Personal Fall Arrest Systems (PFAS) are designed to save lives when working at height. They typically include a full-body harness, a shock-absorbing lanyard, and secure connecting devices. The direct answer is unambiguous: fall protection equipment does expire. Removal from service is determined by the equipment’s physical condition and a non-negotiable mandatory retirement date set by the manufacturer. Understanding the factors that determine this expiration is necessary for maintaining a safe work environment.
Why Fall Protection Equipment Degrades
The materials used in safety harnesses and lanyards, primarily nylon and polyester webbing, are susceptible to a gradual loss of tensile strength over time. This material deterioration is a function of exposure to various environmental stressors that break down the polymer chains within the fibers. Continued exposure to sunlight, specifically ultraviolet (UV) radiation, is a major contributor to this decay, causing the fibers to weaken and become brittle.
Chemical exposure further accelerates degradation, as common workplace substances like solvents, paints, acids, and even some cleaning agents can chemically compromise the webbing material. When absorbed, these contaminants alter the structural integrity of the fibers, resulting in discoloration or stiffness. Temperature extremes also play a role, with excessive heat causing scorching and melting, while prolonged moisture exposure leads to mildew growth that weakens the stitching and webbing.
Mandatory Retirement Based on Age
Even equipment that appears to be in perfect working order must eventually be removed from service based purely on its age. Most manufacturers impose a mandatory retirement timeline for their equipment, regardless of its apparent condition. This proactive measure recognizes that material degradation can occur internally and invisibly over time, even with minimal use.
A typical service life for webbing-based equipment is often set at five years, though some manufacturers extend this period to ten years from the date of manufacture. This manufacturer’s guidance acts as the definitive authority regarding the maximum lifespan of the equipment. Adhering to this specified limit prevents the use of potentially compromised gear where the material integrity has been subtly weakened.
Locating and understanding the date stamps or tags permanently affixed to the equipment is necessary for compliance. These labels typically indicate the date of manufacture, which begins the countdown to the mandatory retirement date. If the equipment lacks legible identification tags or if the date stamp is obscured, the gear must be immediately removed from service. This time-based retirement framework exists independently of the equipment’s physical appearance or usage history.
Immediate Retirement Criteria
Equipment must be immediately retired and destroyed when it sustains damage, regardless of how recently it was purchased or its current age. The single most significant event requiring immediate removal is arresting a fall, known as shock loading. Once a fall has occurred, the equipment’s energy-absorbing components, such as the shock pack in a lanyard, deploy and stretch, permanently deforming the material. This makes the equipment unsafe for any subsequent use.
Beyond fall arrest, physical signs of wear and tear necessitate immediate removal. Workers must look for evidence of cuts, severe abrasions, or noticeable fraying along the edges of the webbing. The stitching, which holds the webbing together and bears the load during a fall, must also be inspected for any broken or pulled threads.
Damage to hardware components also warrants prompt retirement, including any signs of corrosion, deformation, or cracks on metal parts like D-rings and carabiners. Additionally, any evidence of heat damage, such as scorching or melted fibers, or discoloration and stiffness resulting from chemical exposure, indicates that the tensile strength has been compromised. In all these instances, the equipment’s ability to reliably stop a fall is questionable, demanding its permanent destruction and replacement.
The Essential Role of Equipment Inspection
Inspection procedures are the mechanism for determining if equipment has reached its functional expiration date due to physical damage or wear. There are two distinct levels of required inspection that govern the continued use of fall protection gear.
The first is the user or pre-use inspection, which must be performed by the worker before each use or at the beginning of every work shift. The pre-use check is a quick, systematic visual and tactile examination of the entire system, ensuring that no obvious defects are present before climbing. This daily routine confirms that the equipment is immediately ready for safe operation and catches damage that may have occurred during the previous shift.
The second level is the formal, documented inspection, which must be performed periodically by a designated competent person. This individual is specially trained to identify defects and assess the equipment’s overall integrity against manufacturer specifications. This detailed review is typically required on an annual or semi-annual basis, depending on the regulatory environment or manufacturer’s instructions.
The competent person’s inspection involves a meticulous component-by-component examination. The outcome of this formal assessment determines if the equipment remains compliant with safety standards or if it must be tagged out and retired due to unsuitability.
Documentation and Compliance Requirements
The effective management of fall protection equipment is supported by a comprehensive regulatory framework that places specific administrative duties on employers. Governing bodies like the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI) require employers to maintain detailed records regarding equipment service life. This includes documenting all periodic inspections, maintenance performed, and the final retirement of the equipment.
Maintaining accurate records is necessary to demonstrate compliance with the duty to ensure that all gear is used only within its acceptable service life. Without clear documentation of inspection dates and findings, it becomes impossible to prove the equipment is safe and compliant. Furthermore, employers must maintain written fall protection plans and records of employee training, confirming that all workers understand how to properly inspect, use, and store their personal fall arrest systems. These administrative requirements are as important as the physical condition of the gear itself.