A full body harness is the last barrier between a worker and the ground. It also has a finite life, takes a beating, and fails silently when neglected. This is the inspection routine every Irish site should follow.
Three levels of harness inspection
- Pre-use check by the user, every shift, takes 90 seconds.
- Periodic inspection by a competent person, every 6-12 months, recorded in writing.
- Manufacturer recall checks - register your serial numbers with the maker.
The HSA expects all three. Missing the periodic inspection is a routine Improvement Notice trigger.
Pre-use check - the 12 points
- Webbing: no cuts, fraying, burns, chemical stains, melted fibres or surface damage
- Stitching: no broken, pulled, cut or unraveled threads, especially on load-bearing seams
- D-ring (dorsal): no cracks, no corrosion, free movement, correct orientation
- D-ring (sternal / chest): same checks, attachment plate flat against the harness
- Buckles: latch and release cleanly, no bent metal, no missing pawls
- Adjusters: grip and slide smoothly, no slippage under load
- Labels: EN 361 mark, serial number, manufacturing date, last inspection date all readable
- Fall indicator: if present, has not been triggered (red tab, ripped stitch indicator)
- Connection points: snap hooks and karabiners gates close fully, locking sleeves work
- Lanyard: shock pack intact (not deployed), webbing checked as above
- Cleanliness: no concrete, paint, plaster or chemical contamination - paint and concrete are abrasives that destroy webbing
- Storage: not stored on a nail, not in direct sunlight, not damp
When to retire a harness immediately
If any of the following are present, the harness is dead - bin it, do not "use it just for today":
- Has arrested a fall (any fall, even a short one)
- Webbing cut, burned, melted or chemically degraded anywhere
- Stitching damaged on a load-bearing seam
- D-ring cracked, distorted or corroded
- Manufacturing date over 10 years old (most makers cap at 10)
- Inspection date expired
- Serial number or labels unreadable
- Visible fall indicator triggered
Cut the webbing in two before disposing - that prevents anyone fishing it back out of the skip.
Periodic inspection - what the competent person does
Every 6-12 months (manufacturer dependent, exposure dependent), a competent person performs a deeper inspection: full webbing flex test, stitch-by-stitch check, hardware function under simulated load, label legibility, connector wear measurement, anti-rotation lock test on snap hooks. The result is recorded in a register with date, inspector name, harness serial, status (Pass / Fail / Quarantined) and signature. The HSA can ask to see this register at any visit.
Storage and care
- Hang on a wide rounded peg - never a nail or sharp hook
- Out of direct UV (UV cooks the webbing in months on Irish summer sites)
- Dry, ventilated, away from welding sparks, battery acid and solvents
- Clean with mild soap and water - no detergents, no bleach, no pressure washer
- Air dry, never tumble dry, never near a heater
Common Irish-site harness mistakes
- Sharing harnesses between trades without re-adjusting and re-checking - sizing matters for arrest performance
- Storing in the back of a transit van under tools all winter
- Spray-painting the worker name across the webbing - paint chemicals destroy nylon
- Letting concrete splatter dry into the webbing
- "Borrowed for the weekend" by the gaffer for a domestic job
The role of Working at Heights Training
The Working at Heights Course covers harness selection, fitting, the 12-point pre-use check, retirement criteria and the rescue plan. After 45 minutes online your worker downloads their Working at Heights Certificate, and your file has the evidence the HSA wants.
FAQs
Does an unused harness still expire?
Yes. Date of first use is what most manufacturers count, with a maximum 10 year shelf-plus-service life. Read the label.
Can I inspect my own harness or do I need an external company?
The pre-use check is by the wearer. The 6-12 monthly periodic inspection must be by a "competent person" - that can be in-house if they have the training, but most Irish small businesses use a third party.
What is the cheapest way to keep my crew compliant?
Online Working at Heights Training + a quarterly external harness inspection. Start the course in 45 minutes.
Lock in compliance today. Start the Working at Heights Course online and download a printable harness inspection log along with your certificate.
