3D Model — Orbit & Inspect
Anatomy of a Full Body Harness
Dorsal D-Ring
Located on the back, centred between shoulder blades. PRIMARY fall arrest attachment point. All fall-arrest lanyards and SRLs connect here.
Sternal D-Ring
Located on the chest. Alternative fall arrest attachment and ladder climbing connection point. Also used for confined space retrieval.
Shoulder Straps
Run over each shoulder from front to back. Distribute arrest forces across the upper body. Must sit flat without twisting.
Leg Straps
Sub-pelvic straps around each thigh. MUST be snug — pass-through or quick-connect buckles. A loose leg strap causes severe injury in a fall.
Chest Strap
Connects the two shoulder straps across the chest. Prevents shoulder straps from spreading apart during a fall arrest.
Waist Belt
Optional component for tool attachment and work positioning only. NOT load-bearing in fall arrest. Never connect a fall-arrest lanyard to the waist belt.
Lanyard Keeper
Elastic loop on the shoulder strap to secure unused lanyard tail and prevent it from snagging on structures during work.
Donning Procedure
Follow this sequence every time you put on a harness:
- Step 1: Hold harness by the dorsal D-ring — let straps hang freely. Shake out any twists.
- Step 2: Step through the leg straps (one leg at a time). Pull harness up over shoulders like a vest.
- Step 3: Connect the chest strap across the sternum. Adjust to sit at mid-chest height.
- Step 4: Tighten all straps until snug — you should be able to fit two fingers flat under each strap (no more).
- Step 5: Check the dorsal D-ring is centred between the shoulder blades — have a buddy verify.
- Step 6: Verify all buckles are fully engaged and locked. No loose tails hanging free.
Critical Rules
Mandatory Requirements
- Dorsal D-ring is the ONLY approved fall arrest attachment point (unless manufacturer specifies otherwise)
- Harness must fit snugly — a loose harness causes severe injury in a fall (spinal loading, sliding through)
- All buckles must be fully engaged — partially buckled = unbuckled
- Harness is PERSONAL equipment — fitted to the individual worker, not shared without re-fitting
- Never modify, paint, or apply chemicals to any harness component
- Never use the waist belt as a fall arrest attachment point
Suspension Trauma
After a fall, a worker hanging motionless in a harness can develop suspension trauma (orthostatic intolerance) — a potentially fatal condition.
Critical Warning — Time Is Limited
- Blood pools in the legs within 5–20 minutes of motionless suspension
- Leads to unconsciousness, renal failure, and death if not rescued
- Worker should pump legs and push against any surface to maintain circulation
- Suspension trauma straps (if fitted) allow the worker to stand in the harness and relieve pressure
Rescue Plan Is Mandatory
- A rescue plan must exist BEFORE any work at height begins
- Rescue must be achievable within 10 minutes maximum
- Self-rescue, assisted rescue, and mechanical rescue methods must all be considered
- After rescue: place worker in a W-sitting position (NOT flat on their back) — sudden release of pooled blood can cause cardiac arrest
Inspection & Rejection Criteria
Inspect harness before every use. Run every strap through your hands. Remove from service if ANY of the following are found:
Reject Immediately If
- Frayed or cut webbing: any visible damage to strap fibres
- Bent or cracked D-rings: distortion from fall loading or impact
- Buckles don’t lock: tongue won’t engage, quick-connect doesn’t click
- Stitching pulled or damaged: broken stitches, pulled thread patterns
- Labels illegible: manufacturer, model, date of manufacture, or standards markings unreadable
- Harness has been in a fall: must be destroyed — internal damage is invisible
- UV degradation: faded colour, stiff or brittle webbing (from prolonged sun exposure)
- Chemical contamination: exposure to acids, solvents, paints, or fuels
- Heat or burn damage: melted fibres, scorching, or discolouration from heat
Good Condition Indicators
- All webbing supple and undamaged, consistent colour
- D-rings smooth, round, and free of distortion
- All buckles engage and lock positively
- Stitching intact with no pulled or broken threads
- All labels and markings legible
- Date of first use recorded and within service life
Lifespan & Maintenance
| Requirement | Detail |
|---|---|
| Typical service life | 5 years from first use |
| Formal inspection interval | Every 6 months |
| Inspected by | Competent person (trained inspector) |
| Date of first use | MUST be recorded on the harness tag |
| After a fall | Remove from service & destroy |
| Storage | Hang in a cool, dry, dark place. Away from chemicals, sharp edges, UV. |
Always check the manufacturer’s specific service life — some may differ from the 5-year general rule. The manufacturer’s instructions override general guidance.
Standards & References
- AS/NZS 1891.1 — Industrial fall-arrest systems and devices: Harnesses and ancillary equipment
- AS/NZS 1891.4 — Industrial fall-arrest systems and devices: Selection, use and maintenance
- AS/NZS 5532 — Manufacturing requirements for harnesses (replaces older parts of 1891.1)
- WHS Regulation 2017 — Chapter 6, Part 4: Falls
- Safe Work Australia — Guide to Managing the Risk of Falls at Workplaces
The full body harness is the single most critical piece of personal fall-arrest equipment. Proper fit, inspection, and rescue planning are non-negotiable.