Fall Protection – Defective Safety Harness

  • Safety Flash
  • Published on 12 February 2024
  • Generated on 11 October 2025
  • IMCA SF 03/24
  • 2 minute read

Several points of failure were identified on and around the area of the plastic back pad of a harness.

What happened?

During equipment recovery operations on the back deck of a vessel, a technician felt something unexpected around the Dorsal ‘D’ ring on the back of his safety harness. Operations were immediately stopped. On inspection, several points of failure were identified on and around the area of the plastic back pad of the harness (see photo).

Defective Safety Harness

Findings/Lessons Learned

  • Before project mobilisation, the task of inspecting the harnesses was assigned to an untrained short service employee, which was contrary to company requirements.
  • There was a failure to adhere to existing internal requirements and control mechanisms associated with the periodic inspection, maintenance and record keeping associated with fall protection equipment systems.
  • There was no evidence that a pre-use inspection – as was required by the company – had been completed by the technician before putting on the harness and starting work.
  • Wear and tear of the harness and metal components indicated exposure to adverse environmental conditions, suggesting that the harness had not been stored and maintained per the original equipment manufacturer’s instructions.

Actions taken

  • Ensure thorough visual inspection of fall protection safety harnesses by an appropriately trained person. Safety harnesses found unfit for service should be quarantined or destroyed.
  • Maintain a comprehensive fall protection equipment register.
  • Always store fall protection equipment in an environment protected from the elements and in accordance with the original equipment manufacturer’s requirements.

Latest Safety Flashes:

Crane cab access platform collapsed

On a vessel crane, the access platform to the crane cab failed catastrophically. 

Read more
Positive: Worn mooring lines spotted and replaced before they parted

It was observed that mooring ropes had nearly reached breaking point.

Read more
Dropped object due to over-ridden limit switch

A limit switch on a crane was over-ridden, resulting in wires parting and objects falling from the crane.

Read more
Worker suffered eye injuries in electric arc incident

A Vessel ETO (Electro-Technical Officer) sustained light burn injuries to the eyes.

Read more
USCG: Lithium-Ion battery system installations

The United States Coastguard has published Safety Alert 14-25 relating to Lithium-Ion (Li-Ion) battery system Installations.

Read more

IMCA Safety Flashes summarise key safety matters and incidents, allowing lessons to be more easily learnt for the benefit of the entire offshore industry.

The effectiveness of the IMCA Safety Flash system depends on the industry sharing information and so avoiding repeat incidents. Incidents are classified according to IOGP's Life Saving Rules.

All information is anonymised or sanitised, as appropriate, and warnings for graphic content included where possible.

IMCA makes every effort to ensure both the accuracy and reliability of the information shared, but is not be liable for any guidance and/or recommendation and/or statement herein contained.

The information contained in this document does not fulfil or replace any individual's or Member's legal, regulatory or other duties or obligations in respect of their operations. Individuals and Members remain solely responsible for the safe, lawful and proper conduct of their operations.

Share your safety incidents with IMCA online. Sign-up to receive Safety Flashes straight to your email.