)'s companion at (d)(21): prompt rescue capability, which is why a written rescue plan belongs with the equipment.
Any FAIL retires the component. There is no "monitor it" option for fall-arrest gear.
How to use this checklist#
Fill in the date, inspector, location, and equipment ID (tie it to the unit's serial number). Check each item Pass, Fail, or N/A, recording specifics in the notes column. Items 14–16 apply to self-retracting lifelines and 17–19 to lifelines and anchorages — mark N/A for components not in the system being inspected. Any component that fails, or that has been subjected to a fall, is removed from service permanently. The record is signed, dated, and tied to the serial number.
Fall protection inspection items#
| # | Inspection item | Pass | Fail | N/A | Notes |
|---|---|---|---|---|---|
| 1 | Harness webbing has no cuts, tears, fraying, abrasion, or chemical burns. | ☐ | ☐ | ☐ | |
| 2 | Harness webbing color is uniform; no UV damage, fading, or stiffness. | ☐ | ☐ | ☐ | |
| 3 | Stitching at all load-bearing points is intact, with no broken or pulled threads. | ☐ | ☐ | ☐ | |
| 4 | D-rings are not bent, cracked, deeply scored, or showing signs of corrosion. | ☐ | ☐ | ☐ | |
| 5 | D-rings rotate and move freely without binding. | ☐ | ☐ | ☐ | |
| 6 | Buckles operate smoothly, lock securely, and show no deformation or rust. | ☐ | ☐ | ☐ | |
| 7 | Friction and tongue buckles hold webbing without slipping under tension. | ☐ | ☐ | ☐ | |
| 8 | Grommets, where present, are not damaged or distorted. | ☐ | ☐ | ☐ | |
| 9 | Impact indicators (load tags) on harness or lanyard show no signs of deployment. | ☐ | ☐ | ☐ | |
| 10 | Lanyard webbing or rope is free of cuts, burns, mildew, or chemical exposure. | ☐ | ☐ | ☐ | |
| 11 | Lanyard snap hooks open, close, and lock; gates spring back fully. | ☐ | ☐ | ☐ | |
| 12 | Snap hook keepers are not bent or damaged; rolled-out connections cannot occur. | ☐ | ☐ | ☐ | |
| 13 | Shock absorber pack is sealed; no signs of activation, tearing, or extension. | ☐ | ☐ | ☐ | |
| 14 | Self-retracting lifeline (SRL) extends and retracts smoothly; brake engages on jerk. | ☐ | ☐ | ☐ | |
| 15 | SRL housing has no cracks, dents, or impact damage; fasteners are tight. | ☐ | ☐ | ☐ | |
| 16 | SRL inspection date and certification are current; recall lookup completed. | ☐ | ☐ | ☐ | |
| 17 | Anchor points are rated for 5,000 lbs (22.2 kN) per worker or engineered. | ☐ | ☐ | ☐ | |
| 18 | Vertical and horizontal lifelines are properly tensioned and undamaged. | ☐ | ☐ | ☐ | |
| 19 | Rope grabs and rope adjusters move freely on the lifeline and lock under load. | ☐ | ☐ | ☐ | |
| 20 | Body wear, lanyard, connectors, and anchor are compatible per manufacturer. | ☐ | ☐ | ☐ | |
| 21 | Date of manufacture is within service life (typically 5 years for harnesses). | ☐ | ☐ | ☐ | |
| 22 | Equipment is stored clean, dry, away from sunlight, chemicals, and sharp objects. | ☐ | ☐ | ☐ | |
| 23 | Workers using the equipment have current training and a written rescue plan. | ☐ | ☐ | ☐ | |
| 24 | Any equipment subjected to a fall is removed from service and not reused. | ☐ | ☐ | ☐ | |
| 25 | Inspection record is signed, dated, and tied to the unit's serial number. | ☐ | ☐ | ☐ |
Corrective actions taken#
Describe any issues found and the steps taken to correct them. Any component that fails inspection — or that has been subjected to impact loading under 1926.502(d)(20) — is removed from service permanently and destroyed or returned to the manufacturer, never returned to the field.
Inspection sign-off#
- Inspector signature: __________________________
- Supervisor signature: __________________________
- Inspection result: ☐ All items passed ☐ Issues require follow-up
Related toolbox talks#
Disclaimer#
This checklist is a general guide based on OSHA 29 CFR 1926.502 and ANSI Z359. Always follow your site-specific procedures, the manufacturer's inspection instructions and service-life limits, and the regulations that apply to your jurisdiction. A written rescue plan is required before anyone is exposed to a fall hazard.