Fall protection test methods

The appendix provides non-mandatory test procedures you can use to determine whether a personal fall protection system meets the performance criteria in paragraphs (d) and (e) of 1910.140.

• These test methods are guidelines (not new regulatory requirements) but are intended to show how to evaluate personal fall arrest and positioning systems for compliance with 1910.140(d) and (e).
• See the appendix title in Appendix D to Subpart I of Part 1910 for context and scope.

Use the specific test weights given in the appendix: 300 pounds ±3 pounds (≈136.4 kg ±1.4 kg) for the strength test, and 220 pounds ±3 pounds (100 kg ±1.6 kg) for the lanyard force test (220 pounds ±2 pounds for other systems). See the appendix for exact tolerances. (Appendix D to Subpart I of Part 1910; 1910.140(d)).

• The appendix also requires the test weight to be a rigid, metal cylindrical or torso-shaped object with a girth of 38 inches ±4 inches.

The fixed anchorage used in tests must be rigid and deflect no more than 0.04 inches (1 mm) when a 2,250‑pound (10 kN) force is applied. (Appendix D to Subpart I of Part 1910; 1910.140(d)).

• This requirement ensures test results reflect the performance of the fall protection system rather than anchorage deformation.

For lanyard system tests the lanyard length should be 6 feet ±2 inches (1.83 m ±5 cm) measured from the fixed anchorage to the harness attachment. (Appendix D to Subpart I of Part 1910; 1910.140(d)(2)).

• Measure from the anchorage to the body-harness attachment point to set up the test.

The standard lanyard force test uses a 6 foot (1.83 m) free fall distance from anchorage level to hanging location for the 220‑pound test weight. If the system’s deceleration device does not automatically limit free fall to 2 feet or the connection distance exceeds 1 foot, the test weight should be rigged to free fall 7.5 feet (2.3 m) from a point 1.5 feet (46 cm) above the anchorage to a hanging location 6 feet below the anchorage. (Appendix D to Subpart I of Part 1910; 1910.140(d)(2)).

• The rigging must allow an unobstructed fall (no interference or hitting the ground).

Deceleration systems that automatically limit free fall to 2 feet or less should be tested with the test weight rigged to free fall 4 feet (1.22 m); for self‑retracting lifelines the test weight may be supported, the unit allowed to retract as in normal use, and then released so the device arrests the fall; force and deceleration distance are measured during that event. (Appendix D to Subpart I of Part 1910; see 1910.140(d)(2)(ii)).

• The appendix explains how to simulate normal retraction and measure arresting forces and elongation for these devices.

A system fails the force test when the recorded maximum arresting force exceeds 2,520 pounds (11.2 kN) when using a body harness. (Appendix D to Subpart I of Part 1910; 1910.140(d)(4)).

• The appendix also requires recording maximum elongation and deceleration distance during the test.

Each test consists of a single drop using a new, unused system; a fresh system must be used for each individual drop. (Appendix D to Subpart I of Part 1910; 1910.140(d)(1)).

• This avoids repeated damage or altered performance affecting results.

The test weight must be a rigid, metal cylindrical or torso‑shaped object with a girth of 38 inches ±4 inches (96 cm ±10 cm). (Appendix D to Subpart I of Part 1910; see the general test conditions).

Load‑measuring instrumentation used in tests must have a frequency response of 120 Hz. (Appendix D to Subpart I of Part 1910).

• Using proper instrumentation ensures accurate capture of short-duration arresting forces.

If any weight detaches from the harness during the strength test, the system is judged to have failed. (Appendix D to Subpart I of Part 1910; see the strength test provisions).

Rope‑grab devices should be moved along a lifeline 1,000 times over the same length of line a distance of not less than 1 foot (30.5 cm), and the mechanism must lock each time; unless the device is permanently marked for a specific lifeline type, several lifeline types (different diameters/materials) should be used in testing. (Appendix D to Subpart I of Part 1910; 1910.140(e)(2)).

• This confirms reliable locking across expected lifeline conditions.

Self‑activating deceleration devices intended for more than one arrest must have their locking mechanisms cycle and lock 1,000 times as they would in normal service. (Appendix D to Subpart I of Part 1910; 1910.140(e)(3)).

• This tests durability and reliable performance over repeated uses.

When a deceleration system uses a connection link or lanyard, the test free fall distance should equal the connection distance (measured from the centerline of the lifeline to the harness attachment), subject to the appendix’s maximum test fall limits. (Appendix D to Subpart I of Part 1910; see 1910.140(d)(2)(ii)(A)).

• The appendix caps the test free fall at a 6 foot maximum for the test weight except where other specific provisions apply.

The appendix directs the use of the maximum free fall distance physically permitted by the system during normal use up to a 6 foot (1.83 m) maximum for the test weight, unless other specific rules apply for special devices. (Appendix D to Subpart I of Part 1910; 1910.140(d)(2)(ii)).

• For some connection‑link systems or integral lifeline systems, the appendix specifies alternate distances as explained in the standard text.

No — the appendix explicitly states that following the test the system need not be capable of further operation. (Appendix D to Subpart I of Part 1910).

• Tests are designed to evaluate performance to the point of arrest; many tests are destructive by design.

Deceleration devices should be evaluated or tested under the environmental conditions (rain, ice, grease, dirt, and lifeline type) for which the device is designed. (Appendix D to Subpart I of Part 1910; see the deceleration device general provisions).

• Testing under representative conditions helps ensure the device will lock and arrest falls reliably in actual use.

Window cleaner belts are tested using a 250‑pound (113 kg) weight dropped 6 feet (1.83 m) with the weight placed in the waistband and the belt terminals at maximum span; failure is any breakage or slippage that frees the weight. Arresting forces must not exceed 2,000 pounds (8.5 kN) for more than 2 milliseconds on initial impact, nor exceed 1,000 pounds (4.5 kN) for the remainder of the arrest. (Appendix D to Subpart I of Part 1910; see 1910.140(e)(2)).

• This test simulates the belt being loaded as when worn by a window cleaner.

Most other positioning systems (except restraint line systems) must pass a drop test where a 250‑pound (113 kg) weight free falls 4 feet (1.2 m); failure is indicated by breakage or slippage sufficient to let the weight fall free to the ground. (Appendix D to Subpart I of Part 1910; see 1910.140(e)(3)).

• The body belt or harness should be affixed to the test weight as it would be to an employee.

For rope‑grab deceleration systems, the lifeline length above the grabbing mechanism centerline to the lifeline’s anchorage must not exceed 2 feet (0.61 m) during testing. (Appendix D to Subpart I of Part 1910; see the lanyard/rope‑grab test setup requirements).

OSHA advises that stepping from a portable ladder onto a low‑slope roof and walking to a work area does not automatically require fall protection, but work performed less than 6 feet from a roof edge must be protected and work 15 feet or more from the edge may require protection depending on whether the work is infrequent and temporary; employers must assess each situation and provide fall protection where required by [1910.28]. See OSHA's interpretation about fall protection on low‑slope roofs for a practical example. (OSHA interpretation on fall protection on low‑slope roofs; 1910.140).

• Employers must perform a hazard assessment and follow applicable OSHA requirements when work near the roof edge creates a fall hazard.