Common Mistakes in Harness and Lanyard Use and How to Avoid Them

Harnesses and lanyards are essential components of fall protection systems in industries like construction, manufacturing, and maintenance. While these tools are crucial for safeguarding workers from falls, improper use can lead to severe injuries or fatalities.

Understanding the common mistakes in harness and lanyard use is key to ensuring the effectiveness of fall protection systems and maintaining workplace safety.

1. Incorrect Sizing and Fit

One of the most frequent mistakes when using harnesses is wearing the wrong size or an improperly fitted harness. A harness that is too loose can allow a worker to slip out during a fall, while a harness that is too tight can cause discomfort and restrict movement.

Avoid This Mistake:

• Always ensure that the harness fits snugly but comfortably. The chest strap should be at mid-chest level, and the leg straps should be tight but not restrictive.
• Perform a pre-use inspection, adjusting the straps to ensure proper positioning before starting work.

2. Failure to Inspect Equipment Before Use

Lanyards and harnesses should be inspected before each use, but many workers skip this step or perform a cursory inspection, which can lead to using damaged or worn-out equipment.

Avoid This Mistake:

• Inspect harnesses and lanyards for signs of wear, fraying, or damage before every use.
• Check buckles, D-rings, and stitching for any signs of damage or malfunction.
• Replace equipment if any defects are found, as even minor damage can compromise safety during a fall.

3. Improper Connection to Anchor Points

A common mistake is attaching lanyards to weak or incorrect anchor points, which may not support the force of a fall. Using improper anchor points can lead to equipment failure or fall-related injuries.

Avoid This Mistake:

• Ensure that the anchor point is rated to support at least 5,000 pounds (22.2 kN) per worker attached.
• Only use designated, secure anchor points approved for fall protection.
• Never attach a lanyard to objects not intended as anchor points, such as scaffolding or handrails.

4. Using the Wrong Type of Lanyard

Not all lanyards are suitable for every job. A shock-absorbing lanyard is designed for fall arrest, while a positioning lanyard is used to secure a worker in place without the risk of a fall. Using the wrong type of lanyard for the job can lead to ineffective fall protection.

Avoid This Mistake:

• Use shock-absorbing lanyards for tasks where there is a risk of falling from height.
• Ensure that self-retracting lifelines (SRLs) or positioning lanyards are used appropriately for specific jobs.
• Consult with a safety professional if uncertain about which type of lanyard to use.

5. Incorrectly Using a Single Lanyard for Multiple Anchor Points

Another mistake is using a single lanyard to move between multiple anchor points without maintaining continuous connection. This practice can leave workers exposed to fall hazards during transitions between locations.

Avoid This Mistake:

• Use a twin-leg lanyard, also known as a Y-lanyard, to maintain a continuous connection while moving between anchor points.
• Ensure one end of the lanyard is always attached to a secure anchor point, especially when transitioning between locations.

6. Inadequate Fall Clearance

Lanyards and harnesses need sufficient clearance to safely arrest a fall. If the fall clearance is too short, the lanyard may not fully extend, causing the worker to hit the ground or another object.

Avoid This Mistake:

• Calculate the required fall clearance before using a lanyard, considering the length of the lanyard, the height of the worker, and any additional slack in the system.
• Ensure that there is adequate distance below the work area to safely arrest a fall.

7. Incorrectly Adjusted D-Ring

The D-ring on the harness, where the lanyard is attached, should be positioned between the worker’s shoulder blades. An improperly adjusted D-ring can cause an imbalance during a fall, potentially leading to injury or an improper arrest.

Avoid This Mistake:

• Position the D-ring between the shoulder blades, ensuring it is centered on the back.
• Adjust the harness to prevent the D-ring from being too high (near the neck) or too low (below the shoulder blades).

8. Not Considering Swing Falls

A swing fall occurs when a worker falls while connected to an anchor point that is not directly above them. This can result in the worker swinging into nearby objects or structures, leading to injury.

Avoid This Mistake:

• Position the anchor point directly overhead whenever possible to reduce the risk of a swing fall.
• If an overhead anchor is not feasible, ensure that the fall path is free of obstacles that could cause injury during a swing.

9. Ignoring Manufacturer Instructions

Each harness and lanyard comes with manufacturer instructions that provide guidance on proper use, maintenance, and limitations. Ignoring these instructions can lead to improper use and decreased safety.

Avoid This Mistake:

• Read and follow all manufacturer instructions for harnesses and lanyards.
• Ensure that workers are trained in the specific use and limitations of their fall protection equipment.
• Keep a copy of the equipment’s user manual on hand for reference.

10. Improper Storage of Equipment

When harnesses and lanyards are not stored correctly, they can become damaged or deteriorate over time. Storing equipment in damp, dirty, or exposed environments can compromise the integrity of the materials.

Avoid This Mistake:

• Store harnesses and lanyards in a clean, dry area away from direct sunlight and extreme temperatures.
• Avoid hanging equipment in areas where it may be exposed to chemicals, sharp objects, or heavy machinery.

Harnesses and lanyards are critical for fall protection, but their effectiveness depends on proper use and maintenance. By avoiding these common mistakes—such as incorrect sizing, improper connections, and neglecting inspections—employers and workers can ensure that fall protection systems are used safely and effectively. Regular training, thorough equipment inspections, and adherence to safety protocols are essential to minimizing fall-related incidents in the workplace.