Every worker who uses fall protection gear knows the importance of safety checks before climbing or working at height. Securing your harness and lanyard properly can make the difference between a safe shift and a life-threatening accident. While many people focus on fall hazards, one often overlooked risk is how a small twist in a lanyard can silently degrade its strength, sometimes without visible warning.
The Hidden Danger of a Twisted Lanyard
Picture a busy job site. You clip in quickly, checking your harness but giving less than full attention to your lanyard’s orientation. Maybe the webbing crossed over itself, or you stepped on it, introducing a half twist without realizing it. This minor misalignment may feel negligible, yet it sets off a dangerous chain reaction.
The internal fibers of a lanyard are designed to carry distributed loads along their length. When twisted, the fibers experience friction and bending stresses that they don’t normally encounter. Each movement causes microscopic abrasion inside the webbing, gradually weakening the structure long before any external damage becomes visible.
According to international standards like EN 354 or ANSI Z359.13, lanyards must withstand forces up to 22 kN (about 5,000 pounds) to ensure reliable fall arrest performance. However, repetitive twisting is not part of these test conditions. In real-world use, a twisted lanyard can lose tearing resistance repeatedly under normal load cycles, and the breaking strength may degrade significantly over time.
How Twisting Affects Load Distribution
During a fall, the harness’s dorsal D-ring and the sub-pelvic and thigh straps are engineered to share the arrest forces efficiently—roughly 60–70% through the pelvic and legs, with the remainder through the shoulders. This distribution minimizes risk of injury and suspension trauma by reducing localized stress and pressure.
A twist distorts this load path. Instead of forces traveling straight along strong, aligned fibers, the load concentrates on kinked or pinched sections that aren’t designed to handle such stress. This increases the chance of fiber breakage and potential failure at loads well below the rated breaking strength.
Moreover, improper alignment can shift load onto sensitive anatomical structures, increasing risks of circulation impediment during suspension. Suspension trauma, caused by restricted blood flow in the legs under hanging conditions, can develop quickly—potentially within minutes.
Recognizing and Managing Twist-Related Wear
One challenge is that early damage from twisting is often hidden inside the webbing or in areas obscured by equipment. Visible signs might be subtle: stiffened segments, hard spots, or slight creases that don’t feel natural. Because of this, reliance solely on visual inspections can lead to missing early warnings.
A simple but highly effective method is performing a tactile check every time you gear up. Run two fingers along the full length of the lanyard from anchor to harness connection, feeling for any unusual stiff areas, raised fibers, or twists. If you detect even a minor twist, unclip and gently shake or straighten the lanyard before reconnecting. This “Twist-Check” habit takes only seconds but strongly reduces the silent buildup of internal stress.
Real-World Example: The Cost of a Neglected Twist
On a rainy afternoon, a seasoned worker hurried to secure his anchor point before wrapping up the day. Clipped in but distracted, he only glanced at his lanyard visually and didn’t feel for twists. Later, he noticed an unfamiliar tug beneath his shoulder blade. Investigating, he found a tight twist near the connector—a spot prone to rubbing during motion and moisture exposure.
If this issue had gone unnoticed during further workdays, the lanyard could have deteriorated internally to the point of failure, particularly under dynamic loading. This near miss highlights why the extra attention to lanyard alignment is critical for safety.
Practical Tips to Prevent Twist-Related Failures
- Perform the Twist-Check: Before starting work, run your fingers along your lanyard’s entire length to identify and correct any twists or kinks.
- Be Mindful During Movements: Avoid stepping on your lanyard and be careful when moving around anchor points to prevent unintentional twisting.
- Inspect Frequently: Regularly check your lanyards for any abnormal stiffness, bulges, or discoloration. If any damage is suspected, remove the equipment from service.
- Train Your Team: Share knowledge about twist-related wear with colleagues to develop a culture of safety vigilance.
Refresh Tip: Shift Your Focus to Daily Micro-Checks
Safety isn’t just about big actions like using harnesses or anchors correctly; it’s about cultivating small, consistent habits that catch problems before they grow. Incorporating a quick tactile check of your lanyard into your gearing routine not only prevents silent material fatigue but also resets your mental focus. This moment of mindfulness sharpens awareness and helps ensure you’re fully engaged before climbing or working at height.
Why Small Actions Matter—Preventing Catastrophic Failures
Many serious fall protection failures start with seemingly insignificant missteps. A single twist in the webbing might not cause immediate problems but can cascade into critical damage under real-world conditions, especially when combined with moisture, dirt, and normal wear.
Creating a routine that includes the Twist-Check interrupts these silent damage pathways, maintaining your gear’s full rated strength and protecting your safety margin.
Conclusion
The next time you prepare for work at height, remember that the safety of your lanyard depends on proper alignment and attentive care. The twist may be small, but its impact can be deadly. By taking the few seconds to run your fingers along your lanyard, straighten any twists, and maintain a tactile inspection habit, you safeguard yourself and your coworkers from preventable accidents.
Routine care and awareness are your best allies in preserving the life and strength of your fall protection gear. Safety is a daily responsibility that starts with small details—don’t underestimate the power of a simple twist check.