In the high-risk arena of working at heights, the safety harness is undoubtedly the key 'protagonist' in protecting workers' lives. However, a heartbreaking accident serves as a stark reminder that even with the 'presence' of a safety harness, tragedy can still strike if its quality and retirement standards are neglected.
The Accident Serves as a Wake-Up Call.
On April 8, 2021, a fatal accident occurred at a power generation company during high-altitude operations. While moving along a structural pole, a worker lost his footing and fell. Although he was wearing a safety harness, the harness failed to prevent the fall as it broke at the back connection point, ultimately resulting in his tragic death.
This accident not only brought immeasurable grief to the victim's family but also served as a stark reminder of the importance of workplace safety.
The accident investigation report identified several indirect causes. The primary contractor failed to fulfill its responsibility for workplace safety, unlawfully subcontracting the project to a secondary contractor. Additionally, the procurement, inspection, storage, and distribution of personal protective equipment (PPE) were poorly managed, with inspection processes being merely procedural. On-site management was ineffective, failing to identify the defective safety harness in time, reflecting a severe lapse in safety oversight.
A series of negligence and mismanagement ultimately led to this tragic incident, underscoring the critical need for stringent safety measures and enforcement.
As the 'lifeline' for workers at heights, the quality and safety of safety harnesses are of paramount importance. However, over time and with changing environmental conditions, safety harnesses may gradually wear out, deteriorate, or even fail. To ensure the safety of every high-altitude worker, it is crucial to strictly adhere to the retirement standards for safety harnesses.
1. Service Life of Safety Harnesses
(1) Pole Work Safety Harness
The service life of a pole work safety harness should generally not exceed three years, and it must be inspected by a professional institution annually. Within two years from the date of purchase, two harnesses from the same batch must be randomly selected for dynamic and static mechanical performance tests in accordance with GB6095 standards. If the harnesses fail the tests, the entire batch must be discontinued. Thereafter, batch sampling tests must be conducted annually.
(2) Work Positioning Safety Harness
The service life of a work positioning safety harness should generally not exceed five years. Within two years from the date of purchase, two harnesses from the same batch must be randomly selected for static mechanical performance tests as per GB6095 standards. If the harnesses fail, the entire batch must be discontinued. Subsequent annual batch sampling tests are required.
(3) Fall Arrest Safety Harness
The service life of a fall arrest safety harness should generally not exceed five years. If a fall incident occurs, the harness must be inspected by a qualified professional. If any damage affecting its performance is found, it must be replaced immediately.
Within two years from the date of purchase, two harnesses from the same batch must be randomly selected for dynamic and static mechanical performance tests following GB6095 standards. If the harnesses fail, the entire batch must be discontinued. Subsequent annual batch sampling tests are required.
For fall protection equipment exceeding its service life, if continued use is necessary, semi-annual sampling inspections must be conducted, and only those that pass can remain in use. In environments with extreme conditions or high-frequency use, the service life should be further reduced accordingly.
2. Safety Harness Retirement Standards
(1) Inspection Criteria for Full Retirement
The performance requirements for fall arrest safety harnesses include:
- Buckles must not come loose; the test dummy must not slip out of the harness or fall to the ground.
- Connectors must remain securely closed, and no components should break.
- The peak impact force of the safety harness must be ≤ 6kN.
- The harness must indicate its extension length, which should not exceed the value stated in the permanent marking.
- The test dummy must not hang upside down when suspended.
- There should be no significant asymmetric slippage or deformation of the harness.
- No metal components should be in contact with the dummy’s underarms or inner thighs while suspended.
- No components should exert pressure on the throat or external genitalia of the suspended dummy.
- The maximum slippage of the webbing or rope within each adjustment buckle must be ≤ 25mm.
- If the harness has a fall indicator, it must function correctly and display the occurrence of a fall.
(2) Hardware Components
The hardware components of the safety harness—including buckles, adjustment buckles, D-rings, webbing loops, and lanyard hooks—must not be damaged, broken, or deformed. They should also be free from sharp edges, burrs, cracks, wear, or corrosion.
For PVC-coated hardware, the coating must be intact, without cuts, cracks, tears, or holes, to maintain non-conductive properties. Additionally, buckles and adjustment buckles must function smoothly.
(3) Webbing and Stitching
- The webbing material must be free from abrasion, cuts, or broken fibers. It should be inspected for tears, wear, mold, burn damage, or fading.
- The stitching should be checked for signs of stretching or cutting. If stitches are broken, it may indicate the harness has been subjected to an impact load, and it must be removed from service.
(4) Impact Indicators and Energy Absorbers
Safety harnesses, fall arresters, and other fall protection equipment equipped with impact indicators must be retired and disposed of immediately if the indicator has been activated.
(5) Illegible Markings
If the product label becomes illegible before the harness reaches its designated retirement period, it must be retired. For example, if the manufacturing date is missing, making it impossible to determine whether the harness has exceeded its valid service life, it must be discarded.
3. Daily Management and Precautions
(1) Storage and Maintenance
When not in use, safety harnesses should be stored under the supervision of a designated person. They must be kept away from high temperatures, open flames, strong acids, strong alkalis, and sharp objects, and should not be stored in humid environments. Regular visual inspections should be conducted, and any abnormalities must result in immediate replacement. The frequency of inspections should be determined based on how often the harness is used.
(2) Pre-Use Inspection
Before each use, the user must carefully inspect the safety harness and all its components for damage, wear, or breakage. All connection points must be secure and reliable. If any issues are found, the harness must be replaced immediately—never take risks with compromised equipment.
(3) Proper Usage
The safety harness must be worn and used strictly in accordance with the user manual and operational guidelines. All components should function as intended. For example:
- Buckles must be securely fastened.
- Straps should be properly adjusted to the correct length.
The structure or intended use of the harness must not be altered or modified in any way.
JINPOWER Reminder: Every worker at heights and safety manager should be well-versed in the retirement standards for safety harnesses. Regular inspections and assessments must be conducted to identify and promptly remove any harnesses that no longer meet safety requirements. Ensuring reliable fall protection at all times is crucial for high-altitude operations. Let us all remain vigilant about the quality and condition of safety harnesses, and with a meticulous approach, safeguard the lives of every worker at heights.