3D Model — Orbit & Inspect
Anatomy of a Twin-Tail Lanyard
Scaffold Hooks
Large-opening hooks (60 mm gate) designed to fit around scaffold tubes and structural steel. Double-action locking gate prevents accidental opening.
Energy Absorber Pack
Rip-stitch or deformable element that deploys in a fall to limit force on the body to <6 kN. Adds up to 1.75 m to deployed length. ONE-TIME USE.
Webbing Tails (2 Legs)
Two separate legs allow 100% tie-off — always connected to at least one anchor point while moving. Each leg is typically 2 m long.
Dorsal D-Ring Connection
Central attachment point that connects to the harness dorsal D-ring (between the shoulder blades). The energy absorber sits between this connection and the tails.
Indicator Stitching
Coloured thread sewn into the energy absorber pack. If the stitching is torn or pulled, the absorber has deployed and the entire lanyard must be destroyed.
100% Tie-Off Procedure
The twin-tail design ensures the worker is never disconnected from an anchor while moving between positions:
- Step 1: Both hooks connected to anchor point A
- Step 2: Connect hook 1 to new anchor point B (now connected to A and B)
- Step 3: Disconnect hook 2 from anchor point A (now connected to B only)
- Step 4: Move to position, connect hook 2 to anchor point B or next point C
- Repeat: Always at least one hook connected at all times
Never
- Disconnect both hooks at the same time — defeats the purpose of twin-tail
- Connect both hooks to the same D-ring on your harness
- Use a single-tail lanyard where 100% tie-off is required
Energy Absorber
The energy absorber is the critical safety component. It deploys during a fall to reduce the maximum arrest force on the worker’s body.
| Parameter | Value |
|---|---|
| Maximum arrest force | < 6 kN |
| Deployment length | up to 1.75 m |
| Mechanism | Rip-stitch or deformable element |
| Reusable? | NO — one-time use |
Critical
- If the energy absorber has deployed (indicator stitching torn), the ENTIRE lanyard must be destroyed
- If ANY fall has occurred on the lanyard — even if the absorber looks intact — remove from service and have it inspected
- The 1.75m deployment length MUST be included in fall clearance calculations
Fall Clearance Calculation
You MUST calculate fall clearance before working at height. If clearance is insufficient, the worker hits the ground.
Minimum Fall Clearance (Twin-Tail Lanyard)
| Component | Distance |
|---|---|
| Lanyard length | 2.0 m |
| Energy absorber deployment | 1.75 m |
| Worker height (below D-ring) | 1.5 m |
| Safety margin | 1.0 m |
| TOTAL minimum clearance | 6.25 m |
This assumes the anchor is at foot level. If the anchor is above the D-ring, subtract the height difference. Always calculate for the worst case.
Lanyard Types
| Type | Material | Best For |
|---|---|---|
| Webbing | Polyester / Nylon strap | Most common, general construction |
| Wire Rope | PVC-coated steel cable | Hot work, sharp edges, welding |
| Elasticated | Elastic webbing | Reduces snag hazards, retracts when not loaded |
Elasticated lanyards are increasingly popular because they stay compact and reduce trip/snag risk. The elastic stretches under body weight but the energy absorber still handles fall arrest forces.
Inspection & Rejection Criteria
Inspect lanyards before every use. Remove from service if ANY of the following are found:
Reject Immediately If
- Frayed or cut webbing — any visible damage to the webbing tails
- Energy absorber deployed — torn indicator stitching means it has been used in a fall
- Hook gates don’t close — gates must close and lock automatically (double-action)
- Corrosion — rust or pitting on hooks, D-rings, or rivets
- Stitching pulled or damaged — load-bearing stitching must be intact
- Any fall has occurred — the entire lanyard must be removed from service and inspected
- Missing/illegible label — no identification = no use
- Chemical damage — discolouration, stiffness, or softening from chemical exposure
Good Condition Indicators
- Webbing supple, no cuts, frays, or abrasion
- Energy absorber pack intact, indicator stitching untorn
- Both hook gates close and lock automatically
- All stitching tight and undamaged
- Labels legible with current inspection date
- No signs of heat, chemical, or UV damage
Applicable Standards
- 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
- WHS Regulation 2017 — Chapter 6, Part 4 — Falls (managing risk of falls at workplaces)
Lanyards must be inspected by a competent person at least every 6 months or per manufacturer’s instructions. A formal register of all height safety equipment must be maintained.