How to Use a Safety Harness and Lanyard — Step-by-Step

Pre-use inspection: what to check on harness and lanyard

Before every use perform a thorough visual and tactile inspection of both the harness and the lanyard. A one-minute visual glance is not sufficient — you must check stitching, webbing, labels, hardware and connectors. Never use equipment with cuts, chemical stains, frayed stitching, bent hardware, distorted D-rings, or missing legible manufacturer labels and inspection dates.

• Webbing: look for cuts, burns, glazing, excessive wear, or discoloration that indicates chemical exposure.
• Stitching: inspect all load-bearing stitch patterns for broken or pulled threads and uniform stitch length.
• Hardware: check D-rings, buckles, snap hooks and karabiners for cracks, deformation, corrosion, and smooth operation.
• Labels & markings: verify manufacturer, model, serial, and rated capacity are present and legible; confirm expiry or next inspection date if applicable.
• Lanyard energy absorber: if present, confirm it has not deployed (shows tear webbing or deployed pack) and that shock pack seals are intact.

Donning a full-body harness: step-by-step procedure

Use a full-body harness rated for fall arrest (not just a positioning belt) and don it in a controlled, level area. Follow a consistent sequence so the harness fits predictably every time. The following steps describe a typical proper method; always follow the harness manufacturer’s user manual first.

• Hold the harness by the dorsal D-ring and shake it so straps fall into place; identify shoulder straps, chest strap and leg straps.
• Slip arms through shoulder straps like putting on a vest; ensure the dorsal D-ring rests between shoulder blades.
• Fasten and adjust leg straps snugly — you should be able to insert a flat hand between strap and thigh, but not a fist.
• Connect chest strap at mid-chest level; tighten until comfortable and secure to prevent the shoulder straps from sliding off.
• Tidy excess webbing using keepers so nothing can snag; perform a final fit check by raising arms and performing a squat to ensure straps stay put.

Selecting and connecting the correct lanyard and connector

Choose a lanyard that matches the system type (fall arrest, restraint, or positioning) and has compatible connectors. Lanyards are sold as shock-absorbing (with energy absorbers), non-energy absorbing (for positioning), or self-retracting lifelines (SRLs). Use only connectors with matching gate strength and locking type.

Connector compatibility and strength

Ensure carabiners/snap hooks are rated for fall arrest (usually stamped with strength ratings such as 22 kN) and are compatible with the harness D-ring geometry to avoid side loading. Use double-locking gates where possible.

Attachment point selection and fall clearance calculation

Attachment must be to an anchor point rated to support fall arrest loads (commonly 5,000 lb / 22.2 kN in the U.S. for single user anchors) or to a system designed by a qualified person. Calculate fall clearance before use to ensure the worker will not strike a lower level.

• Determine harness-to-anchor distance when free-falling — this includes lanyard length, deceleration distance (from the lanyard manufacturer), height of worker, and a safety margin.
• Basic clearance formula example (use manufacturer numbers): Free fall distance + deceleration distance + harness stretch + worker height + 1 m (safety margin).
• If clearance is insufficient, use a shorter lanyard, reposition the anchor overhead, or use an SRL with automatic arresting.

Connection sequence and safe practices while working

Always maintain 100% tie-off when working at height where a fall is possible — at least one secure connection point should be maintained while moving between anchors. Attach lanyards before exposing yourself to a fall hazard and avoid shock loading by keeping attachment geometry as close to overhead as possible.

• Use two-point techniques when transitioning: connect the second lanyard before disconnecting the first if moving between anchors.
• Avoid body belts for fall arrest; use full-body harnesses only.
• Prevent swing falls by placing anchor points overhead and work within the footprint of the anchor.

Rescue planning and post-fall procedures

A written rescue plan is required whenever fall arrest systems are used — determine how to retrieve or lower a suspended worker quickly and safely. Time suspended in a harness can cause suspension trauma; rapid rescue within minutes is essential.

Elements of an effective rescue plan

List responsible rescuers, communication methods, equipment needed (rescue tripod, SRL with retrieval function, rescue lanyard), training frequency, and step-by-step actions. Train workers and rescuers in simulated rescues at least annually.

Care, cleaning, maintenance and storage

Proper maintenance extends service life and preserves strength. Clean webbing with mild soap and water, rinse thoroughly, and air dry away from direct heat or sunlight. Do not use bleach, solvents, or machine-dry. Record inspections and retire equipment when it fails inspection criteria or reaches manufacturer service life.

• Store harnesses and lanyards in a cool, dry place away from UV, chemicals and sharp objects.
• Tag and remove equipment from service immediately if it has been involved in a fall arrest; follow manufacturer rules for retirement or destructive testing.

Common mistakes and how to avoid them

Many incidents are preventable if users understand common errors: incorrect harness fit, improper anchor selection, attaching to non-rated components, allowing excess slack, and skipping inspections. Consistent training, checklists, and supervision address these issues.

• Mistake: hooking lanyard to a harness webbing loop not rated for fall arrest. Remedy: always attach to the designated dorsal or sternal D-ring as specified by manufacturer.
• Mistake: using too long a lanyard near an edge. Remedy: use SRLs or shorter lanyards and calculate clearance before work.
• Mistake: neglecting rescue planning. Remedy: create, document and drill the rescue plan with equipment on site.

Quick inspection & donning checklist (printable)

Final notes and training recommendations

Proper use of harnesses and lanyards is a mix of correct equipment selection, disciplined pre-use checks, correct donning and secure attachment, accurate fall clearance calculations and an actionable rescue plan. Employers should provide hands-on training, documented competency checks and refresher sessions at least annually or whenever procedures change.