Personal Fall Arrest Guidelines

Appendix C provides non-mandatory guidance on test methods that employers and manufacturers can use to show compliance with the personal fall arrest requirements in 1926.502(d).

• These methods are guidance (not mandatory rules) to evaluate strength, arresting force, deceleration, and device performance as described in 1926 Subpart M App C.
• Employers may rely on these recognized tests or other equivalent, validated tests to demonstrate compliance with the requirements in 1926.502(d)(16).

(See 1926.502(d) for the regulatory requirements on personal fall arrest systems.)

The anchorage used for testing should be rigid and must not deflect more than 0.04 inches (1 mm) under a 2,250-pound (10 kN) load, per the test conditions in 1926 Subpart M App C.

• This ensures the anchorage itself does not absorb energy that would otherwise affect the test results required to demonstrate compliance with 1926.502(d)(16).

(See the general test conditions in 1926.502(d).)

The strength and force tests use specified test weights and the least-elastic lanyard or lifeline available with the system when a supplied line is not provided. Appendix C requires a rigid, metal, cylindrical or torso-shaped test weight with a girth of about 38 inches ±4 inches (96 cm ±10 cm) and specific test weights for different tests.

• Strength test weight: 300 lb ±5 lb (135 kg ±2.5 kg) as noted in Appendix C(c)(1).
• Force/impact test weight: 220 lb ±3 lb (100 kg ±1.6 kg) for force tests (Appendix C(d)(2)(i)–(3)(i)).
• The lanyard or lifeline used to create the free-fall distance should be the one supplied with the system or, if none is supplied, the least elastic one that would be used with the system (Appendix C(b)(5)).

(See 1926 Subpart M App C and the force test requirements in 1926.502(d).)

For the strength test, lanyards should be rigged to create a 6-foot free fall (measured from anchorage to the harness attachment) in most cases; rope-grab systems must keep the lifeline length above the grab centerline to anchorage at 2 feet or less.

• Lanyard systems: lanyard length should be 6 ft ±2 in (1.83 m ±5 cm) from anchorage to harness attachment (Appendix C(c)(3)).
• For rope-grab-type deceleration systems: the lifeline length above the centerline of the grab to the anchorage point must not exceed 2 ft (0.61 m) for the test (Appendix C(c)(4)).
• If the system does not automatically limit free fall to 2 ft (0.61 m) or has a connection distance >1 ft (0.3 m), the test weight is rigged to free fall 7.5 ft from a point 1.5 ft above the anchorage to 6 ft below (Appendix C(c)(5)).

(See 1926 Subpart M App C and general personal fall arrest rules in 1926.502(d).)

A system fails the force test if the measured maximum arresting force exceeds 1,260 pounds (5.6 kN) when the system uses a body belt, or 2,520 pounds (11.2 kN) when a full body harness is used.

• The force limits are recorded during the Appendix C force test and represent the maximum allowable peak arresting force for compliance with the performance guidance (Appendix C(d)(4)).
• The Appendix also instructs recording maximum elongation and deceleration distance during the test (Appendix C(d)(5)).

(See the force-test failure criteria in 1926 Subpart M App C and the governing rule at 1926.502(d).)

Lanyard systems are tested using a 220 lb ±3 lb test weight, a 6 ft ±2 in lanyard (anchorage to harness), and a free fall equal to the distance from anchorage level to the hanging location (a total 6 ft free fall) with no interference.

• Test weight: 220 lb ±3 lb (Appendix C(d)(2)(i)).
• Lanyard length: 6 ft ±2 in measured from fixed anchorage to harness attachment (Appendix C(d)(2)(ii)).
• Free fall: test weight falls free from anchorage to hanging location (6 ft total) without hitting the ground or obstructions (Appendix C(d)(2)(iii)).

(See 1926 Subpart M App C and the related regulatory requirements in 1926.502(d).)

For non-lanyard systems the free fall distance used in the force test should be the maximum fall distance physically permitted by the system during normal use, up to 6 feet, except where the Appendix specifies otherwise (such as connection link distances or self-retracting devices).

• If a deceleration system uses a connection link or lanyard, the test free fall equals that connection distance (Appendix C(d)(3)(ii)(A)).
• For integral lifeline/self-retracting devices that automatically limit free fall to 2 ft or less, the test free fall equals the normal-use free fall permitted by the device (Appendix C(d)(3)(ii)(B)).

(See 1926 Subpart M App C and the personal fall arrest criteria in 1926.502(d).)

Rope-grab deceleration devices should be moved 1,000 times over the same length of lifeline (at least 1 ft) and must lock reliably every time; unless the device is permanently marked for a particular lifeline, testing should include several lifeline types and diameters.

• Mechanical reliability: move device 1,000 times and verify the mechanism locks each time (Appendix C(e)(2)(i)).
• Lifeline compatibility: test with different lifeline materials and diameters unless the device is permanently marked for a specific lifeline (Appendix C(e)(2)(ii)).

(See 1926 Subpart M App C and the applicable performance provisions in 1926.502(e).)

Other self-activating deceleration devices intended for more than one arrest should have locking mechanisms that lock on each of 1,000 trial arrests under normal service conditions.

• This performance guideline (1,000 successful locks) is provided in Appendix C(e)(3) as a recognized test method to evaluate multi-arrest capability.

(See 1926 Subpart M App C and related device requirements in 1926.502(e)(3).)

You must select and evaluate fall arrest systems considering the environmental conditions they will face (rain, dirt, chemicals, temperature, etc.), and testing should account for those same conditions to ensure the system performs as intended.

• Appendix C(b)(7) requires performance evaluation taking into account the range of environmental conditions for which the system is designed.
• Appendix C(II)(a)(1) advises employers to consider environmental effects (acids, moisture, heat/cold) when choosing systems and to monitor system effectiveness in use.

(See 1926 Subpart M App C and general performance rules in 1926.502(d).)

No—Appendix C states that following the prescribed test, the system need not be capable of further operation; destructive testing may be used to evaluate performance.

• Appendix C(b)(8) explicitly allows that the system need not continue to operate after the test, recognizing samples may be sacrificed to verify strength and arresting performance.

(See 1926 Subpart M App C and the performance expectations in 1926.502(d).)

Employers should not assume components are interchangeable; any substitution or change to a personal fall arrest system must be evaluated or tested by a competent person to confirm the modified system meets the standard before use.

• Appendix C(II)(c) warns that not all components are interchangeable and gives the example that connecting a lanyard between a body belt and a self-retracting deceleration device may create excessive free fall.
• Appendix C(II)(c) requires competent-person evaluation/testing for substituted components to ensure compliance with 1926.502(d)(16).

(See 1926 Subpart M App C and the regulatory requirements in 1926.502(d).)

When personal fall arrest systems are used, employers must assure that employees can be promptly rescued or can rescue themselves; employers should evaluate the availability of rescue personnel, ladders, or rescue equipment.

• The regulatory requirement is in 1926.502(d)(20).
• Appendix C(II)(f) emphasizes planning for prompt rescue because a suspended employee may not be able to reach a work level independently and lists evaluating rescue personnel and equipment.

(See 1926.502(d)(20) and rescue guidance in 1926 Subpart M App C.)

Employers must train employees in safe selection and use of personal fall arrest systems and provide system-specific supplier information including force measurements, elongation, deceleration distance, application limits, hook-up techniques, inspection, cleaning, and storage.

• Appendix C(II)(d) lists training topics such as application limits, anchoring/tie-off techniques, estimating free-fall and deceleration distances, inspection and storage.
• Appendix C(II)(e) recommends employers obtain supplier data: force measured during tests, maximum elongation, deceleration distance, caution statements, application limits, proper hook-up and anchorage details, inspection/use/cleaning/storage methods, and specific compatible lifelines.

(See training and instruction guidance in 1926 Subpart M App C and the standard at 1926.502(d).)

Self-retracting lifelines and integral deceleration systems that automatically limit free fall to 2 ft or less are tested with a shorter free fall (for example, a 4 ft rigging for the strength test) and the test weight is allowed to be supported while the device retracts as it would in normal use.

• Appendix C(c)(6) specifies a 4 ft (1.22 m) free fall rigging for deceleration devices with integral lifelines/lanyards that limit free fall to 2 ft or less during strength testing.
• For force tests, Appendix C(d)(3)(ii)(B) requires using the maximum fall the system permits in normal use (self-retracting devices are tested while retraction occurs as in normal use).

(See testing procedures in 1926 Subpart M App C and 1926.502(d).)

Employers should protect components like lanyards, connectors, and lifelines from damage when work operations (welding, chemical cleaning, sandblasting, etc.) can harm them; otherwise they must select alternative securing systems.

• Appendix C(II)(a)(2) specifically advises protecting components subject to damage or using other systems when damage is likely.
• Appendix C(II)(b) also recommends obtaining supplier performance data and monitoring system effectiveness once in use.

(See the selection and use considerations in 1926 Subpart M App C and performance requirements in 1926.502(d).)

Appendix C recommends that load-measuring instrumentation used in the tests have a frequency response of 500 Hz to capture dynamic forces accurately.

• This ensures test instrumentation can accurately register peak arresting forces during the drop tests described in Appendix C(b)(3).

(See instrumentation requirements in 1926 Subpart M App C and the related testing guidance in 1926.502(d).)

Yes—Appendix C requires that each drop test use a new, unused system sample for the test so that test results reflect the system's initial performance characteristics.

• Appendix C(d)(1) states the test consists of a single drop using a new, unused system for each test.

(See the test-sample and drop-test instruction in 1926 Subpart M App C and the performance expectations in 1926.502(d).)

Employers do not always need to individually test every system component; they may rely on supplier-provided performance data or testing of similar systems if sufficient information demonstrates similarity of function and design.

• Appendix C(II)(b) advises obtaining supplier testing results and notes that the performance of some systems may be based on data and calculations from similar systems provided similarity is well-documented.
• However, when interchange of components or unique conditions exist, a competent-person evaluation or additional testing may be necessary to verify compatibility and compliance with 1926.502(d)(16).

(See 1926 Subpart M App C for guidance and 1926.502(d) for requirements.)

Connecting a lanyard between a body belt and a self-retracting deceleration device can create additional free fall for which the device was not designed and may reduce system effectiveness.

• Appendix C(II)(c) gives this example to illustrate that some component combinations change arrest dynamics and can increase free fall distance beyond design limits, potentially violating 1926.502(d)(16).
• Any such substitution must be evaluated and tested by a competent person before use.

(See interchangeability guidance in 1926 Subpart M App C and regulatory context in 1926.502(d).)

Employers should match the fall arrest system type to the specific work situation, minimize possible free fall distance, evaluate environmental hazards and access to prompt rescue, and plan for maintenance, inspection, and rescue resources before use.

• Appendix C(II)(a)(1) instructs selecting systems appropriate to the environment (conditions like acids, dirt, moisture, electrical hazards) and ensuring prompt rescue plans.
• Appendix C(II)(f) reiterates the employer’s duty under 1926.502(d)(20) to assure prompt rescue capability.

(See selection, environmental, and rescue planning guidance in 1926 Subpart M App C and the regulatory requirement at 1926.502(d)(20).)

A conveyance operating with temporary or incomplete guides, or suspended by temporary suspension means or temporary hoist machines, meets the definition of a suspended scaffold and must follow suspended scaffold fall protection requirements in 1926.451(g) and falling object protection in 1926.451(h).

• OSHA’s interpretation in the 2023 letter clarifies that conveyances using temporary suspension/guide systems are considered suspended scaffolds and must comply with scaffold fall protection rules; see the OSHA letter at https://www.osha.gov/laws-regs/standardinterpretations/2023-12-05.
• When the conveyance is a suspended scaffold, comply with scaffold rules found in Subpart L and fall-protection requirements in Subpart M, including appropriate personal fall arrest systems per 1926.502(d).

(See the OSHA interpretation at https://www.osha.gov/laws-regs/standardinterpretations/2023-12-05 and 1926.502(d).)

Employers should obtain supplier data including the force measured during the sample force test, maximum lanyard elongation, deceleration distance for devices, caution statements and application limits, proper hook-up and anchorage details, inspection/use/cleaning/storage methods, and specific compatible lifelines.

• Appendix C(II)(e) lists these recommended data items employers should get and provide to employees during training (force, elongation, deceleration distance, limits, hook-up techniques, inspection and storage procedures, etc.).
• Having this supplier data helps employers verify that the system meets performance expectations described in 1926.502(d)(16).

(See supplier instruction guidance in 1926 Subpart M App C and the regulation 1926.502(d).)

During the force test you should also record the maximum elongation of the lanyard or lifeline and the deceleration (stopping) distance of the system in addition to the peak arresting force.

• Appendix C(d)(5) requires recording maximum elongation and deceleration distance as part of the force-test data set.
• These measurements help determine total fall clearance requirements and whether the system meets the arresting-force criteria in Appendix C(d)(4).

(See required force-test recordings in 1926 Subpart M App C and performance rules in 1926.502(d).)

The test weight must be hoisted to the required level and quickly released without imparting any appreciable motion to it other than gravity-induced free fall.

• Appendix C(b)(6) specifies the weight should be quickly released and not have appreciable initial motion to ensure consistent, valid impact results.

(See the release procedure guidance in 1926 Subpart M App C and 1926.502(d).)

You must regularly inspect all components of a personal fall arrest system and immediately remove any component with significant defects from service. Under 1926.502(d)(21) personal fall arrest systems must be regularly inspected, and Appendix C explains common defects (cuts, tears, mold, distorted hooks, unfitted buckle tongues, loose mountings, non‑functioning parts, internal rope deterioration, chemical or fire damage).

• Tag or mark defective parts as unusable or destroy them so they cannot be reused.
• Remove and replace any component with significant defects before returning the system to service.

(See Personal Fall Arrest Guidelines, Appendix C).

A registered professional engineer or another appropriately qualified person must design an anchorage point installed immediately prior to use. Appendix C states that when anchorages are installed immediately before use, they should be designed by a registered professional engineer with fall‑protection experience or by a qualified person with appropriate education and experience (see 1926 Subpart M Appendix C).

• Also consider the anchorage strength and compatibility requirements in 1926.502(e).

Yes, steel members or I‑beams can be appropriate anchor points if you use an acceptable connection and a qualified person has evaluated the anchorage. Appendix C lists steel members or I‑beams as possible anchorages provided an acceptable strap or connection is used and a qualified person evaluates their suitability (see 1926 Subpart M Appendix C).

• Avoid clipping a lanyard snaphook back onto itself as the connection.
• Ensure the chosen attachment does not create a shear or cutting condition; protect webbing or rope from sharp edges.
• Verify anchorage strength and configuration per 1926.502(e)(3).

Tying a knot in a rope lanyard or lifeline can reduce its strength by about 50% or more, so you must compensate or avoid knots when possible. Appendix C warns that knots can cut lanyard strength dramatically and recommends using stronger gear, shortening the lanyard, raising the tie‑off point to reduce free fall, or replacing the rope with a connector that eliminates the knot (see 1926 Subpart M Appendix C).

• Where knots are unavoidable in emergency situations, use appropriately stronger equipment and minimize free fall.
• Prefer factory‑made connectors or lanyards with integrated end fittings instead of knots.

Tying a rope lanyard or lifeline around an H or I beam can reduce its strength by as much as 70% due to edge cutting, so you must protect the line or use an alternate material. Appendix C advises using webbing lanyards or wire‑core lifelines around beams, protecting the lanyard from the edge, or greatly minimizing free fall distance (see 1926 Subpart M Appendix C).

• Use abrasion‑resistant straps, padding, or engineered beam anchors.
• Have a qualified person evaluate any improvised anchor connection for strength.

You should avoid tie‑offs that pass over rough or sharp surfaces because they drastically reduce lifeline strength and instead use protected or alternative rigging. Appendix C warns that tie‑offs over rough or sharp surfaces reduce strength drastically and recommends alternatives such as a snaphook/dee ring connection, wire rope tie‑off, padding of the surface, or an abrasion‑resistant strap (see 1926 Subpart M Appendix C).

• If unavoidable, add protective padding or an abrasion sleeve and consult a qualified person on the configuration.

As the sag angle in a horizontal lifeline decreases, the impact force is amplified and the system and anchorages must be designed by a qualified person. Appendix C explains that when the sag angle is less than 30 degrees the impact force can be amplified (about 2:1 at 15° sag and about 6:1 at 5° sag), so the lifeline and anchorages should be strengthened accordingly and the overall design must be done by qualified persons (see 1926 Subpart M Appendix C).

• Never assume a horizontal lifeline sized for a lanyard will carry amplified impact loads without re‑calculation.
• Use a qualified person to determine allowable loads, geometry, and anchor increase factors.

Multiple tie‑offs to a single horizontal lifeline are risky because one employee’s fall and the lifeline movement during arrest can pull other employees off their positions. Appendix C warns that if one employee falls, the motion of the lifeline may cause other attached workers to fall, and it requires increasing lifeline and anchorage strength for each additional tied‑off employee (see 1926 Subpart M Appendix C).

• Limit multiple attachments and have a qualified person design horizontal lifelines for multi‑user use.

An eye‑bolt’s rated strength applies along the bolt’s axis and its strength is greatly reduced if the load is applied at an angle (shear), so select and install eye‑bolts accordingly. Appendix C explains that eye‑bolt strength is rated along its axis and is significantly reduced under angled loads and that you should also choose an eye size that prevents accidental disengagement of snap‑hooks (see 1926 Subpart M Appendix C and 1926.502(e)).

• Use shoulder eye‑bolts for angular loads or specify appropriate fittings designed for off‑axis loading.
• Verify compatibility of connector dimensions to prevent unintentional release.

No, the sliding hitch (prusik) should not be used for lifeline/lanyard connections except in emergencies, and the one‑and‑one sliding hitch should never be used. Appendix C states that due to large strength reductions the sliding hitch should only be used in emergency situations where no other practical option exists; the one‑and‑one is unreliable and prohibited, while two‑and‑two or three‑and‑three may be used in emergencies with precautions to limit free fall (see 1926 Subpart M Appendix C).

• Prefer factory‑made connectors and engineered attachments instead of knots.

Generally no; each employee must have a separate vertical lifeline except in the specific construction task of elevator shaft work where two employees may share a lifeline. Appendix C reiterates the standard requirement that each employee must have a separate lifeline, with the limited exception for employees constructing elevator shafts (see 1926.502(d)(21) and 1926 Subpart M Appendix C).

• Plan rigging so each worker has an independent vertical lifeline unless the narrow regulatory exception applies.

Avoid nonlocking snaphook connections known to cause roll‑out unless you use properly designed locking snaphooks; specifically avoid direct connection of a snaphook to a horizontal lifeline, two snaphooks on one dee‑ring, two snaphooks connected to each other, a snaphook clipped back onto its own lanyard, a snaphook to a webbing loop, or improper dimensions that allow keeper depression. Appendix C lists these prohibited connections and points to the requirement in 1926.502(d)(6) and 1926 Subpart M Appendix C explains why they can cause roll‑out.

• Use properly designed locking snaphooks or engineered connectors for these situations.

Free fall must never exceed 6 feet (1.8 m) because the system’s maximum arresting force is evaluated under normal use with a maximum 6‑foot free fall and extra free fall significantly increases arrest forces and injury risk. Appendix C emphasizes keeping free fall to a minimum and states it must not exceed 6 feet; see 1926.502 and 1926 Subpart M Appendix C.

• Design tie‑offs and anchorage heights to limit free fall and reduce arresting force on the worker.

Attach the lanyard tie‑off at or above the fall‑arrest equipment connection point on the body to avoid adding extra free fall distance. Appendix C explains that the tie‑off should be at or above the harness connection point because attaching to the working surface often results in free fall greater than 6 feet (see 1926 Subpart M Appendix C).

• Calculate total fall distance including the lanyard length plus the distance from the working surface to the harness D‑ring.

Elongation of the lanyard and the stopping distance of deceleration devices must be added to free fall distance to compute the total stopping distance and required clearance below the worker. Appendix C states that lanyard stretch and deceleration device activation create additional stopping distances that must be included when determining clearance and that the lifeline elongation can add significantly when attached near its end (see 1926 Subpart M Appendix C).

• Use manufacturer data for elongation and deceleration distances and add them to the free fall distance when planning tie‑offs and clearance below.

You should allow a minimum of 12 feet (3.7 m) of lifeline below the securing point of a rope‑grab deceleration device, or extend the lifeline to the ground or next working level, to prevent the rope grab from sliding off the end. Appendix C recommends at least 12 feet below the rope grab termination (or continuous extension) to prevent inadvertent disengagement (see 1926 Subpart M Appendix C).

• Terminate the lifeline properly and prevent the rope grab from moving past the end during normal work or a fall.

Plan tie‑offs to minimize swinging and avoid obstructions in the potential fall path, and choose attachment points that reduce the chance of striking structures during arrest. Appendix C emphasizes selecting tie‑offs that minimize exaggerated swinging, considering the jack‑knifing motion when a body belt is used, and avoiding obstructions that could cause severe injury during a fall (see 1926 Subpart M Appendix C).

• Prefer overhead anchorages where feasible and select locations that keep the fall path clear of structures and edges.

Heavy self‑retracting deceleration devices should be secured overhead so the employee does not have to support the weight of the device. Appendix C recommends overhead anchorage for heavy SRLs to avoid the device’s weight being borne by the worker and notes special considerations if the device is used on a horizontal lifeline (see 1926 Subpart M Appendix C).

• Follow the manufacturer’s instructions for mounting location and compatibility with horizontal lifelines to prevent device migration and swing hazards.

Yes; equipment that allows employees to rescue themselves after a fall, such as descent‑capable devices, may be desirable in some situations. Appendix C notes that in certain situations devices that permit self‑rescue after the fall has been arrested can be useful (see 1926 Subpart M Appendix C).

• Ensure any self‑rescue device is compatible with the overall fall‑protection plan, manufacturer instructions, and does not compromise arresting force and clearance calculations.