Safety lanyards are critical components of fall protection systems, yet their effectiveness depends entirely on correct usage. Even experienced workers can make simple mistakes that compromise their safety on the job.
In this blog post, we'll cover the top five mistakes workers make when using safety lanyards and provide tips on how to avoid them, ensuring you stay protected while working at heights!
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#1. Incorrect Anchorage Point Selection
One of the most common errors workers make is attaching their safety lanyard to an improper anchorage point. An anchorage point must be strong enough to support the forces generated during a fall and should meet OSHA’s requirement of supporting at least 5,000 pounds per worker.
How to Avoid This:
Before starting work, ensure that anchorage points are clearly identified and labeled as suitable for fall protection. Use only OSHA or ANSI-approved anchorage connectors, and if you're unsure, consult your site safety supervisor for guidance. A best practice is to always anchor above your head to reduce the risk of free fall.
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#2. Using a Lanyard That's Too Long or Too Short
Another frequent issue is using a lanyard that is either too long or too short for the job. A lanyard that’s too long increases the free-fall distance, which could lead to serious injury, while one that’s too short may restrict your movement, making the job more difficult and uncomfortable.
How to Avoid This:
Select the appropriate length of lanyard for the work environment. For work areas where there's limited clearance, consider using a self-retracting lanyard (SRL) like the 20FT COBRA SRL. SRLs automatically adjust length and keep the line taut to reduce free-fall distance, enhancing both safety and mobility.
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#3. Improper Use of Shock Absorbers
Some workers mistakenly believe that using a shock-absorbing lanyard in every situation is necessary. However, there are scenarios—like low-clearance jobs—where a shock-absorbing lanyard may not deploy effectively, putting the worker at risk. Conversely, not using one when needed can result in serious injury due to the force of a sudden stop during a fall.
How to Avoid This:
Understand when shock absorption is necessary. For higher platforms or when there’s enough clearance, a shock-absorbing lanyard is ideal as it reduces the impact on the body. In situations with minimal fall clearance, opt for SRLs or non-shock-absorbing lanyards that stop a fall quickly without the need for extended deceleration.
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#4. Failure to Inspect Lanyards Regularly
Even the best safety lanyards can fail if they aren't properly maintained. Fraying, cuts, burns, or worn hardware can reduce a lanyard’s effectiveness, putting workers at risk of injury in the event of a fall. Too often, workers overlook the importance of a daily inspection, leading to the use of compromised equipment.
How to Avoid This:
Inspect your safety lanyard thoroughly before each use. Look for signs of wear and tear, such as fraying fibers, cuts, and damage to stitching. Also, check the hardware, including buckles and hooks, for corrosion or any other deformities. Regularly replace damaged lanyards to ensure compliance and safety.
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#5. Improper Connection to Harness D-Rings
Connecting the safety lanyard to the wrong D-ring on a harness is a dangerous yet avoidable mistake. Each D-ring serves a different purpose; for example, the dorsal D-ring (located at the back) is typically used for fall arrest, while side D-rings are used for work positioning.
How to Avoid This:
Train workers to understand the specific purpose of each D-ring and how to use them correctly. Most fall protection systems rely on the dorsal D-ring for fall arrest, so ensure workers are connecting their lanyards to the right point. Reinforce this during training sessions and refreshers to reduce the likelihood of misuse.
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Using safety lanyards correctly is essential for ensuring the protection of workers in fall-risk environments. By avoiding these common mistakes—such as selecting improper anchorage points, using the wrong lanyard length, and failing to inspect equipment regularly—you can significantly reduce the risk of fall-related injuries. Proper training, regular equipment inspection, and using the right gear for the job are key steps in staying safe!
Recommended Products
To help you avoid these common mistakes, check out some of our most popular products below!
Equip your team with the right tools and knowledge to ensure they stay safe on the job. For more information on safety lanyards and other fall protection equipment, browse our full collection today!
Single vs. Double • 100% Tie-Off • How to Use • Benefits
Single Leg Safety Lanyard VS. Double Leg Lanyard
We at KwikSafety want to highlight the differences between our single- and double-leg safety lanyards. With our growing collection, we want to ensure every crew gets the right gear for the job. Peek at the comparison visuals below for a quick taste of what’s best for you.
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What is a Safety Lanyard?
A safety lanyard is the connector in a fall protection system that links the worker to an approved anchor. It typically clips to the harness back D-ring and may include an energy absorber, or function as a restraint lifeline.
How to Use a Safety Harness and Lanyard
All KwikSafety harnesses have a primary back D-ring centered on the spine. To use a lanyard: connect one hook to the D-ring, and the other to a rated anchor point. Keep slack minimal and maintain proper clearance.
Single vs. Double-Leg (Twin) Lanyards: What’s the Difference?
The visual cue is simple: a single-leg has one line from the snap hook; a double-leg has two. Functionally, certain jobs require 100% tie-off while moving between anchors—this is where a double (twin) leg shines. A single-leg is lighter and less bulky for straightforward work where you won’t switch anchors mid-task.
Benefits of a Double-Leg Safety Lanyard
Double-leg lanyards let you move between anchor points without disconnecting, helping maintain 100% tie-off within the lanyard’s reachable range. This reduces fall exposure during transitions and boosts workflow on dynamic sites.
Standards Snapshot
Our safety lanyards are ANSI tested and are OSHA compliant, ensuring reliable performance when used as part of a properly designed fall protection system.
Types • Internal vs External • Type 1 vs Type 2 • Use Cases
Safety Lanyards: Which One is Right for Your Job?
Choosing a lanyard comes down to anchor height, movement needs, and site hazards. Use this quick guide to single, double, flat-web, and positioning lanyards—plus when to pick internal vs external shock packs. Explore our Safety Lanyards collection.
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What is a Safety Lanyard?
A safety lanyard connects your harness to an approved anchor. It may include an energy absorber to reduce fall forces or function for restraint/positioning to keep you from reaching an edge. Always use with a rated harness, anchor, and required clearance.
Types at a Glance
Single-Leg: One line for simple, fixed work. Lighter and less bulky. Examples: RATTLER 6’, BOA 6’.
Double-Leg (Twin): Two legs for 100% tie-off while moving between anchors. Examples: PYTHON 6’, RATTLER Twin 6’.
Flat-Web: Low-profile to help reduce snags in tight spaces. Examples: TAIPAN Single / TAIPAN Twin.
Positioning: Holds you in place on vertical or fixed work; not for fall arrest. Example: COPPERHEAD 4’–6’ Adjustable.
Internal vs External Shock Absorbers
Internal: Absorber is built into the web for a slimmer profile and fewer snag points—ideal for steel work, framing, and tight scaffolds.
External: Visible tear-pack makes pre-shift checks fast and intuitive—popular for general construction, utilities, and MRO.
Type 1 vs Type 2 (Anchor Height)
Type 1: For anchors at or above the dorsal D-ring; less energy absorption needed due to minimized free-fall.
Type 2: For anchors below the dorsal D-ring; adds more energy absorption for increased free-fall potential.
Choosing the Right One
Fixed work, minimal movement: Single-leg with internal absorber.
Frequent transitions: Double-leg for 100% tie-off.
Tight, snag-prone areas: Flat-web option.
Hands-free wall/structure work: Positioning lanyard (not for arrest).
Length & Clearance
Most shock-absorbing lanyards are 6 ft. Keep slack short and verify fall clearance: lanyard length, deceleration distance, D-ring shift, body height, and a safety margin. When in doubt, consult your competent person.
Standards Snapshot
Our safety lanyards are ANSI tested and are OSHA compliant, ensuring reliable performance when used in a properly designed fall protection system.
Physics • Materials • Internal vs External • Standards
The Science of Energy Absorption in Shock-Absorbing Lanyards
Shock-absorbing lanyards reduce peak arrest forces by managing how fall energy is dissipated. Below, we break down the physics, materials, absorber types, and test standards that make these devices reliable on real jobsites.
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The Physics Behind Shock-Absorbing Lanyards
When a person falls, gravitational potential converts to kinetic energy. Lanyards control deceleration so less force is transmitted to the body and anchor. Extending the stop distance/time lowers the peak load—often shown on force–distance graphs where the area under the curve equals energy absorbed.
Key Concepts
Kinetic Energy: Energy of motion, proportional to mass and velocity during the fall.
Deceleration: Slowing the fall over distance/time to reduce peak impact force.
Impact Force: The arresting load on the worker/system; lower is safer.
Materials Used in Shock-Absorbing Lanyards
Performance depends on material behavior under load and over time.
Webbing: High-strength polyester or nylon for durability, cut/abrasion resistance, and controlled elongation.
Energy-Absorbing Elements: Engineered stitch-tear packs or internal elongation fibers that deform in a fall to dissipate energy.
External Shock Absorbers vs. Internal Shock Absorbers
External Shock Absorbers
External packs use stitched webbing designed to tear progressively under load. They’re easy to see and inspect, aiding pre-shift checks.
Visibility: Clear indication of deployment and damage.
Modularity: Some systems allow separate service/replace of the pack.
Internal Shock Absorbers
Internal systems conceal the energy-absorbing web/fibers within the lanyard leg. The low-profile design reduces snag points and exposure to elements.
Streamlined: Less bulk for climbing, steel work, and tight scaffolds.
Protected: Mechanism shielded from abrasion and weather.
Testing Standards for Shock-Absorbing Lanyards
These products undergo dynamic drops and strength tests to verify energy absorption and maximum arrest forces.
ANSI Z359.13: Performance for personal energy absorbers and lanyards.
OSHA 1926.502: Fall protection system criteria for construction.
EN 355: European energy absorber performance standard.
Testing simulates real-world falls to confirm the lanyard deploys as designed and keeps arrest forces within allowable limits.
Mitigating Fall Impact Forces
By extending deceleration and dissipating energy, shock-absorbing lanyards help protect workers and anchors from excessive loads. Select absorber type, lanyard style, and anchor strategy based on task, movement, clearance, and environment.
Standards Snapshot
Our shock-absorbing lanyards are ANSI tested and are OSHA compliant, ensuring reliable performance when integrated into a properly designed fall protection system.
What Makes a Safety Lanyard ANSI Z359.13 Compliant?
Not all lanyards are created equal. To pass jobsite inspections and protect workers, a lanyard must meet ANSI/ASSP Z359.13. Here’s how the standard defines performance, strength, labeling, and connector rules.
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🔍 What is ANSI Z359.13?
ANSI/ASSP Z359.13 sets minimum performance criteria for personal energy absorbers and lanyards. If gear doesn’t comply, it may fail to control fall forces—or be rejected on regulated jobsites.
⚙️ Performance Requirements
Limit maximum arrest force (MAF) to ≤ 1,800 lb.
Average arrest force (AAF) must be < 1,350 lb.
Energy absorber elongation must be ≤ 48 in.
Deceleration distance must be < 60 in.
These limits keep peak loads on the worker and system within safe bounds during a fall.
💪 Strength Ratings
Webbing & Stitching: Minimum tensile strength of 5,000 lb.
Energy Absorbers: Must pass dynamic drop tests without failure.
Connectors: Minimum gate strength of 3,600 lb.
Static and dynamic tests verify durability in use and during arrest.
🏷️ Required Labeling
Manufacturer, model, serial number, and date of manufacture.
Reference to ANSI Z359.13 and applicable ratings.
Capacity range (commonly 130–310 lb, unless otherwise rated).
Warnings, inspection, and care instructions (permanent and legible).
Missing or illegible labels can trigger an inspection failure.
🔗 Connector Compatibility
Self-closing, self-locking hooks required.
Must be compatible with anchors/D-rings to prevent rollout.
Connector components should comply with ANSI Z359.12.
Assuming compliance without labels or test documentation.
🧰 ANSI Compliance Saves Lives
Compliance isn’t just about passing audits—it’s about controlling fall forces. Our safety lanyards are ANSI tested and are OSHA compliant, ensuring trustworthy performance when integrated into a properly designed fall protection system.
Need help selecting ANSI-compliant lanyards? Our lineup includes single-leg energy absorbers and twin-leg tie-off systems, all clearly labeled for jobsite compliance.
📋 A Practical Guide for Safety Managers, Site Supervisors, and New Workers
OSHA Fall Protection 101: Are Your Safety Lanyards Up to Code?
When it comes to fall protection, safety lanyards are more than just a strap and hook—they’re a critical part of a life-saving system. If your site involves work at heights, OSHA and ANSI standards require that your lanyards—and how you use them—meet strict performance and inspection guidelines. Here’s how to tell if yours are up to code.
In this guide, we break down the key OSHA standards related to safety lanyards, when and how to use them, and what to look for during inspections.
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🧰 When Are Safety Lanyards Required?
Safety lanyards are required as part of a personal fall arrest system (PFAS) wherever a worker is exposed to a fall hazard of:
Industry
Fall Height Requiring Protection
Construction (OSHA 1926)
6 feet or more
General Industry (OSHA 1910)
4 feet or more
Scaffold Work
10 feet or more
Protect workers near unprotected sides/edges, leading edges, holes, or other fall hazards. The lanyard connects the harness to an anchor point and helps arrest the fall before it becomes fatal.
Lanyards used in fall arrest systems must meet these criteria:
Maximum arresting force: Must not exceed 1,800 lbs (8 kN) on the worker.
Free fall limit: Must not allow more than 6 feet of free fall.
Total fall distance: Consider deceleration distance, lanyard length, harness stretch, and worker height.
Most compliant lanyards incorporate a shock-absorbing feature to reduce impact. ANSI Z359.13 adds testing and labeling requirements for energy-absorbing lanyards to ensure durability and consistency.
Capable of supporting at least 5,000 pounds per employee attached, or
Designed and installed as part of a complete PFAS by a qualified person to maintain a safety factor of at least two times the intended load.
Additionally:
Lanyards must be compatible with the anchorage and harness used.
Snap hooks and D-rings must be self-locking and not prone to rollout.
Avoid mixing components from different manufacturers unless explicitly rated for compatibility.
Improper combinations can invalidate compliance and increase risk—always confirm components work together as a tested system.
🔍 Why Inspections and Proper Use Matter
Even high-performance lanyards are useless (or dangerous) if not inspected or used correctly.
🛠️ Daily Visual Inspection Checklist:
Frayed webbing or broken stitching
Rust or deformation in hooks and hardware
Burn marks, chemical stains, or discoloration
Labels and serial numbers still legible
🗂️ Annual Competent Person Inspection:
A qualified person should inspect all fall protection equipment at least annually, with documentation on file.
✅ Tip: If you can’t 100% confirm the condition of a lanyard—retire it immediately.
📌 Key Takeaways
✅ Requirement
🔎 Why It Matters
OSHA-compliant lanyard with shock absorption
Reduces injury by limiting fall impact
Free fall limited to 6 ft
Prevents deadly deceleration forces
Anchors rated at 5,000 lbs
Ensures anchor won’t fail during a fall
Daily and annual inspections
Prevents failure from unnoticed wear
System compatibility (harness + anchor + lanyard)
Keeps PFAS functioning as designed
🧯 Stay Compliant, Stay Safe
Whether you're outfitting new hires or reviewing current gear, ensuring your lanyards are OSHA- and ANSI-compliant is non-negotiable. Use this guide for safety audits, toolbox talks, and training.
Our safety lanyards are ANSI tested and are OSHA compliant, ensuring consistent performance when integrated into a properly designed fall protection system.
Need help choosing the right safety lanyard for your crew? Our specialists can help you match standards with site needs.
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