If you’re like most folks in construction, maintenance, or any job where you’re working high up, fall protection gear isn’t just another piece of kit—it’s your safety net. But let’s be real, how many times have you grabbed that old harness from the back of your truck, looked at the frayed strap, and thought, “Is this still good? Or should I toss it?” As a fall protection supplier, I field this question every single day, and the short answer is: it’s not just about the date on the tag. It’s about how you use it, store it, and the tiny, easy-to-miss signs that it’s time to replace. Fall Protection
First off, let’s get one thing straight—manufacturers put that “retire by” date on every single piece of fall protection (harnesses, lanyards, self-retracting lifelines, even anchor connectors) for a reason. Most of these dates are 5 to 10 years from the date of manufacture, but that’s only if the gear has never seen action. If you pull a harness made in 2018 out of storage and it’s never been used, maybe it’s fine to keep around for backup? Wait, no—wait, hold on. I actually had a customer last year who argued with me that his 7-year-old unused harness was totally good because it was “just sitting on a shelf.” Wrong. Synthetic fabrics (nylon, polyester) break down over time from UV exposure, even if they’re tucked away in a dark closet. Temperature swings, humidity—all that stuff eats away at the fibers, making them weaker without you even noticing. So that date on the tag isn’t a suggestion—it’s a hard stop for unused gear too, especially if it’s nearing or past that mark.
But here’s the big secret I tell every new customer: you might need to replace that gear way before the retire-by date. How? Let’s walk through the common culprits that mess up fall protection, because 9 times out of 10, the damage is visible if you know what to look for.
First up, let’s talk about the obvious stuff: physical damage. I’m not talking about a tiny scuff on a buckle—though even that can be a red flag. I’m talking about frayed straps, cut fibers, tears, or abrasions deep enough that you can see the inner core of the webbing. Last month, a roofer brought in a lanyard that had a 2-inch cut on the strap from rubbing against a sharp roof edge. He said he noticed it but thought “it’s just a little nick.” Nope. That lanyard’s load capacity is cut in half right there—even if it looks mostly intact. Metal parts matter too. Check for rust, dents, or bent hooks. If a lock on a carabiner doesn’t snap shut firmly, or if the gate is twisted when it’s closed, that’s a failure waiting to happen. I once had a guy use a self-retracting lifeline that had a bent reel—he didn’t think it was a big deal, but when he tripped at 12 feet, the reel jammed, and he hit the ground hard. Scary stuff, and all because he skipped a quick check.
Then there’s the stuff you can’t see right away: chemical damage. This is the one that catches people off guard. If you work around paint, solvents, concrete additives, or even fertilizer (yes, fertilizer—super harsh on synthetic fibers), those chemicals eat away at webbing. You might not notice it until the harness is already weak, because the damage is internal. How to spot it? If the webbing feels stiff, sticky, or discolored (like faded to a dull grey instead of the bright color it was when new), that’s a sign. I had a concrete finisher tell me he washed his harness with a degreaser once to get the concrete off—big mistake. The degreaser broke down the nylon so much that when he tested the harness’s strength, it only held 30% of what it should. If you use any harsh cleaners on your gear, or if it’s exposed to chemicals on the job, that gear is done—no exceptions, even if it’s only a year old.
UV exposure is another silent killer. If you leave your harness or lanyard on the roof of your work truck in the sun all day, every day, that’s like leaving a piece of rope out to bake. UV rays break down synthetic fibers over time, even without physical damage. A lot of people think “it’s just the strap, the metal parts are fine”—nope, the webbing is what takes the load when you fall. I recommend stowing your gear in a cool, dry, dark place when you’re not using it—not tossed on the back seat of your truck. Even a few months of daily sun exposure can weaken a lanyard enough to fail.
Now, what about things that seem minor but still mean replacement? Let’s say you had a fall, even a small one. You leaned out too far, and the lanyard went tight, arresting your fall (thank goodness, you’re safe). But that gear—harness, lanyard, whatever—just took a huge impact. Even if it looks totally undamaged, the force of that fall could have stretched the webbing, damaged the internal stitching, or warped the metal parts. OSHA and every major fall protection manufacturer say that after any fall, you have to retire that piece of gear immediately. I can’t tell you how many times I’ve heard someone say “it was only a 2-foot fall, it’s fine.” No. The force of even a short fall is enough to damage the gear beyond repair. Don’t risk it.
Wait, let’s also talk about the difference between inspection and replacement. A lot of companies do weekly or monthly inspections of their gear, right? That’s great, but inspections are for checking for damage before each use, not for making the call to replace. If your inspector notes a small fray on the edge of a strap, that might mean you can cut the affected part off a lanyard (some lanyards are designed to be shortened by cutting the excess) and still use it—but if that fray is deep, or on a load-bearing part, you replace it. Inspections are part of the process, but they don’t replace knowing when it’s time to toss the gear.
Another thing I see all the time: using gear for jobs it’s not designed for. That’s a big one. A lot of people use their fall protection lanyard to tie off to a scaffold, but then they’ll use the same harness to lift equipment with a crane. Wait—no. Fall protection gear is only for fall arrest, not for lifting or securing loads. If you use it for something it’s not rated for, even once, that can damage the gear. I had a customer do that, and the harness stitching pulled apart when he tried to lift a 50-pound toolbox. Lucky for him, no one was hurt, but that harness was useless after that. If your gear is rated for fall arrest only, don’t use it for anything else.
Now, let’s get practical. How do I actually keep track of when to replace my gear? First, label every single piece with the manufacture date and the retire-by date. Most suppliers will do this for you when you buy gear, but if not, grab a permanent marker and write it on the back of the harness label or the lanyard. Keep a log of every time you use the gear, any falls it arrested, any damage you noticed, and any cleaning or storage you did. That log will save you when you’re wondering “is this still good?” at the end of the season.
Wait, what about gear that’s been sitting in a supply closet for years? A lot of companies keep extra harnesses for new hires or backup, and then forget about them. If that gear is past its retire-by date, don’t use it. Even if it’s never touched, synthetic fibers degrade over time. I had a general contractor come to me with 10 unused harnesses he’d had for 8 years, and he thought they were still good. We tested one, and it only had 40% of its rated strength. He had to replace all of them, which cost him a lot more than if he’d replaced them on time.
Let’s bust a few myths while we’re at it, because I hear these all the time. Myth 1: “If I can’t see damage, the gear is fine.” No, chemical and UV damage is often internal—you can’t see it. Myth 2: “I can just replace the broken part, not the whole harness.” Most harnesses are a single, load-rated unit—you can’t replace a frayed strap without compromising the overall strength. Myth 3: “Generic gear is the same as brand-name, so I can skip the replacement date.” Generic gear doesn’t have the same rigorous testing, and their retire-by dates are usually way too long—stick to reputable brands that test their gear for safety.
Now, when should you actually reach out to replace? Let’s make a quick checklist to follow every time you pull out your gear:
- Is it past the manufacture date’s retire-by limit? If yes, replace it.
- Do you see frayed webbing, cuts, tears, or deep abrasions? Replace it.
- Is the webbing stiff, sticky, discolored, or shows signs of chemical exposure? Replace it.
- Do metal parts have rust, dents, bent hooks, or stuck locks? Replace it.
- Did this gear arrest a fall of any height? Replace it immediately.
- Have you ever used this gear for lifting or securing loads (not just fall arrest)? Replace it.
I know replacing gear can feel like a hassle, or an unnecessary cost, but here’s the thing: it’s way cheaper to replace a harness than to deal with a fall. I’ve seen the aftermath of people who tried to use old gear—broken bones, long-term disability, even fatalities. That’s not worth saving a few hundred bucks on new equipment.
As a fall protection supplier, my job isn’t just to sell you gear—it’s to make sure you use it safely. If you’re not sure if your old harness or lanyard is still good, bring it by, send us a photo, or just reach out. We can walk you through an inspection, help you figure out if it’s time to replace, and get you set up with the right gear that fits your job. No pushy sales stuff, just honest advice.
At the end of the day, fall protection is all about being diligent. It’s not about being paranoid—it’s about knowing that the gear you rely on to keep you safe has to be in top shape every single time you climb. Don’t wait for a small damage to turn into a disaster. Check your gear regularly, keep track of those dates, and when in doubt, replace it. That’s the best way to stay safe on the job, and make sure you get to go home at the end of every day.
And if you need help sorting out your current gear, or stocking up on new fall protection that’s built to last, don’t hesitate to reach out to our team for a no-pressure chat about what you need.
Shock Absorbing Lanyard References:
- Occupational Safety and Health Administration (OSHA). 29 CFR 1926 Subpart M: Fall Protection. U.S. Department of Labor, 2022.
- American National Standards Institute (ANSI). ANSI Z359.1-2021: Safety Requirements for Personal Fall Arrest Systems, Subsystems, and Components. American National Standards Institute, 2021.
- Fall Protection Equipment Manufacturers Association (FPEMA). Recommended Practices for Inspection, Care, and Retirement of Personal Fall Protection Equipment. 2020.
- National Institute for Occupational Safety and Health (NIOSH). Fall Protection in Construction: A Guide for Employers and Workers. Centers for Disease Control and Prevention, 2019.
Shanghai Cosystar International Trading Co., Ltd.
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