Top 5 Mistakes Workers Make with Safety Lanyards (And How to Avoid Them)

Safety lanyards are critical components of fall protection systems, yet their effectiveness depends entirely on correct usage. Even experienced workers can make simple mistakes that compromise their safety on the job.

In this blog post, we'll cover the top five mistakes workers make when using safety lanyards and provide tips on how to avoid them, ensuring you stay protected while working at heights!

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#1. Incorrect Anchorage Point Selection

One of the most common errors workers make is attaching their safety lanyard to an improper anchorage point. An anchorage point must be strong enough to support the forces generated during a fall and should meet OSHA’s requirement of supporting at least 5,000 pounds per worker.

How to Avoid This:

Before starting work, ensure that anchorage points are clearly identified and labeled as suitable for fall protection. Use only OSHA or ANSI-approved anchorage connectors, and if you're unsure, consult your site safety supervisor for guidance. A best practice is to always anchor above your head to reduce the risk of free fall.

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#2. Using a Lanyard That's Too Long or Too Short

Another frequent issue is using a lanyard that is either too long or too short for the job. A lanyard that’s too long increases the free-fall distance, which could lead to serious injury, while one that’s too short may restrict your movement, making the job more difficult and uncomfortable.

How to Avoid This:

Select the appropriate length of lanyard for the work environment. For work areas where there's limited clearance, consider using a self-retracting lanyard (SRL) like the 20FT COBRA SRL. SRLs automatically adjust length and keep the line taut to reduce free-fall distance, enhancing both safety and mobility.

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#3. Improper Use of Shock Absorbers

Some workers mistakenly believe that using a shock-absorbing lanyard in every situation is necessary. However, there are scenarios—like low-clearance jobs—where a shock-absorbing lanyard may not deploy effectively, putting the worker at risk. Conversely, not using one when needed can result in serious injury due to the force of a sudden stop during a fall.

How to Avoid This:

Understand when shock absorption is necessary. For higher platforms or when there’s enough clearance, a shock-absorbing lanyard is ideal as it reduces the impact on the body. In situations with minimal fall clearance, opt for SRLs or non-shock-absorbing lanyards that stop a fall quickly without the need for extended deceleration.

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#4. Failure to Inspect Lanyards Regularly

Even the best safety lanyards can fail if they aren't properly maintained. Fraying, cuts, burns, or worn hardware can reduce a lanyard’s effectiveness, putting workers at risk of injury in the event of a fall. Too often, workers overlook the importance of a daily inspection, leading to the use of compromised equipment.

How to Avoid This:

Inspect your safety lanyard thoroughly before each use. Look for signs of wear and tear, such as fraying fibers, cuts, and damage to stitching. Also, check the hardware, including buckles and hooks, for corrosion or any other deformities. Regularly replace damaged lanyards to ensure compliance and safety.

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#5. Improper Connection to Harness D-Rings

Connecting the safety lanyard to the wrong D-ring on a harness is a dangerous yet avoidable mistake. Each D-ring serves a different purpose; for example, the dorsal D-ring (located at the back) is typically used for fall arrest, while side D-rings are used for work positioning.

How to Avoid This:

Train workers to understand the specific purpose of each D-ring and how to use them correctly. Most fall protection systems rely on the dorsal D-ring for fall arrest, so ensure workers are connecting their lanyards to the right point. Reinforce this during training sessions and refreshers to reduce the likelihood of misuse.

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Using safety lanyards correctly is essential for ensuring the protection of workers in fall-risk environments. By avoiding these common mistakes—such as selecting improper anchorage points, using the wrong lanyard length, and failing to inspect equipment regularly—you can significantly reduce the risk of fall-related injuries. Proper training, regular equipment inspection, and using the right gear for the job are key steps in staying safe!

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