Lanyard Wear Indicators: How to Spot Early Signs of Damage on Fall Arrest Lanyards

When working at height, your fall protection equipment is often the last line of defence between a safe working day and a potentially life-changing incident. Yet one of the most common issues identified during equipment inspections is surprisingly simple: damaged lanyards that should have been removed from service long before our Engineer Surveyor arrived.

Understanding lanyard wear indicators and recognising fall arrest lanyard defects early can help prevent accidents, maintain compliance, reduce downtime, and most importantly, protect the people who rely on the equipment every day.

At Carn Engineering, we regularly inspect working-at-height equipment across construction, manufacturing, utilities, telecommunications, facilities management, and industrial environments. One thing remains consistent across every sector: damaged equipment is often overlooked until a formal inspection reveals the risk.

Why Lanyard Wear Matters

A fall arrest lanyard is designed to absorb and dissipate energy during a fall, reducing the forces transmitted to the user. However, any damage to the webbing, stitching, hardware, or energy absorber can significantly affect its performance.

Many people assume damage will be obvious, but that’s not always the case. UV exposure, chemical contamination, repeated loading, improper storage, and harsh environmental conditions can all degrade equipment over time.

This is why standards such as BS EN 365 require regular inspection and maintenance of personal protective equipment used for work at height.

Understanding the warning signs is the first step towards ensuring your equipment remains safe and compliant.

The Reality of Working at Height in the UK and Ireland

Falls from height continue to be one of the biggest causes of workplace fatalities across the UK and Ireland.

According to the Health and Safety Executive (HSE), falls from height remain the leading cause of fatal workplace injuries in the UK, accounting for more than a quarter of all worker fatalities each year.

Thousands more workers suffer serious injuries following falls from height, resulting in lost working days, project delays, investigations, insurance claims, and significant costs for employers.

In Ireland, the Health and Safety Authority (HSA) consistently identifies falls from height as one of the leading causes of workplace fatalities and serious injuries, particularly within construction, maintenance, agriculture, and industrial sectors.

These statistics reinforce a simple reality: damaged equipment should be identified during inspection, not after an incident occurs.

Critical Lanyard Wear Indicators Every Worker Should Check

1. Check the Webbing for Damage

The webbing is the primary load-bearing component of the lanyard and should be inspected before every use.

Look for:

• Cuts or tears

• Fraying

• Abrasion

• Heat damage

• Chemical staining

• Stiff or brittle sections

These are among the most common fall arrest lanyard defects and should never be ignored. If damage is present, remove the lanyard from service immediately.

2. Inspect Stitching and Seams

Stitching is designed to distribute forces during a fall and is a key part of any lanyard inspection checklist.

Check for:

• Broken threads

• Loose stitching

• Pulled seams

• UV damage

• Distortion

Damaged stitching is one of the most important lanyard wear indicators and can significantly affect the lanyard's performance.

3. Examine Connectors and Hardware

Inspect all metal components, including carabiners, hooks, and adjusters.

Look for:

• Corrosion

• Cracks

• Deformation

• Excessive wear

• Faulty locking mechanisms

Hardware defects are often a clear sign of when to replace a lanyard, even if the webbing appears undamaged.

4. Check the Shock Absorber

If fitted, inspect the energy absorber for:

• Tears

• Water damage

• Loose stitching

• Signs of deployment

A deployed or damaged shock absorber is one of the most serious common lanyard damage signs and requires immediate replacement.

5. Verify Labels and Traceability

Ensure labels remain legible and display:

• Manufacturer details

• Serial number

• Date of manufacture

• Applicable standards

Missing or unreadable labels are often overlooked lanyard wear indicators but can make equipment non-compliant.

6. Look for Environmental Damage

Exposure to UV, chemicals, salt air, heat, and moisture can accelerate deterioration.

These conditions can cause hidden fall arrest lanyard defects that may not be obvious during a quick visual check, making regular inspections essential.

What Competent Engineer Surveyors Look For

A professional inspection involves much more than simply checking for obvious damage.

Competent Engineer Surveyors assess:

• Signs of previous shock loading

• UV degradation

• Environmental exposure

• Manufacturing defects

• Product recalls

• Connector functionality

• Compatibility between equipment components

• Inspection records and traceability

• Evidence of misuse

• Correct storage practices

This deeper level of assessment is often why equipment passes daily user checks but fails a formal inspection. Professional inspections are designed to identify hidden issues before they become safety risks.

When to Replace a Lanyard

One of the most frequently asked questions we receive is when to replace a lanyard.

A lanyard should be removed from service immediately if:

• It has arrested a fall

• Damage is found during inspection

• The shock absorber has deployed

• Hardware is damaged or deformed

• Labels are missing or illegible

• A competent Engineer Surveyor determines it is no longer safe

• The manufacturer specifies retirement based on age or condition

It's important to remember that replacement decisions should not be based solely on visible damage.

The service history, inspection records, environmental exposure, and manufacturer guidance must also be considered.

When it comes to life-saving equipment, caution should always take priority.

If in doubt, take it out.

Daily Checks vs Formal Inspections

Daily pre-use inspections remain one of the most important parts of any work-at-height safety programme.

Users should carry out a visual and tactile inspection before every use, looking for the lanyard wear indicators outlined above.

However, user checks are not a substitute for a formal inspection by a competent person.

A documented lanyard inspection checklist should be completed at appropriate intervals, with formal inspections carried out in accordance with manufacturer guidance, industry best practice, and BS EN 365 requirements.

In harsh working environments, inspections may need to be conducted more frequently than the standard six-month interval.

Why Professional Lanyard Inspections Matter

Many organisations rely entirely on daily checks to identify defects.

While these checks are essential, they are not designed to identify every type of deterioration.

In our experience, some of the most serious fall arrest lanyard defects are not immediately obvious. UV degradation, chemical exposure, hidden webbing damage, compromised stitching, and previous shock loading can all affect equipment performance without displaying obvious visual signs.

Professional inspections help organisations:

• Identify hidden lanyard wear indicators

• Detect common lanyard damage signs before failure occurs

• Maintain compliance with regulatory requirements

• Reduce risk to workers

• Demonstrate due diligence during audits and investigations

• Extend equipment life through proper management

When an incident occurs, one of the first questions investigators ask is whether the equipment was suitable, properly maintained, and adequately inspected.

A documented inspection regime provides both protection and evidence that your organisation takes safety seriously.

Need Professional Working at Height Equipment Inspections?

If you've identified any of the lanyard wear indicators discussed above, noticed potential fall arrest lanyard defects, or you're unsure when to replace a lanyard, professional inspection is the safest course of action.

Carn Engineering provides competent inspections for:

• Fall arrest lanyards

• Safety harnesses

• Anchor points

• Lifeline systems

• Rescue equipment

• Fixed and portable height safety equipment

Our experienced Engineer Surveyors help organisations across the UK and Ireland remain compliant, reduce risk, and ensure workers can carry out their jobs safely and confidently.

If you're in doubt, get in touch. If something doesn't look right, get in touch. If you want complete confidence in your equipment, get in touch.

Contact Carn Engineering today to arrange a professional inspection and keep your team safe, compliant, and ready for work. We’re here to keep your team safe and compliant.

Contact us on: info@carnengineering.com