Competent Inspector Manual

(1)

A Student Guide to Basic Fall Protection

Application

F a l l P r o t e c t i o n

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Leaders in safety innovation

Capital Safety, home of the DBI-SALA and PROTECTA

brands is the world’s leading manufacturer dedicated

solely to fall protection. We are also the pioneer in

the development of intelligent safety technology,

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providing new and improved systems to give you the

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•

INNOVATION to improve your safety and productivity

.

C o n t a c t U s T o d a y

Capital Safety USA

DBI-SALA Training

3833 SALA Way, Red Wing, MN 55066-5005

Phone: 651-388-8282 Toll Free: 800-328-6146 FAX: 651-388-5065

Web Site:

www.capitalsafety.com

EMAIL: [email protected]

© Capital Safety 2007

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Electronic, mechanical, photocopying, recording or otherwise without

prior written permission from Capital Safety USA.

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FALL PROTECTION EQUIPMENT INSPECION GUIDE

Chapter

1 Introduction

Chapter

2 Body Supports

Chapter

3 Lanyards

Chapter

4 Connection Devices

Chapter

5 Anchorage Connectors

Chapter

6 Self-Retracting Lifelines

Chapter

7 Lifelines & Rope Grabs

Appendix

1 Detailed Inspection Logs

Appendix

2 DBI-SALA Technical Bulletins

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Introduction

Objectives

By the end of this chapter, students should be able to explain

the how the following apply to equipment inspection:

State, Provincial and Federal laws and legislation applicable

to inspection;

ANSI (American National Standards Institute), or CSA

(Canadian Standards Association) Standards for equipment

inspection; and

Manufacturer’s (i.e. DBI-SALA) requirements for inspection.

General

roperly functioning fall protection equipment is vital for every person

that works at heights. This equipment is designed to arrest and

protect a worker in case of a fall, so it is important to know how to

properly inspect and care for your equipment. It is extremely important

to follow the laws, standards, and manufacturer’s recommendations for

inspections

How important is the inspection process?

…VERY!

In this chapter you will learn about the CSA and ANSI standards,

manufacturer’s recommendations, and the laws that pertain to workers,

supervisors, and employers regarding equipment inspection.

OHSA

The Laws regarding Fall Protection equipment in the United States are

covered under OSHA and State OSHA legislation. In addition to OSHA,

the ANSI consensus standards may be applied for fall protection

equipment inspection. In Canada, Provincial and Federal regulation, as

well as CSA standards, dictate the need and frequency of inspections for

fall protection equipment. Each State, and Province may have different

legislation, applying to employers and employees, the typical for each are

listed below:

P

Chapter

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Canada

 Construction Regulation; and/or

 Industrial or General regulation

United States

 OSHA 1926.502 Construction Standard

 OSHA 1910.66 General Industry Standard

In North America there are only minor differences in regulations,

however, companies that work across states and provinces should ensure

that they know these differences. Generally, most regulations state that

the user of the fall arrest equipment shall inspect each component of the

system prior to use. There are newer regulations in some States and

Provinces, which state that the user must comply with the manufacturer

and ANSI, or CSA requirements. As an employer or user of fall protection

equipment, it is a requirement to understand and follow these regulations

and standards.

ANSI, CSA, and most manufacturers, state that each part of a fall arrest

system must be inspected prior to use, and in addition to this, at least

annually by a competent person other than the user. If the equipment

has been subject to a fall, it shall be removed from service and discarded;

or removed from service, labeled and stored; or returned to service if it

has been authorized for reuse by a competent or qualified person

according to the manufacturer’s recommendations.

Standards:

United States - ANSI

Canada - CSA

A10.14-1991

Z259.11-92 Shock Absorber

Z359.2 -2007

Z259.2.1-98 Fall Arrester & Vertical Lifelines

Z259.2.2-98 Self retracting Devices PFAS

Z259.10 M90/98 Full Body Harness

Z259.1 Safety Belts & Lanyards

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Summary

This module has been a brief overview of the Legislation, Standards, and

manufacture’s recommendation of fall protection inspection requirements.

Students must make an effort after this session to read and understand

the requirements pertaining to their specific local in further detail.

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2-1

Full Body Harnesses

Objectives

By the end of this chapter, students should be able to:

Perform a full body harness inspection and name the four key

inspection components.

Explain the difference between a prior-to-use inspection vs. a

CSA/ANSI, and manufacturer’s recommended inspection

Use an inspection log sheet to record a harness inspection.

Recommend criteria for harnesses

storage, cleaning, and

maintenance.

General

he full body harness is an integral part of the fall arrest system.

Though designed ruggedly for practical use in the construction

industry, the harness requires daily and annual inspections.

Further, there may be legislative requirements in some locations that

require more frequent inspections than the CSA and ANSI standards

dictate. In the end, all of the rules and regulations are there to make sure

that if you were ever to fall, your harness is going to work.

The four key components of the

full body harness requiring

inspection are:

• Hardware

• Webbing

• Labels

• Stitching

T

Chapter

2

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2-2

IMPORTANT: If the full body harness has been subjected to fall arrest or impact

forces it must be immediately removed from service.

IMPORTANT: Extreme working conditions (harsh environments, prolonged use,

etc.) may require increasing the frequency of inspections.

FREQUENCY

• Before each use, by the user

• By a competent person, other than the user, at least annually

• The results of the inspection should be recorded

Inspection Criteria

Hardware: is any integral metal and

plastic component on the harness:

• • Dorsal D ring

• Dorsal back pad

• Buckles

• Keepers

• D, L, P, E, positioning rings

Webbing: is the synthetic fiber straps that makeup the harness; all

stitch patterns and webbing must be checked for:

• Frays

• Cuts

• Broken fibers

• Tears

• Abrasions

• Mold

• Burns

• Discoloration

• Holes

• Or any other damage

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2-3

INSPECTION STEPS:

Step 1

Inspect harness hardware (buckles, D-rings, back pad, loop keepers);

these items must not be damaged, broken, distorted, and must be free of

sharp edges, burrs, cracks, worn parts, or corrosion.

PVC coated hardware must be free of cuts, rips, tears, holes, etc. to

ensure non-conductivity. Ensure buckles work freely. Inspect all buckle

springs.

Step 2

Inspect webbing material it must be free of all:

• frays

• cuts

• broken fibers

Also check for tears, abrasions, mold, burns, or

discoloration.

Inspect stitching; check for pulled or cut stitches. Broken stitches may be

an indication that the harness has been impact loaded and must be

removed from service.

Step 3

Inspect labels; all labels should be present and

fully legible.

Step 4

Inspect each system component or subsystem according to manufacturer's

instructions.

Pass-Thru Buckle: Pass male buckle through female buckle and pull free end of webbing to tighten.

Quick-Connect Buckle:

Insert male portion into receptor until click is heard. Pull free end of web to

tighten.

Tongue Buckle: Pass webbing through buckle and then tongue through grommet. Secure

web through keeper. Parachute Buckle:

Pass web up through center slot of buckle, over knurled bar and back under frame. Pull web to tighten.

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2-4

Step 5.

Record the inspection date and results in the company

inspection and maintenance log, and check off the inspection

box on the label attached to the harness.

If inspection reveals a defective condition, remove unit from service

immediately and destroy.

MAINTENANCE, SERVICING, STORAGE

Clean full body harness with water and a mild soap solution.

Do not uses bleach or bleach solutions.

Wipe off hardware with a clean, dry cloth, and hang to air dry.

Do not force dry with heat.

Store full body harnesses in a cool, dry, clean environment out of

direct sunlight.

Avoid areas where chemical vapors may exist.

Thoroughly inspect the full body harness after extended storage.

An excessive buildup of dirt, paint, etc. may prevent the full body

harness from working properly, and in severe cases degrade the

webbing to a point where it should be removed from service.

More information on cleaning is available from DBI-SALA. If you

have questions concerning the condition of your harness, or have

any doubt about putting it into service contact DBI-SALA.

(11)

2-5

DBI-SALA - Supplemental Inspection Information

Life Expectancy: DBI-SALA does not have a cut-off date for service life for its

equipment. As long as the product continues to pass the inspection, the item

can continue to be used. The Owner's User Manual should be consulted

regarding inspection frequency, and details on inspections.

Holes/Burns: In critical areas of the product such as lanyards, shoulder or leg

straps on full body harnesses, or on strength members of a product, a hole or

burn, larger than 1/16 inch diameter, shall be grounds for rejection. More than

two through holes on the same strap, shall be grounds for rejection. Holes on

less critical components, such as chest straps of full body harnesses, or wear

pads on products, can be up to 1/4 inch diameter before the part is rejected.

See "Heat Damage" section.

In most areas, cuts in webbing exceeding 1/8 inch in length shall be grounds for

rejections. In areas near the dorsal d-ring, cuts of any length are grounds for

rejection.

Stitching: More than two ripped or cut stitches, within the same stitch pattern,

shall be grounds for rejection. Ripped or cut stitches may be an indication that

the product has been impact loaded.

Cleanliness: General dirtiness normally will not be grounds for rejection, unless

the buckles and other moving parts of the product are not able to function

properly. Paint on webbing can cause web fiber rupture when the part is flexed

therefore, web coated with paint shall be rejected. Web soaked with oils or

other fluids should be inspected closely. Product MSD sheets should be

reviewed to determine possible effects on products.

Heat Damage: Areas damaged by heat (brown, hard areas) sources (i.e., weld

slag, flames, etc) shall be closely reviewed. Large concentrations of damage are

grounds for rejection.

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Lanyards

Objectives

By the end of this chapter students should be able to:

Identify different types of lanyards.

Perform inspections on various lanyards.

List the legal requirements for inspection as well as CSA/ANSI

consensus standards and a manufacturer’s inspection requirements

Use an inspection log sheet to record a lanyard inspection.

Chapter

3

EZ Stop II Web Lanyard EZ Stop II Shockwave Lanyard EZ Stop II Wire Rope Lanyard EZ Stop II Tie-Back Lanyard EZ Stop III Web Lanyard EZ Stop II Energy Absorber Component EZ Stop III Shock Wave Lanyard Stitching Label Lanyard Nylon or Polyester Web

Self Locking Snap hook Self Locking Snap hook Lanyard Nylon or Polyester Rope

(13)

INSPECTION

FREQUENCY:

• Before each use, by the user,

• By a competent person, other than the user, at least annually,

• The results of the inspection should be recorded.

I

N

S

INSPECTION STEPS:

Step 1.

Inspect lanyard hardware (snap hooks, adjusters, thimbles, spreader

bar, etc.). These items must not be damaged, broken, distorted, or

have any sharp edges, burrs, cracks, worn parts, or corrosion. Ensure

the connecting hooks work properly. Hook gates must move freely and

lock upon closing. Ensure adjusters, if present, work properly.

Step 2.

Inspect the lanyard per the following as applicable:

WEBBING AND STITCHING:

 Inspect webbing

o Material must be free of

 Frays

 Cuts

 Broken fibers.

o

Check for

 Tears

 Abrasions

 Mold

 Burns

 Discoloration

IMPORTANT: Extreme working conditions (harsh environment, prolonged use, etc.)

may require increasing the frequency of inspections

IMPORTANT: If this equipment has been subjected to forces resulting from the arrest

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All of the above factors are known to reduce rope strength

 Inspect stitching

o

Check for pulled or cut stitches

o

The webbing must be free of

 Knots

 Excessive soiling

 Heavy paint buildup

 Rust staining

o Check for chemical or heat damage indicated by

 Brown patches

 Discolored areas

 Brittle areas

o

Check for ultraviolet damage indicated by

 Discoloration and the presence of splinters or slivers on the

webbing surface (Chalking).

All of these above factors are known to reduce webbing strength.

SYNTHETIC ROPE:

 Inspect rope for concentrated wear

o Material must be free of

 Frayed strands

 Broken yarns

 Cuts

 Abrasions

 Burns

 Discoloration

o The rope must be free of

 Knots

 Excessive soiling

 Heavy paint buildup

 Rust staining

o

Rope splices must be tight, with at least five (5) full tucks, and

thimbles must be held by the splice

o Check for chemical or heat damage indicated by

 Brown marks

 Discolored, or brittle areas

o Check for ultraviolet damage, indicated by

 Discoloration and the presence of splinters and slivers on the

rope surface

(15)

Step 3

Inspect labels. All labels must be present and fully legible.

Step 4

Inspect each system component or subsystem according to associated

manufacturer’s instructions.

Step 5

Record the inspection date and results on the inspection log.

 If inspection reveals a defective condition, remove unit from service

immediately and destroy, or

 Contact a factory authorized service center for repair.

MAINTENANCE - SERVICING - STORAGE



Clean lanyard with water and a mild detergent solution.

o

Wipe off hardware with clean, dry cloth, and hang to air dry

o Do not force dry with heat

If you have any questions regarding cleaning of this equipment, or require

more information contact DBI-SALA.

An excessive buildup of dirt, paint, etc., may prevent the lanyard from

working properly, and in severe cases degrade the webbing or rope to a

point where it has become weakened and should be removed from service.

If you have any questions concerning the condition of your lanyard, or have

any doubt about putting it into service, contact

DBI-SALA.

 Additional maintenance and servicing procedures (i.e. replacement

parts) must be completed by a factory authorized service center only.

 Store the lanyard in a cool, dry, clean environment out of direct sunlight.

o Avoid areas where chemical vapors may exist.

o Thoroughly inspect the lanyard after extended storage.

IMPORTANT: Only DBI-SALA or parties authorized in writing may make repairs to this

equipment.

(16)

Inspecting the Energy Absorber for Activation

FREQUENCY

• Before each use, by the user

• By a competent person, other than the user, at least annually

• The results of the inspection should be recorded

IMPORTANT: If the energy absorbing lanyard or energy absorber component

has been subjected to fall arrest or impact forces, it must be immediately

removed from service.

IMPORTANT: Extreme working conditions (harsh environment, prolonged use,

etc.) may require increasing the frequency of inspections.

The following inspection items are indications that the energy absorber has been subjected to impact loading, has been activated, and should be removed from service

Torn Webbing

Torn or Broken Cover Open end or ripped out

stitching

Measured Length more than six (6) inches longer than length marked on label

(17)

Inspection Steps: Energy Absorbing Lanyard

Step 1

Inspect energy absorbing lanyard or energy absorber component hardware

• Snap hooks

• Adjusters

• Swages

• Thimbles, etc

These items must not be damaged, broken, distorted, or have any sharp

edges, burrs, cracks, worn parts, or corrosion. Ensure the connecting

hooks work properly. Hook gates must move freely and lock upon

closing. Ensure adjusters (if present) work properly.

Step 2

Inspect the energy absorbing lanyard or energy absorber component per

the following as applicable:

WEBBING AND STITCHING:

 The webbing material must be free of

o

Frays, cuts, or broken fibers

 Check for tears, abrasions, mold, burns, or discoloration, etc.

 The webbing must be free of knots

o Excessive soiling

o Heavy paint buildup

o

Rust staining

 Check for chemical or heat damage indicated by

o

Brown

o Discolored, and/or

o Brittle areas

 Check for ultraviolet damage indicated by

o Discoloration

o

The presence of splinters or slivers on the webbing surface.

 Inspect stitching for pulled or cut stitches.

o Broken stitches may be an indication the energy-absorbing lanyard or

energy absorber component has been impact loaded and must be

removed from service

All of the above factors are known to reduce webbing strength.

(18)

WIRE ROPE:

Inspect entire length of the wire rope. Always wear

protective gloves when inspecting wire rope.

 Inspect for broken wires by passing cable through

gloved hands and:

o Flexing it every few inches to expose breaks

o Broken wires can be removed by bending the

wire back and forth parallel to the rope

length

 Remove the energy-absorbing lanyard from service immediately and

destroy if there are six or more randomly distributed broken wires in one

lay or three or more broken wires in one strand in one lay.

 A “lay” of wire rope is the length of wire rope that it takes for a strand (the

larger groups of wires) to complete one revolution or twist along the rope.

 Remove the energy-absorbing lanyard from service immediately and

destroy if there are any broken wires within 1 inch of the metal

compression sleeves (swages) at either end of the assembly.

 The wire rope should be free of corrosion.

Step 3

ENERGY ABSORBING COMPONENT: Inspect energy absorber to determine if it

has been activated. There should be no evidence of elongation. Ensure energy

absorber cover is secure and not torn or damaged. On the EZ Stop® III

Shockwave™ Lanyard models, the lanyard webbing will stretch out to reveal the

warning on the impact indicator label.

Step 4

All labels should be present and fully legible

Step 5

Inspect each system component or subsystem per associated manufacturer's

instructions.

Step 6

Record the inspection date and results in the inspection log

If inspection reveals an unsafe condition, remove unit from service immediately,

or contact an authorized service center for repair.

NOTE: Only DBI-SALA or parties authorized in writing may make repairs to this

equipment.

(19)

MAINTENANCE, SERVICING, STORAGE

 Clean lanyard with water and a mild detergent solution.

o Wipe off hardware with a clean, dry cloth, and hang to air dry

o Do not force dry with heat

If you have any questions regarding cleaning of this equipment, or require

more information, contact DBI-SALA.

 An excessive buildup of dirt, paint, etc., may prevent the lanyard from

working properly

o In severe cases, it can degrade the webbing or rope to a point where

it has become weakened and should be removed from service

If you have any questions concerning the condition of your lanyard, or have

any doubt about putting it into service, contact DBI-SALA.

 Store the lanyard in a cool, dry, clean environment out of direct sunlight.

o Avoid areas where chemical vapors may exist

o Thoroughly inspect the lanyard or energy absorber component after

extended storage

(20)

Hooks and Carabiners

Objectives

BY the end of this chapter students should be able to:

Inspect snap hooks and carabiners

Explain the changes required by ANSI for gate strength.

Use an inspection log sheet to record snap hook and carabiner

inspections.

DESCRIPTION

Snap Hooks: Snap hooks are self closing/self locking connectors. The snap

hooks provide an eye for attachment of a lifeline or lanyard. Some snap

hooks have an eye, which swivels relative to the hook.

Carabiners: Self-locking carabiners are self closing/self locking connectors;

some include a pin that may be used to retain a permanently connected

lanyard or lifeline.

Chapter

4

Snaphook Carabiners Nose Gate Nose Nose Nose Nose Nose Gate Gate Gate Gate Gate

Gate must close Warning Lock Lock Gate must lock Part Number Mfg. ID Year of Mfg Part Number Mfg. ID Year of Mfg. Part Number Mfg. ID Year of Mfg. Part Number Mfg. ID Year of Manufacture Part Number Mfg. ID Year of Mfg. Part Number Mfg. ID Year of Mfg. Lanyard/Lifeline

Swivel Eye Lanyard/Lifeline Eye Lock

Lanyard/Lifeline

Optional Retaining Pin

9503175 ¾” Throat Opening 9500100, 2100000 ¾” Throat Opening 2007153 2 ¼” Throat Opening 2000523, 2000524 ¾” Throat Opening 2000106

1 3/16” Throat Opening 2” Throat Opening 2000108

Gate must close Warning Lock Gate must lock

(21)

INSPECTION

FREQUENCY:

 Before each use, visually inspect according to manufacture and

standards.

 The snap hook or carabiner must be inspected by a competent

person, other than the user, at least annually. Results of each

formal inspection must be recorded according to legislative

standards

New Design Requirements: As of November

2007, ANSI Z359.1 has specified new strength

requirements for snap hook and carabiner gates.

The new snap hooks and carabiners have a

minimum tensile strength of 5,000 lbs. in the

intended direction of the load. Further, the front of

the gates will be able to withstand a load of 3600

lbs. and withstand a side load of 3600 lbs.

MAKING CONNECTIONS:

USE CONSIDERATIONS: When

making a connection using a snap

hook or carabiner, the mating

connector must be compatible in size

and shape, for the intended load

direction for each hook. Improper

loading directions can cause the

hook to fail or the gate to open,

releasing the load. Do not use

hooks that will not completely close

over the attachment object. Do not

connect snap hooks to snap hooks,

carabiners to carabiners, or snap

hooks to carabiners. Do not install

more than one snap hook or

carabiner into a single connection ring or opening (except for emergencies).

Do not connect snap hooks or carabiners to objects or openings that may

abrade or wear the hook material.

IMPORTANT: If this equipment has been subjected to fall arrest or impact forces, it must be

immediately removed from service and destroyed, or returned to an authorized service center for repair.

(22)

MAKING CONNECTIONS: When

using a hook to connect to the

anchorage connector, ensure roll

out cannot occur. Rollout occurs

when interference between the

hook and mating connector causes

the hook gate to unintentionally

open and release. Self -locking

snap hooks and carabiners should

be used to reduce the possibility of

roll out. Do not use hooks or

connectors that will not completely

close over the attachment object.

BEFORE EACH USE, carefully inspect the equipment it to assure it is in

good working condition. Check for worn or damaged parts. Inspect for

sharp edges, burrs, cracks, distortion, or corrosion. Gates must close and

lock. Inspect other fall arrest or restraint equipment according to

manufacturer's instructions.

INSPECTION STEPS:

Step 1

Inspect the snap hook or carabiner for damage. Look carefully for cracks,

sharp edges, burrs, dents, or deformities. Check for bending or distortion.

Step 2

Inspect the snap hook or carabiner for excessive corrosion. The gate and lock

should operate smoothly, with no difficulty. Gates must fully close and

engage nose of hook.

Step 3

Inspect markings. Markings should be present and fully legible.

Step 4

Inspect each system component or subsystem according to manufacturer's

instructions.

Step 5

Record the inspection date and results in the in the inspection and

maintenance log at the end of this module.

NOTE: Only DBI-SALA, or parties authorized in writing, may make repairs to

this equipment.

If the inspection reveals a defective condition, remove unit from service, or contact an authorized service center for repair.

Correct connection Correct connection

Incorrect connection

Correct connection Incorrect connection

Rough Edge Tight Fit

Connection Compatibility

(23)

MAINTENANCE AND SERVICING

If gate operation is sluggish, apply a small amount of WD-40 or similar

moisture repellant agent to the hinge end only. If you have questions

concerning the condition of the snap hook or carabiner, contact your

manufactures representative or refer to the accompanying user guide for the

product.

(24)

Anchorage Connectors

Objectives

By the end of this module students should be able to:

Perform inspections of various anchorage connectors such as Anchor

Straps, Beam Clamps, and Trolleys

Use an inspection log sheet to record anchorage connector inspections.

A Selection of Anchorages Connectors

Chapter

5

Beam Trolley Fixed Beam Anchor

Boom Belt _{Scaffold Choker}

Chain Tie-off Standard Tie-off Adaptor Adjustable Tie-off Adaptor Kevlar Web Tie-off Adaptor

(25)

must pass through the large D-ring. The connecting subsystem must be connected to

the small D-ring only. Do not attach the subsystem to both D-rings.

APPLICATIONS

PURPOSE: There are many Anchorage Connectors in today’s market

designed for a variety of personal fall arrest, restraint, and work

positioning, suspension, or rescue systems. Tie-off adapters and scaffold

chokers may be used as an anchorage connector for a horizontal lifeline if

the system is designed, installed, and used under the supervision of a

qualified person. Do not hang, lift, or support tools or equipment from

this equipment.

Kevlar web tie-off adapters should be used when working with high

temperature tools or materials, or in high temperature environments

(foundries, chemical manufacturing, steel fabrication, emergency rescue

services, fire services, welders, oil industry, and nuclear industry).

STRUCTURE: The structure to which the anchorage connector is attached

must be free of corrosion, cracks, deformities, or other defects that may

weaken the structure. Do not attach an anchorage connector to a vertical

structure unless a means of restraining the connector from sliding down

the structure is present. If the anchorage connector were to slide down

the structure in a fall arrest situation, serious injury to the user is

possible.

CONNECTING TO THE ANCHORAGE CONNECTOR: The connection to

the installed anchorage connector must be with a self-locking snap hook

or self-locking carabiner only, for tie-off adapters, connect your

subsystem to the small D-ring only.

Do not use a knot to connect a lifeline to the anchorage connector.

Do not pass lanyard or lifeline through the anchorage connector

D-ring and hook back into lanyard or lifeline.

Ensure connections are fully closed and locked.

When using an energy-absorbing lanyard, connect the energy absorber

"pack" end to the harness. Ensure self -retracting lifeline is positioned so

that retraction is not hindered. Always protect lifeline or lanyard from

abrading against sharp or abrasive surfaces in your work area.

WARNING: The anchorage connector must be tight against the anchoring structure. Do

not leave slack in the tie-off adapter, this may increase the free fall distance in the

event of a fall. Do not leave slack in

the anchorage connector. Do not attach sub-system to both D-rings on tie-off adaptor

(26)

Tie off Adaptors

INSPECTION

FREQUENCY:

 Before each Use: Inspect the tie-off adaptor

as detailed in the steps below.

 Formal Inspection: A formal inspection of the

anchorage connector must be performed at

least annually by a competent other than the

user. The frequency of formal inspections

should be based on conditions of use or

exposure.

 Recording: Record the inspection results in the inspection and

maintenance log at the end of this module.

INSPECTION STEPS:

Step 1

Inspect the anchorage connector hardware, including

 Chain (if applicable)

 Pivotal link

 D-rings

 O-ring

 Rivets

 Adjuster buckle

These items must not be damaged, broken, distorted or have any sharp

edges, burrs, cracks, worn parts, or corrosion.

IMPORTANT: If this equipment has been subjected to fall arrest forces it must be

(27)

Step 2

Inspect the anchorage connector webbing and stitching.

The webbing must be free of:

 Frays

 Cuts

 Broken fibers

 Tears

 Abrasions

 Mold

 Discoloration

The webbing must also be free of:

 Knots

 Excessive soiling

 Heavy paint build-up

 Rust staining

Check for chemical or heat damage indicated by:

 Brownish areas

 Discoloration

 Brittle areas

Check for ultraviolet degradation indicated by:

 Discoloration

 Presence of splinters or white powder

 Slivers on the webbing surface

Check for pulled or cut stitches

 Broken stitches may be an indication that the anchorage connector

has been impact loaded and must be removed from service

All the above factors are known to reduce the strength of the

anchorage connector. Damaged or questionable anchorage

connectors must be removed from service.

Step 3

Ensure the condition of the anchorage will support the anchorage connector

loads. An anchorage connector connected to a damaged anchorage must not

be used.

Step 4

Ensure the anchorage connector is securely attached to the anchoring

structure. If anchorage connector is loose, do not use.

Step 5

Inspect each system component or subsystem according to associated

manufacturer's instructions.

(28)

Step 6

Record the inspection date and results in the inspection log at the end of this

module

MAINTENANCE, STORAGE

Clean anchorage connector with water and a mild detergent solution.

 Wipe off hardware with a clean dry cloth

 hang to air dry

 Do not force dry with heat

An excessive build-up of dirt, paint, etc. may prevent the anchorage

connector from working properly, and may degrade the webbing to a point

where it has become weakened and should be removed from service.

If you have questions concerning the condition of your anchorage connector,

or have any doubt about putting it into service, contact DBI-SALA.

Store the anchorage connector in a cool, dry, clean environment, out of direct

sunlight. Avoid areas where chemical vapors exist. Thoroughly inspect the

anchorage connector after extended storage.

Fixed Beam Anchor

INSPECTION

FREQUENCY: Before each use, inspect the Fixed Beam Anchor. The Fixed

Beam Anchor must be formally inspected by a competent person other than

the user at least annually.

Record the results in an inspection and maintenance record log

IMPORTANT: If this equipment has been subject to fall arrest forces it must be removed from service and destroyed, or returned to DBI-SALA for inspection or repair.

Column Side Mount

(29)

INSPECTION STEPS:

Step 1

Inspect Fixed Beam Anchor for damage; look for:

 Cracks

 Dents

 Deformities

 Bending or wear on the support tube

 Beam hooks

 Adjustment pin

 Adjustment handle

Ensure no parts are missing

Step 2

Inspect entire unit for excessive corrosion

Step 3

Ensure the detent pin can be inserted through the adjustment holes, and

locks in place

Step 4

Inspect labels. All product information labels must be present and fully

legible

Step 5

Record the inspection date and results in the inspection and maintenance log

If inspection reveals an unsafe or defective condition remove unit from

service and destroy, or return to DBI-SALA for repair.

NOTE: Only DBI-SALA or parties authorized in writing may make repairs to

this equipment.

MAINTENANCE, SERVICING, STORAGE

CLEANING: Periodically clean the Fixed Beam Anchor using water and a mild

soap solution. Do not use acids or other caustic chemicals that could damage

the system components. A lubricant may be applied to the detent pin.

USER EQUIPMENT: Maintain, service, and store harness and personal fall

(30)

Beam Trolleys

INSPECTION

FREQUENCY: Before each use, visually inspect the Trolley. The Beam Trolley

must be formally inspected by a competent person other than the user at

least annually.

Record the results in an inspection and maintenance record log

INSPECTION STEPS:

Step 1

Inspect trolley for damage. Look for cracks or deformities. Look for

excessive wear or damage to the anchorage point. All fasteners must be

secure.

Step 2

Inspect trolley wheels. All wheels should turn freely and be undamaged.

Step 3

Inspect entire unit for corrosion.

Step 4

The warning label must be present and fully legible.

Step 5

Record inspection results in log

IMPORTANT: If this equipment has been subject to fall arrest forces it must be removed

(31)

MAINTENANCE, SERVICING, STORAGE

MAINTENANCE: Clean the trolley using water and mild detergent. Wipe dry

with a clean cloth and hang to air dry. Do not force dry with heat. An

excessive build-up of dirt, paint, etc. may prevent the trolley from working

correctly. No lubrication is required.

SERVICING: Must be completed by an authorized service center.

Authorization must be in writing.

STORAGE: Store this equipment in a cool, dry, clean environment. Inspect

the trolley after extended storage.

ID Label Standard Adjustable Length Tie-Off Adaptors and Boom Belt

Kevlar Web Tie-Off Adaptors

(32)

© Capital Safety 2006 1-800-328-6146 MHB123107 6-1

Self-Retracting Lifelines (SRL)

Objectives

By the end of this chapter, students should be able to:

Perform inspections on Types I, II, and III SRL’s.

Use an inspection log sheet to record the SRL inspections.

General: Self Retracting Lifelines may be divided into three categories:

Type 1: 10 feet and shorter with typically an external shock absorbing system,

Type 2: 10 feet and over, generally having an internal shock absorbing system,

Type 3: Type Two self retracting lifelines with a retrieval mechanism.

This chapter will look at the inspection requirement for each category.

APPLICATIONS

PURPOSE: DBI-SALA self-retracting lifelines (SRL) are designed to be

components in personal fall arrest systems (PFAS). They may be used in most

situations where a combination of worker mobility and fall protection is required

(i.e. inspection work, general construction, maintenance work, oil production,

confined space work, etc.). Some SRL models incorporate a built-in retrieval

feature. These models have the same fall arrest capabilities as those described

above when used in their non-retrieval mode. In the retrieval mode, these

models may be used for emergency rescue (raising or lowering) of personnel

within the capacity range stated. It is also permissible to use retrieval models

for raising and lowering of materials within the stated capacity range.

Type One (Talon)

INSPECTION FREQUENCY:

Chapter

(33)

BEFORE EACH USE: Inspect the SRL

according to the inspection steps listed in this

section.

AFTER A FALL: Inspect SRL by factory

authorized service center

IMPACT INDICATOR: To inspect the impact

indicator, find the fold in the web lifeline

stitched with red thread. If the red stitching is

torn or missing and the fold opened, the SRL

has been impacted and must be removed from

service and returned to an authorized service center for repair. Do not

re-stitch fold.

WARNING: If the SRL has been subjected to fall arrest or impact

forces it must be removed from service and returned to an authorized

service center for repair.

(34)

INSPECTION STEPS:

Step 1

Check for loose screws and bent or damaged parts.

Step 2

Check housing for distortion, cracks, or other damage. Ensure the anchorage

point is not damaged or distorted.

Step 3

Lifeline must fully extend and retract smoothly with no hesitation or slack line

condition.

Step 4

Ensure the device locks when the lifeline is pulled sharply. Lockup should be

positive, with no slipping.

Step 5

Labels must be present and fully legible.

Step 6

Check for corrosion on the entire unit.

Step 7

Check lifeline for cuts, burns, chemical damage, or severely abraded areas.

Lifeline must not be damaged.

Step 8

Check connecting hooks or carabiners for damage, distortion, or corrosion, and

working condition.

Step 9

Inspect each component of the personal fall arrest system according to

manufacturer’s instructions.

Step 10

Record inspection results in the inspection and maintenance log

REMOVE SRL FROM SERVICE if inspection reveals an unsafe or defective

condition. Contact an authorized service center for repair. Only DBI-SALA or

parties authorized in writing may make repairs to the SRL.

(35)

MAINTENANCE, SERVICING, AND STORAGE

MAINTENANCE:

HOUSING: Periodically clean the exterior

of the SRL with water and a mild

detergent. Position the SRL so water can

drain out. Clean labels as required.

LIFELINE:

Clean lifeline with water and a mild

detergent. Rinse and thoroughly air dry.

Do not force dry with heat. An excessive

build-up of dirt or other contaminants may

prevent the lifeline from fully retracting,

causing a potential free fall hazard.

Return SRL to an authorized service center for lifeline replacement if

necessary.

PERSONAL FALL ARREST SYSTEM COMPONENTS:

Clean and store associated system components according to manufacturer’s

instructions.

SERVICING:

Do not disassemble the SRL. Do not lubricate any part of the SRL.

Additional maintenance and servicing must be performed by an authorized

service center. A return authorization number must be issued by DBI-SALA.

STORAGE:

Store the SRL in a cool, dry, and clean environment, out of direct sunlight.

Avoid storing the SRL in areas where chemical vapors exist. Thoroughly

inspect the SRL after extended storage.

DESCRIPTIONS

Talon 8 ft. Series Self-Retracting Lifeline: Includes quick connect

anchorage attachment handle and 8 ft. nylon web lifeline; or, order picker

anchorage attachment handle and 8 ft. nylon web lifeline.

Talon 16 ft. Series Self-Retracting Lifeline: Includes swivel eye

anchorage attachment and 16 ft. nylon web lifeline.

Specification Label Warning Label

(36)

INSPECTION FREQUENCY:

Type Two (Ultra-Lok)

Before Each Use:

Inspect as per steps listed below.

After Fall Arrest

Inspect load indicator and entire SRL by factory authorized service center if

impact indicator is deployed.

IMPACT INDICATOR: To inspect the impact indicator, look for exposed

color band on hook. If the hook is in the “indicated mode,” an impact

loading has occurred. SRL's which have been subjected to impact loading:

 Must be removed from service for inspection

 Do not attempt to reset impact indicator

 Return to an authorized service center for resetting



NOTE: On some models swivel will not turn freely in “indicated mode.”

INSPECTION STEPS

Step 1

Inspect for loose bolts and bent or damaged parts.

Step 2

Inspect housing for distortion, cracks, or other damage.

Step 3

Lifeline should pull out and retract fully without hesitation or creating a slack

line condition.

Step 4

Ensure device locks up when lifeline is jerked sharply. Lockup should be

positive with no slipping.

Step 5

(37)

Step 6

Look for signs of corrosion on the entire unit.

Step 7

WIRE ROPE: Inspect wire rope for cuts, kinks, broken wires, corrosion,

chemical contact areas, or severely abraded areas. Slide up cable bumper

and inspect ferrules for cracks or damage. NOTE: Replace the wire rope

assembly if there are six or more randomly distributed broken wires in one

lay, or three or more broken wires in one strand in one lay. A “lay” of wire

rope is the length of wire rope it takes for a strand (the larger groups of

wires) to complete one revolution or twist along the rope. Replace the wire

rope assembly if there are any broken wires within one inch (25mm) of the

ferrules.

SYNTHETIC ROPE (Spectra and Technora): Inspect synthetic rope for

concentrated wear, frayed strands, broken yarns, cuts, and abrasions. The

lifeline must be free of knots throughout its length. Inspect for excessive

soiling, paint build-up, and rust staining. Inspect for chemical or heat

damage indicated by brown, discolored, or brittle areas. Inspect for

ultraviolet damage indicated by discoloration and the presence of splinters

and slivers on the rope surface.

Step 8

Inspect connecting hooks for signs of damage, corrosion, and working

condition. Swivel should rotate freely. Inspect impact indicator.

Step 9

WIRE ROPE MODELS: Inspect reserve lifeline payout. If a fall has been

arrested when most of the lifeline was out, it is possible that the reserve

lifeline has been deployed. To inspect for reserve lifeline deployment, pull

lifeline out of the SRL until it stops. If the reserve lifeline cable stop or cable

guide sleeve is visible, the reserve lifeline has been spent, and the unit must

be serviced by an authorized service center before reuse. If the reserve

lifeline has not been deployed, that portion is acceptable and the inspection

can continue.

WARNING: Do not tie or knot lifeline. Avoid lifeline contact with sharp or

abrasive surfaces. Inspect lifeline frequently for cuts, fraying, burns, or signs

of chemical damage. Dirt, contaminants, and water can lower dielectric

properties of the lifeline. Use caution near power lines.

NOTE: All of the above factors are known to reduce rope strength. Rope

strength is reduced proportional to the cross sectional area of the rope

damaged. Damaged or questionable ropes must be replaced

(38)

SYNTHETIC ROPE MODELS (Spectra and Technora):

Inspect reserve lifeline payout. If a fall has been arrested, it is possible the

reserve lifeline has been deployed. To inspect for reserve lifeline

deployment, pull lifeline out of the SRL until it stops. If the reserve

lifeline-warning label is visible, the reserve lifeline has been spent and the unit must

be serviced by an authorized service center before use. See Figure 14. If

the reserve lifeline has not been deployed (the reserve lifeline label is not

visible) that portion is acceptable and the inspection can continue.

Step 10

Inspect each system component or subsystem according to manufacturer's

instructions.

Step 11

Record inspection results in the inspection log

MAINTENANCE, SERVICING, STORAGE

Periodically clean the exterior of the SRL using water and a mild soap

solution. Position the SRL so excess water can drain out. Clean labels as

required.

Clean lifeline with water and mild soap solution. Rinse and thoroughly air

dry. Do not force dry with heat. An excessive buildup of dirt, paint, etc.

may prevent the lifeline from fully retracting back into the housing causing a

potential free fall hazard. Replace lifeline if excessive buildup is present.

Lifeline replacement, as well as additional maintenance and servicing

procedures, must be completed by an authorized service center. An

authorization and return number must be issued by DBI-SALA. Do not

attempt to disassemble the SRL. Store SRL in a cool, dry, clean environment

out of direct sunlight. Avoid areas where chemical vapors may exist.

Thoroughly inspect the SRL after any period of extended storage.

(39)

© Capital Safety 2006 1-800-328-6146 MHB123107 6-8 Swivel Eye Inspection Label Warning Label Ultra-Loc Label ID Label Connections Label Wire or Synthetic Rope Bumper

Self Locking Hook

DESCRIPTIONS:

ULTRA-LOK® WIRE & SYNTHETIC

ROPE STYLE SELF RETRACTING

LIFELINES:

Includes swivel eye anchorage, self-locking

swivel snap hook with impact indicator,

and choice of galvanized wire rope lifeline

or stainless steel wire rope lifeline in

lengths of 20, 30, and 50 feet, or synthetic

rope lifeline in lengths of 20 and 30 feet.

ULTRA-LOK® WEB STYLES

SELF-RETRACTING LIFELINES:

Includes swivel eye anchorage, self-locking

snap hook, and 1-inch wide nylon web

lifeline in lengths of 11 and 20 feet.

ALUMINUM HOUSING WEB STYLE

SELF-RETRACTING LIFELINES:

Includes a lightweight, heavy duty, extruded aluminum housing, self-locking

snap hook, and 1-inch wide nylon web lifeline in a length of 11 feet

ALUMINUM HOUSING WIRE ROPE STYLE SELF RETRACTING

LIFELINES:

Includes a lightweight, heavy duty, extruded aluminum housing, self-locking

swivel snap hook with impact indicator, and choice of galvanized wire rope

lifeline or stainless steel wire rope lifeline in a length of 11 feet.

(40)

Type Three

INSPECTION FREQUENCY (Retrievals):

Before Each Use:

Inspect per steps listed

After Use of Retrieval Mode

After raising or lowering, inspect load indicator

and entire SRL. Applications, which require

continuous raising and lowering, may require

increased inspection and servicing frequency.

Contact DBI-SALA if you have any questions

regarding inspection frequency.

IMPACT INDICATOR:

Inspection of impact indicator is dependent on

the type of SRL being inspected and as

discussed in the course and in the user

instruction manual for each specific unit.

(41)

Follow steps 1 through 11 as per Ultra lok SRL’s and add the below steps

for retrieval units.

INSPECTION STEPS FOR RETRIEVAL COMPONENTS:

Step 12

Inspect retrieval arm for distortion or other damage. Retrieval handle should

engage into retrieval arm with ease and push button should work freely.

Step 13

Shift knob should rotate freely when engaging/disengaging. Pull ring on shift

knob should spring back when released.

Step 14

Inspect retrieval mode for operation. To test, raise and lower a test weight

(sand bag) of between 75 lbs. and 310 lbs. Retrieval operation should be

smooth and even. When the retrieval handle is released, the weight should

not move and retrieval handle should stay in position (no movement). A

“clicking” sound should be evident when raising load.

Step 15

Retrieval pawl cover must be secure and without deformation. Optional

mounting bracket must be securely attached to SRL and free from defects.

Detent pin must operate freely. If inspection reveals a defective condition,

remove the SRL from service immediately and contact an authorized service

center for repair.

MAINTENANCE, SERVICING, STORAGE

Periodically clean the exterior of the SRL with water and mild soap solution.

Position the SRL so excess water can drain out. Clean labels as required.

Clean lifeline with water and mild soap solution. Rinse and thoroughly air

dry. Do not force dry with heat. An excessive buildup of dirt, paint, etc.,

may prevent the lifeline from fully retracting, causing a potential free fall

hazard. Replace the lifeline if there is excessive buildup.

NOTE: Only DBI-SALA or parties authorized in writing may make repairs to this equipment.

WARNING: If the lifeline contacts acids, remove unit from service and wash

(42)

© Capital Safety 2006 1-800-328-6146 MHB123107 6-11 If the Impact Indicator has been broken and the loop torn apart, the SRL has been impact loaded and should be removed from service and

returned to an

authorized service center for repair.

Lifeline replacement and additional maintenance and servicing procedures

must be completed by an authorized service center. Authorization and a

return number must be issued by DBI-SALA. Do not lubricate any parts. Do

not disassemble the SRL.

Clean and store body support and associated system components according

to manufacturer's instructions. Store SRL in a cool, dry, clean environment,

out of direct sunlight. Avoid areas where chemical vapors may exist.

Inspect the SRL after extended storage.

General Requirements For all Blocks

CABLE AND ROPE STYLE BLOCKS:

To inspect the impact indicator, look

for an exposed red color band. If the

hook is found to be in “indicated

mode,” an impact load has occurred.

SRL’s, which have been subjected to

impact loading, must be removed

from service for inspection. Do not

attempt to reset the impact indicator.

Return to an authorized service center

for resetting.

WEB STYLE BLOCKS:

These SRL's incorporate

an impact indicator in the

web lifeline. The web near

the hook end of the lifeline

is folded onto itself and

stitched with red thread,

forming a small loop. The

stitched loop will pull out

at approximately 450 lbs.

If the red stitching is

intact, the SRL has not

been impacted. If the red

stitching is broken the SRL

has been impacted

Red Band Indicated Mode Normal Mode Reserve Lifeline Red Band Reserve Lifeline Label Indicator Fold Impact Indicator Fold After Impact Impact Indicator Fold Before Impact

(43)

LIMITATIONS:

The following application limitations must be considered before using SRL:

CORROSION: Do not leave this equipment for long periods in environments

where corrosion of metal parts could occur because of vapors from organic

materials. Use caution when working around sewage or fertilizer because of

their high concentration of ammonia, which is very corrosive. Use near

seawater or other corrosive environments may require more frequent

inspections or servicing to assure corrosion damage is not affecting the

performance of the product.

CHEMICAL HAZARDS: Solutions containing acids, alkali or other caustic

chemicals, particularly at elevated temperatures, may damage DBI-SALA

SRL's. When working with such chemicals, frequent inspection of the entire

SRL must be completed. Chemical damage to the lifeline is difficult to detect

and it is recommended that the lifeline be replaced periodically to ensure

safety. The lifeline may only be replaced by an authorized service center).

Consult DBI-SALA if in doubt about using this equipment around chemical

hazards.

HEAT: This equipment is not designed for use in high temperature

environments. Provide protection for this equipment when using near

welding, metal cutting, or similar activities. Hot sparks may burn or damage

this equipment. Consult DBI-SALA for details on use in high temperature

environments.

NOTE: SRL's using Spectra synthetic rope is not flame or heat resistant. Do

not use in environments exceeding 140°F (60°C). Do not allow Spectra rope

to contact materials exceeding 140°F (60°C). SRL is using Technora

synthetic ropes are heat resistant up to 900°F (480°C). 15

WARNING: If the self-retracting lifeline has been subjected to fall arrest or

impact forces, it must be removed from service

IMPORTANT: Extreme working conditions (harsh environment, prolonged

(44)

Vertical Lifelines & Rope Grabs

Objectives

In this module through discussion and practical inspection techniques, the

student will gain the knowledge and experience to complete a proper

inspection of:

Vertical Lifelines

Rope Grabs

and

Recording the inspection process.

A Selection of Lifelines

Vertical

Lifelines:

PURPOSE:

Vertical lifelines and

vertical lifeline

subsystems are

intended to be used

as part of a personal

fall arrest or restraint

system when coupled

with a rope grab.

They provide the

pathway or anchor for

the sliding rope grab

to travel. These

lifelines and lifeline

subsystems (with the

exception of 3/8 inch

wire rope) are not

designed for use in

horizontal lifeline

systems. Applications

include: Inspection

work, construction,

demolition,

maintenance, window

washing, oil

production, and

confined space rescue

to name a few.

Chapter

7

1202749 (3/4” polyester/polypropylene rope, 30 feet) 1202753 (5/8” polyester/polypropylene rope, 30 feet)

1202750 (3/4” polyester/polypropylene rope, 30 feet) 1202754 (5/8” polyester/polypropylene rope, 30 feet)

5901003 (3/8” wire rope, 30 feet)

Rope Cut to Length

5/8” Polyester/Polypropylene Rope 5/8” Polyester Rope

3/4” Polyester/Polypropylene Rope 3/4” Polyester Rope

Competent Inspector Manual

A Student Guide to Basic Fall Protection

Application

F a l l P r o t e c t i o n

Leaders in safety innovation

Capital Safety, home of the DBI-SALA and PROTECTA

brands is the world’s leading manufacturer dedicated

solely to fall protection. We are also the pioneer in

the development of intelligent safety technology,

leading the way toward a new era of safety

management solutions. We are committed to

providing new and improved systems to give you the

complete confidence you need in your safety program.

• QUALITY for the performance you can trust.

• BREADTH for the best and most cost effective solutions.

• EXPERTISE to meet your unique fall protection requirements.

• TRAINING to ensure and motivate safety compliance.

INNOVATION to improve your safety and productivity

C o n t a c t U s T o d a y

Capital Safety USA

DBI-SALA Training

3833 SALA Way, Red Wing, MN 55066-5005

Phone: 651-388-8282 Toll Free: 800-328-6146 FAX: 651-388-5065

Web Site:

www.capitalsafety.com

EMAIL: [email protected]

© Capital Safety 2007

All rights reserved. No part of this publication may be reproduced, stored

in a retrieval system or transmitted in any form or by any means.

Electronic, mechanical, photocopying, recording or otherwise without

prior written permission from Capital Safety USA.

FALL PROTECTION EQUIPMENT INSPECION GUIDE

TABLE OF CONTENTS

Chapter

1

Introduction

Chapter

2

Body Supports

Chapter

3

Lanyards

Chapter

4

Connection Devices

Chapter

5

Anchorage Connectors

Chapter

6

Self-Retracting Lifelines

Chapter

7

Lifelines & Rope Grabs

Appendix

1

Detailed Inspection Logs

Appendix

2

DBI-SALA Technical Bulletins

Introduction

Objectives

By the end of this chapter, students should be able to explain

the how the following apply to equipment inspection:

State, Provincial and Federal laws and legislation applicable

to inspection;

ANSI (American National Standards Institute), or CSA

(Canadian Standards Association) Standards for equipment

inspection; and

Manufacturer’s (i.e. DBI-SALA) requirements for inspection.

General

roperly functioning fall protection equipment is vital for every person

that works at heights. This equipment is designed to arrest and

protect a worker in case of a fall, so it is important to know how to

properly inspect and care for your equipment. It is extremely important

to follow the laws, standards, and manufacturer’s recommendations for

inspections

How important is the inspection process?

…VERY!

In this chapter you will learn about the CSA and ANSI standards,