HOW TO INSPECT A SAFETY HARNESS BEFORE EVERY USE

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A full-body harness is the last line of defence between a construction worker and a fatal fall. But a harness is only as reliable as its condition. Webbing degrades. Stitching frays. D-rings corrode. Buckles fail. The only way to know your harness is safe to use is to inspect it before every single use — not once a week, not when it looks worn, but every time you pick it up.

Under Ontario Regulation 213/91 (Construction Projects), fall protection equipment must be inspected by a competent worker before each use. CSA Standard Z259.10-18 (Full Body Harnesses) sets the design and performance requirements for harnesses used in Canada and provides the framework for what a proper inspection should cover. This article walks through the complete pre-use inspection process, step by step.

Step 1 — Check the Labels

Before examining the physical condition of the harness, start with the labels. Every CSA-certified harness must have a permanently attached label that includes critical information:

• Manufacturer name and model — confirms the harness is a recognized product from a legitimate manufacturer.
• CSA certification mark — the harness must bear the CSA mark indicating it has been tested and certified to Z259.10. A harness without CSA certification cannot be used on an Ontario construction project.
• Date of manufacture — this is essential for determining the harness's service life. Most manufacturers recommend a maximum service life of 5 years from the date of first use or 7 years from the date of manufacture, whichever comes first. Some manufacturers specify shorter periods. Always follow the manufacturer's guidelines.
• Weight capacity — standard harnesses are rated for workers weighing between 130 lbs (59 kg) and 310 lbs (140 kg). If a worker exceeds the rated capacity, a heavy-duty harness rated for higher weights must be used. Using a harness beyond its rated capacity compromises its ability to arrest a fall safely.
• Serial number — used for tracking inspection records and identifying the harness in documentation.

If the labels are missing, illegible, or have been painted over, the harness must be removed from service. Without readable labels, you cannot verify certification, manufacture date, or weight rating.

Step 2 — Inspect the Webbing

The webbing is the structural backbone of the harness. Run every strap through your hands, feeling for damage as you visually examine both sides. Start at one end and work methodically through every strap — shoulder straps, chest strap, back strap, leg straps, and sub-pelvic strap.

• Cuts and nicks — any cut in the webbing, no matter how small, is a failure point. A cut that severs even a few fibres significantly reduces the strap's tensile strength. Remove the harness from service.
• Fraying — loose or pulled fibres along the edges of the webbing indicate abrasion damage. Minor edge fraying from normal use is common, but if the fraying extends into the body of the strap or if you can see broken fibres, the harness is compromised.
• Burns and heat damage — exposure to welding sparks, grinding debris, or direct heat sources can melt or weaken synthetic webbing. Look for melted spots, discolouration, hardened areas, or a glossy appearance on the webbing surface. Heat-damaged webbing may feel stiff or brittle to the touch.
• Chemical damage — contact with acids, solvents, paints, and other chemicals can degrade nylon and polyester webbing. Signs include discolouration, a paint-like residue that stiffens the webbing, or an unusual odour. If the harness has been exposed to chemicals, consult the manufacturer's guidelines for chemical compatibility.
• UV degradation — prolonged exposure to sunlight breaks down synthetic fibres over time. UV-damaged webbing may appear faded, feel brittle, or show surface cracking. Harnesses stored in direct sunlight or used exclusively outdoors for extended periods should be inspected with extra attention to UV damage.

Step 3 — Inspect the Stitching

The stitching that holds the webbing together at connection points, D-ring attachments, and buckle anchors is load-bearing. If the stitching fails, the harness fails.

• Broken or pulled stitches — look for broken thread, pulled loops, or gaps in the stitch pattern. Compare both sides of symmetrical connection points — if one side shows more wear than the other, it may indicate uneven loading or damage.
• Contrast stitching — many harness manufacturers use contrasting thread colours (such as red stitching on black webbing) specifically to make inspection easier. If you can see gaps in the colour pattern, stitches have failed.
• Abrasion at stitch points — the areas where webbing passes through hardware or folds over at connection points are high-wear zones. Check these areas closely for worn or thinning stitching.

Step 4 — Inspect the D-Rings

D-rings are the connection points where lanyards, self-retracting devices (SRDs), and other connectors attach to the harness. The dorsal (back) D-ring is the primary fall arrest attachment point.

• Deformation — a D-ring that has been bent, twisted, or pulled out of shape has been overloaded and must not be used. Compare the shape to a new D-ring if you are unsure.
• Corrosion — rust, pitting, or other corrosion on metal components weakens the material and creates stress points. Surface rust can be an early warning sign of deeper corrosion.
• Cracks — inspect the metal for cracks, especially at the bend points of the D-ring. Cracks may not be visible to the naked eye in early stages, so feel for rough spots or irregularities in the metal surface.
• Free movement — D-rings should pivot freely on their attachment straps. A D-ring that is stuck, bound, or frozen in position may not orient correctly during a fall, which can affect the load path and the harness's performance.

Step 5 — Inspect the Buckles

Buckles must engage, lock, and release properly. Test every buckle during your inspection.

• Tongue buckles — insert the tongue into the buckle and confirm it seats fully. The tongue should pass through the grommet hole in the webbing and lock into position. Pull on the strap to confirm it holds under tension.
• Quick-connect (pass-through) buckles — thread the webbing through the buckle, fold it back, and confirm that the buckle grips the webbing securely. The webbing should not slip through the buckle under load.
• Chest strap buckle — the chest strap buckle must engage and hold the shoulder straps at the correct position on the sternum. If the chest strap does not engage properly, the shoulder straps can slip off during a fall.
• Corrosion and damage — check all metal and plastic buckle components for cracks, corrosion, deformation, and sharp edges.

The Post-Fall Retirement Rule

Any harness that has been subjected to fall arrest forces — meaning a worker has fallen and the harness has arrested the fall — must be immediately removed from service and destroyed. This applies even if the harness shows no visible damage. The forces generated during a fall arrest can cause internal damage to the webbing fibres and deform metal components in ways that are not visible during a visual inspection. There are no exceptions to this rule.

Tag the harness clearly as "DO NOT USE" and cut the webbing to prevent anyone from putting it back into service. Document the date of the fall event, the harness serial number, and the circumstances for your records.

Documentation

While Ontario Regulation 213/91 requires that fall protection equipment be inspected before each use, maintaining written inspection records is a best practice that protects both the worker and the employer. A simple inspection log should include the date, the inspector's name, the harness serial number, the inspection results (pass or fail), and any actions taken (returned to service, removed from service, sent for repair).

Many employers use pre-printed inspection tags that attach to the harness, or digital inspection forms that workers complete on a tablet or phone. The format does not matter. What matters is that the inspection happens and that there is a record of it.

A harness inspection takes less than five minutes. It is the shortest, simplest safety check on any construction site — and it is the one that can save your life. Do it every time. No exceptions.