Tips for Ensuring an Effective Inspection of Your Fall Arrest System

Have you ever wondered what's really standing between your workers and a potentially fatal fall? Are you confident that your fall arrest equipment is truly ready to perform when it matters most? These questions might seem confrontational, but they're absolutely critical for anyone responsible for workplace safety in Melbourne.

Falls from height remain one of the leading causes of serious workplace injuries and fatalities across Australia. Your fall arrest system is quite literally a lifeline, yet it's only as reliable as its last inspection. A frayed harness strap, a corroded connector, or a malfunctioning self-retracting device could mean the difference between a close call and a tragedy.

In this guide, you'll discover everything you need to know about inspecting your fall arrest system effectively. We'll walk through each component, explore Australian standards, and provide practical checklists you can use straight away. Whether you're conducting pre-use checks or scheduling formal inspections, this information will help keep your team safe and your workplace compliant.

Understanding Your Fall Arrest System Components

Before diving into inspection procedures, it's vital to understand what you're actually checking. A fall arrest system isn't a single piece of equipment it's an integrated assembly of components working together to protect workers.

Full Body Harnesses

The full body harness is the foundation of any fall arrest system. It distributes fall arrest forces across the body's strongest points: the shoulders, thighs, and pelvis. When inspecting harnesses, pay close attention to all webbing, buckles, D-rings, and stitching patterns.

Lanyards and Energy Absorbers

Lanyards connect the harness to anchor points, while energy absorbers reduce the impact force during a fall. These components take significant stress and require careful examination for cuts, abrasions, and deployment indicators.

Anchor Points and Connectors

Your anchor point must support the required load capacity typically at least 15 kN for personal fall arrest. Connectors like carabiners and snap hooks need checking for proper gate function and any signs of deformation.

Self-Retracting Devices (SRDs)

SRDs automatically adjust cable length as workers move. They require functional testing to confirm proper retraction, locking mechanisms, and cable condition.

How Often Should Fall Arrest Equipment Be Inspected?

Getting your inspection frequency right is non-negotiable for compliance and safety. Different situations call for different inspection schedules.

Pre-Use Inspections

Every single time someone puts on a harness or clips into a lanyard, they should conduct a quick visual check. This takes just a few minutes but catches obvious defects before they become dangerous. Train all workers to spot fraying, damaged hardware, and missing labels.

Formal Periodic Inspections

Beyond daily checks, your fall arrest equipment needs thorough formal inspections at least every six months. Many Melbourne workplaces opt for quarterly inspections, particularly in harsh environments or where equipment sees heavy use. Document these inspections meticulously.

Post-Incident Inspections

Any equipment involved in a fall even a minor one must be removed from service immediately and professionally inspected. The forces involved in arresting a fall can cause invisible damage that compromises future performance.

What Are the Australian Standards for Fall Arrest System Inspections?

Understanding your legal obligations isn't just about avoiding fines it's about protecting lives.

AS/NZS 1891 Requirements

The AS/NZS 1891 series sets out requirements for industrial fall arrest systems and devices. This standard specifies design requirements, testing procedures, and inspection protocols. Your equipment must comply with these standards to be legally used in Australian workplaces.

The standard requires that competent persons inspect equipment at intervals not exceeding six months. It also mandates detailed record-keeping and clear retirement criteria for damaged equipment.

Compliance Obligations for Melbourne Workplaces

Melbourne workplaces fall under WorkSafe Victoria's jurisdiction. Employers have a duty to provide and maintain equipment that's safe and without risks to health. This includes regular inspections by qualified personnel and immediate removal of defective equipment.

Failing to meet these obligations can result in significant penalties, improvement notices, or worse serious injuries to your workers.

Step-by-Step Guide to Inspecting Your Fall Arrest System

Let's get practical. Here's how to conduct a thorough inspection of your fall protection equipment.

Visual Inspection Checklist

Start with a systematic visual examination:

- Check all webbing for cuts, fraying, burns, chemical damage, or UV degradation

- Examine stitching for pulled threads, broken patterns, or wear

- Inspect metal components for cracks, corrosion, distortion, or sharp edges

- Verify all labels remain legible with clear manufacturer information and date codes

- Look for any unauthorised modifications or repairs

Functional Testing Procedures

Visual checks alone aren't enough. You need to verify that everything actually works:

- Test all buckles for smooth operation and secure fastening

- Check carabiner gates for proper spring tension and locking

- Extend and retract SRDs to confirm smooth operation

- Verify energy absorber indicators haven't deployed

- Test adjustable components for proper function

Documentation and Record-Keeping

Every inspection needs proper documentation. Record the date, inspector's name, equipment serial numbers, findings, and any actions taken. Keep these records for at least seven years they're your evidence of compliance and help track equipment history.

Common Signs of Wear and Damage to Look For

Knowing what to look for makes inspections far more effective.

Fraying, Cuts, and Abrasions

Webbing damage is the most common issue you'll encounter. Even minor fraying reduces load capacity. Cuts from sharp edges or abrasions from rough surfaces can compromise structural integrity. Any significant damage means immediate retirement of the equipment.

Corrosion and Metal Fatigue

Metal components don't last forever. Look for rust, pitting, discolouration, and white powder on aluminium parts. Check for cracks around stress points like D-ring attachment areas. Bent or deformed hardware indicates potential overloading.

Stitching and Webbing Deterioration

Factory stitching follows specific patterns designed to show wear. Missing or broken stitches weaken critical connections. UV exposure causes webbing to fade and become brittle—particularly problematic in Melbourne's variable weather conditions.

Who Is Qualified to Inspect Fall Protection Equipment?

Not just anyone can sign off on fall arrest equipment inspections.

Competent Person Requirements

A competent person must have the knowledge, training, and experience to identify defects and assess equipment condition. They need to understand manufacturer specifications, relevant standards, and proper inspection techniques. Many organisations train dedicated safety personnel for this role.

When to Use a Certified Inspector in Melbourne

While competent internal staff can handle routine inspections, certain situations require professional intervention. Complex systems, equipment approaching retirement age, or any uncertainty about condition warrants engaging a certified inspector. Professional services provide independent verification and detailed reports that satisfy regulatory requirements.

Choosing a Reliable Fall Arrest Inspection Service in Melbourne

When selecting an inspection provider, look for demonstrated competence and proper credentials. Ask about their inspector qualifications, insurance coverage, and reporting procedures.

A quality provider will offer clear turnaround times, detailed reports, and advice on equipment replacement. They should understand Melbourne's regulatory environment and keep current with standard updates.

Check references from similar businesses and verify their track record. The cheapest option isn't always the best your workers' safety deserves proper investment.

Protecting Your Workers Starts with Proper Inspections

We've covered a lot of ground here, from understanding your equipment components through to selecting professional inspection services. The key takeaway? Regular, thorough inspections aren't optional they're fundamental to workplace safety.

Your inspection fall arrest system only works if it's properly maintained. That means daily pre-use checks by trained workers, formal periodic inspections by competent persons, and immediate attention to any equipment that's been involved in a fall or shows signs of damage.