Fall protection equipment should be inspected before every use, formally inspected by a competent person at least once a year, and immediately after any event that could affect its integrity, such as a fall, impact, chemical exposure, or severe weather. Regular inspections are essential for OSHA compliance, worker safety, and extending the service life of personal fall arrest systems (PFAS).
For commercial roofing contractors, where employees routinely work at heights, a thorough inspection program can prevent catastrophic accidents and costly OSHA violations.
Why Frequent Inspections Matter
Fall protection equipment is designed to save lives, but it can only do so if every component functions exactly as intended. Exposure to sunlight, moisture, extreme temperatures, chemicals, abrasion, and daily wear gradually weakens equipment. Even equipment that appears undamaged may have hidden defects that compromise its strength.
OSHA requires employers to ensure that fall protection systems remain safe and reliable. Routine inspections help identify damaged equipment before it is used on a roof, reducing the likelihood of falls and injuries.
OSHA Inspection Requirements
OSHA’s fall protection standards require that fall protection equipment be inspected regularly.
The general inspection schedule includes:
- Before every use by the worker using the equipment
- At least annually by a competent person with documented inspections
- After any fall arrest event
- Whenever equipment has been exposed to unusual conditions such as fire, chemical spills, severe impacts, or prolonged weather exposure
Manufacturers may recommend inspection intervals that exceed OSHA’s minimum requirements. Contractors should always follow whichever requirement is more stringent.
What Should Be Inspected?
Every component of the personal fall arrest system should be examined carefully.
Full-Body Harness
Inspect for:
- Cuts, tears, or frayed webbing
- Burn marks
- Chemical damage
- Mold or mildew
- UV degradation
- Loose or missing stitching
- Distorted or cracked D-rings
- Broken buckles
- Missing labels or identification tags
If labels are unreadable, the harness should generally be removed from service because inspection history and manufacturer information can no longer be verified.
Lanyards and Lifelines
Check for:
- Broken fibers
- Frayed edges
- Knots
- Cuts
- Abrasion
- Damaged energy absorbers
- Deployed shock packs
- Corrosion on hooks
- Bent or damaged connectors
A deployed energy absorber means the lanyard has already experienced a fall arrest and must not be reused.
Self-Retracting Lifelines (SRLs)
Inspect for:
- Smooth extension and retraction
- Locking mechanism function
- Cable damage
- Corrosion
- Housing cracks
- Missing fasteners
- Signs of contamination
Manufacturers often require periodic servicing in addition to visual inspections.
Anchorage Connectors
Inspect:
- Roof anchors
- Beam clamps
- Permanent anchor points
- Temporary anchors
Look for:
- Corrosion
- Loose fasteners
- Bent components
- Cracks
- Structural movement
- Signs of overload
The anchor point is only as strong as the structure to which it is attached.
Who Can Perform Inspections?
Workers should perform a visual and tactile inspection before every use.
However, OSHA also requires inspections by a competent person—someone capable of identifying existing and predictable hazards and authorized to take corrective action. These formal inspections should be documented according to company policy and manufacturer recommendations.
For large commercial roofing companies, many safety managers maintain inspection logs for every harness, lanyard, and SRL using equipment serial numbers.
When Should Equipment Be Removed From Service?
Fall protection equipment should be removed immediately if it has:
- Arrested a fall
- Torn or cut webbing
- Missing stitching
- Excessive wear
- Rust or corrosion
- Cracked metal hardware
- Heat damage
- Chemical contamination
- UV deterioration
- Missing identification labels
- Failed inspection
Never attempt to repair damaged fall protection equipment unless the manufacturer specifically authorizes repairs. Most damaged harnesses and lanyards must be permanently retired.
Proper Storage Helps Reduce Inspection Failures
Good storage practices help preserve equipment between inspections.
Store fall protection equipment:
- In a clean, dry location
- Away from direct sunlight
- Away from chemicals
- Off the floor
- Protected from sharp objects
- In designated storage bags or lockers
Proper storage minimizes unnecessary wear and extends equipment life.
Best Practices for Commercial Roofing Contractors
Professional roofing companies often implement comprehensive inspection programs that include:
- Daily pre-use inspections
- Annual documented competent-person inspections
- Equipment tracking by serial number
- Employee inspection training
- Immediate replacement of damaged equipment
- Manufacturer maintenance schedules
- Written fall protection plans
- Periodic safety audits
These practices improve OSHA compliance while creating a safer work environment for roofing crews.
Shieldline Roofing’s Expert Opinion
At Shieldline Roofing, we inspect fall-protection equipment before use and whenever conditions could affect its integrity. A formal inspection schedule should also follow the equipment manufacturer’s instructions and the applicable OSHA requirements, especially after a fall or impact event.
Our Key Insights
OSHA requires personal fall-arrest systems to be inspected before each use for wear, damage, and deterioration, and defective components must be removed from service. OSHA also requires systems that have arrested a fall to be removed from service until a competent person determines they are safe for reuse.
The Bottom Line
Fall protection equipment should always be inspected before every use, receive a formal inspection by a competent person at least once every year, and be removed from service immediately if damage or a fall event occurs. For commercial roofing projects, consistent inspections are one of the most effective ways to prevent falls, protect workers, maintain OSHA compliance, and ensure every piece of safety equipment performs as designed when lives depend on it.Learn More
