A Fall Protection Deep Dive
OSHA regulations, weight capacity, aeriel lifts, and other critical fall protection considerations.
- By Dennis Capizzi
- Oct 15, 2025
It is no surprise that Fall Protection tops the list of the Occupational Health and Safety Administration’s (OSHA) list of the Top 10 most frequently cited workplace standards, as for the 14th year in a row it is number one on the 2024 list.1
Regardless of whether you have years of experience in the construction industry or are new to the job, you are most likely familiar with the “ABCs of Fall Protection,” consisting of Anchor Points, Body Harnesses, and Connecting Devices. But what about some of the more complex scenarios and applications that go beyond the ABCs? An understanding of some of these more specific and often asked questions can help ensure you have the proper fall protection PPE for your jobsite and application and help prevent contributing to the OSHA Top 10.
What is the Weight Capacity for Fall Protection PPE?
The American National Standards Institute (ANSI) standard – ANSI Z359.11 – states that a full-body harness should be able to support users within the capacity range of 130 – 310 lbs.2 A harness may be rated to a larger capacity (e.g., 400 lbs.) for OSHA and CSA standards, but to meet the ANSI standard, capacity must conform to the ANSI limits shown in large type on the label’s first page.
As background, the technology behind the fall protection equipment products and the industry testing standards ultimately dictate these weight ranges. Falls can generate extremely high forces that must be taken into consideration when determining the proper weight capacity for PPE. For example, users who are too light may not generate enough force to deploy the energy absorbing pack, or users who are too heavy may require additional distances to help stop a fall, which are outside scope of the calculated fall clearance charts.
What Standards Are Available for Arc-Rated Personal Fall Limiters?
Like standard Self-Retracting Lanyards (SRLs) and PFLs, arc-rated PFLs will be rated to the applicable regional standard; this includes ANSI and OSHA standards for the United States and the CSA standard for Canada. For arc-flash products specifically, there is a standard called ASTM F887. This standard only applies to fall protection harnesses, energy-absorbing lanyards, arborist saddles, climber straps, and a few other items.
Self-retracting devices are not included in the ASTM F887 standard. However, the same test methods can be applied to the self-retracting devices to determine whether they are suitable for use in arc-flash applications. This includes exposing the device to an electric arc. Under the ASTM F887 testing standards, any load-bearing materials must not have after-flame for greater than 5 seconds, or in other words, it must self-extinguish in 5 seconds or less. Non-load-bearing components and accessories must self-extinguish in 15 seconds. There cannot be melting or dripping on any load-bearing material. After the arc-flash testing is complete, the self-retracting device that was exposed to an arc-flash will be dynamically tested and must arrest the test mass after a drop.3
How Do the Revisions to OSHA 29 CFR 1926.95 Impact PPE Selection?
Released in December 2024 and effective January 2025, revisions to 29 CFR § 1926.95 “Personal Protective Equipment in Construction” clarify the language around PPE fit. Specifically, § 1926.95(c) now states that “Employers must ensure that all personal protective equipment: (1) Is of safe design and construction for the work to be performed; and (2) Is selected to ensure that it properly fits each affected employee.”4
When selecting PPE in light of this revision, considerations may include factors such as sizing and adjustability. For example, harnesses often come in various sizes, and depending on the manufacturer, additional features that allow the user to tighten or loosen the harness as needed, or feature additional contoured padding, can help improve fit and enhance worker comfort.
Why Are External Energy Absorbers Now on the Majority of PFLs?
The main reason users are seeing more energy absorbers outside of the PFL or SRL these days is largely due to the trends towards leading-edge rated (Class II) products. Class II products are designed to help reduce risk in a leading-edge fall event where the line constituent becomes snagged or stuck on the edge. This prevents the line from moving smoothly during deceleration and then forces rise, which could sever the line. Having an energy absorber near the end user (or weight during the standard test) helps to manage these forces and to help reduce the risk of the line being severed.
Be cautious, though, just because there is an energy absorber near the connector, external to the PFL or SRL, this does not necessarily mean a product is “leading edge” or Class II rated. Always read the product label and user instructions to confirm the Class II standard icon is found on the product.
What PPE Should be Considered in Aerial Lifts and Other Mobile Elevated Work Platforms (MEWPs)?
When it comes to aerial lifts and other MEPWs, the ANSI recommendation is to use a restraint lanyard that prevents the worker from being able to fall out of the basket. If that is not possible, then ANSI recommends that workers use a Class II, leading-edge SRD for MEWPs or any other tie-off that is below the d-ring of the harness.
As a reminder – and especially when it comes to some of the more unique jobsite hazards and applications that may require arc-rated gear or concerns about weight capacity – training and proper use of the selected PPE are important to helping maintain safety while working at height. National standards and state, provincial, and federal laws may require the user to be trained before using fall protection PPE. Reference to product user manuals may also be incorporated as part of a user safety training program that is appropriate for the user’s occupation. Employers often provide these instructions to users before use of the product and allow users to retain the instructions for ready reference. Employers may require the user to read, understand (or have explained), and follow all instructions, labels, markings, and warnings supplied with the product and with those products intended for use in association with it.
REFERENCES:
- https://tinyurl.com/25m7mbt2
- https://tinyurl.com/4fyw8f2e
- https://tinyurl.com/6p4znp9f
- https://tinyurl.com/yf74u6mr
This article originally appeared in the October 2025 issue of Occupational Health & Safety.