The initial installation of fall protection is an important milestone in safety, but it's typically a first step. Long-term safety protocols require understanding that corrosion, loose components and worn harnesses can undermine efforts. These and other maintenance issues can turn compliant systems into hidden hazards.

Fall protection maintenance isn't an option. It's a necessary shield against the risks of dangerous falls. According to data from the Bureau of Labor Statistics, in 2023 alone, falls accounted for 885 workplace deaths. That's around 17% of all occupational fatalities. The only category with more fatal accidents was transportation injuries.

Even small issues, like frayed webbing or a loose bolt, can lead to dangerous system failure. Stay ahead of those failures by following the steps in this article to help keep fall protection systems compliant and functional.

Why Fall Protection Maintenance Matters

OSHA regulations under 29 CFR 1910 and 1926 require fall protection systems to be kept in safe condition at all times. That goes beyond an initial or even periodic inspection.

Over time, environmental factors like UV exposure, moisture or temperature changes, along with regular use, can compromise equipment. Degradation may not always be obvious, creating a lurking danger that the safety system will fail. For example, a corroded railing base or sun-damaged lifeline might look intact but fail under stress when relied upon.

Note that you need more than regular inspections. Inspections identify potential issues, but well-thought-out maintenance programs correct them. Neglecting either of these critical steps — inspection or maintenance — is a compliance failure and safety risk.

Core Maintenance Tasks by System Type

Every fall protection system or component faces unique stressors. Maintenance should not be one-size-fits-all but should address the priorities and needs of the component. Consider three system categories and the common maintenance tasks for each below.

Passive Systems

Passive systems like guardrails and barriers require consistent checks to ensure they're stable and secure, especially with constant exposure to elements like wind and weather extremes.

Common maintenance tasks include:

• Tightening all bolts and hardware
• Inspecting components for corrosion or rust, especially where elements connect
• Repainting or resealing surfaces to prevent UV- or moisture-related deterioration

Active Systems

Personal fall protection equipment like harnesses or SRLs are subject to wear and tear with ongoing use. Regular care helps to extend the lifespan of such equipment and ensure reliability during critical moments.

Common maintenance tasks include:

• Inspecting straps, stitching and D-rings before and after every use
• Cleaning harnesses and lanyards to prevent mildew
• Storing gear in a dry, temperature-controlled space away from direct sunlight

Fixed Anchors and Lifelines

Anchors and lifelines are essential for secure tie-off points. However, they can face environmental damage over time.

Common maintenance tasks include:

• Inspecting anchors and hardware for rust, cracks or unexpected movement
• Testing and documenting lifeline tension and integrity
• Resealing rooftop penetrations and flashing to maintain water resistance

Building a Repeatable Maintenance Schedule

A maintenance program only helps you protect workers and your facility if it's consistent. Building a structured, repeatable and well-documented maintenance program helps you enforce better safety and compliance.

Creating a Maintenance Schedule

Start by breaking maintenance tasks into daily, monthly and annual routines.

• Daily: pre-use checks for harnesses and related hardware
• Monthly: inspection of rooftop seals, rails, or other vulnerable areas
• Annually: thorough evaluation and testing of anchors, guardrails and lifelines following manufacturer requirements

Obviously, this list is not complete. Consider the needs of your fall protection gear and what maintenance tasks — on what schedule — best protect your workers and company.

Tips for Creating a Repeatable Maintenance Schedule

• Use checklists and logs to standardize inspection and maintenance processes and keep things aligned with compliance needs.
• Assign clear responsibilities, naming who handles inspections, who tags worn gear and who schedules and oversees repair and replacement.
• Leverage digital tools for setting reminders and tracking completed tasks.
• Document everything, including the date of the inspection or maintenance, what was done, conclusions and findings and what should come next.
• Review and adjust your maintenance program periodically to account for changing use patterns, environmental shifts, new manufacturer guidance and anything else that might impact the maintenance performed and when it's required.

When to Repair vs. Replace Fall Protection Gear

While regular inspections of fall protection gear can uncover maintenance and repair needs, some problems require more. Tightening bolts or cleaning harnesses are common maintenance tasks, for example. But OSHA requires any equipment exposed to a fall or with signs of damage, like frayed straps or bent D-rings, to be removed from service immediately.

Makeshift fixes, like tape or glue, are not acceptable. Consult manufacturer guidelines to understand service life limits and when replacement is the safest and only compliant option.

Solving the Most Common Fall Protection Maintenance Challenges

Your safety programs can falter when maintenance isn't easy to manage. Here are some common obstacles to efficient and convenient maintenance:

• No clear ownership: When no one is responsible, tasks can slip through the cracks. Assign a safety lead or team to track and enforce maintenance activities.
• Time constraints: Busy schedules push maintenance down the list. Use digital reminders or integrate fall protection tasks into routine facility checklists.
• Poor documentation: Without accurate records, it’s hard to track equipment condition. Keep simple logs noting inspection dates, findings, and completed repairs.
• Limited training: If employees don’t know how to inspect or report issues, problems go unnoticed. Provide hands-on training and refreshers to build confidence.
• Inconsistent processes: Lack of standardization causes missed steps. Use checklists to keep inspections and repairs uniform across teams.

Ongoing Maintenance Is Ongoing Safety

Installing appropriate, high-quality fall protection systems is a great step toward safety. But your work doesn't end there. Maintaining that protection helps keep your team safe and your company compliant. It also helps protect your investment in equipment by maximizing the functional life of systems.

Reach out to Safety Rail Source for fall protection solutions to get started on your compliance and safety journey today.