Working high up is risky enough without your safety gear letting you down. In Canada, rain and wet conditions are a regular reality on worksites, so your fall protection PPE faces a constant threat from moisture. 

Water can silently weaken harness webbing, cause deadly corrosion on metal hardware, and hide damage that isn't always obvious to the eye. 

In 2022 alone, 993 workplace fatalities and nearly 348,747 lost-time injuries occurred, highlighting the urgent need to ensure your protective equipment is in working condition.

This guide will walk you through exactly how to maintain fall protection PPE in wet conditions. 

We’ll cover the crucial steps of inspection, proper cleaning, safe drying, and correct storage, along with the role of training, knowing when to replace gear, and meeting Canadian fall safety standards. 

Because when you're off the ground, proper care can be the difference between safe work at heights and serious accidents.

Why Wet Conditions Are a Serious Risk for Fall Protection PPE

Water might seem harmless, but on a worksite, it’s a silent destroyer of your safety gear. Moisture doesn’t just make your fall protection PPE uncomfortable; it actively attacks its critical components, putting you at risk every time you work at height.

For harnesses and lanyards, wet conditions weaken the strong nylon or polyester webbing. The fibres can swell and lose their strength, drastically reducing the equipment’s ability to catch a fall. 

If not dried properly, this damp webbing becomes a ground for mildew and mould, which slowly eat away at the material from the inside out.

The metal parts are just as vulnerable. D-rings, snap hooks, and connectors are all prone to rust and corrosion when exposed to moisture. 

This rust can create rough spots that cut into webbing or, even worse, cause a metal component to freeze up or fail under the immense pressure of a fall.

Using compromised gear means trusting your life to equipment that may no longer meet safety standards. Understanding these risks is the first step to preventing them.

Inspection Protocols Before and After Use

Your fall protection PPE is your lifeline. To ensure it won't fail when you need it most, a rigorous two-step inspection routine is essential, especially after exposure to rain, snow, or moisture. 

This approach combines your own daily vigilance with scheduled expert review to catch any damage, visible or hidden.

Daily Pre-Use Inspection

Before you strap on your gear every single day, you need to give it a thorough hands-on check. 

This is your first and most important defence against using faulty equipment. Run through this checklist and keep an eye out for the specific signs of moisture damage:

1. Webbing: Run the entire length through your hands. Look for fraying, cuts, or abrasion. Feel for unusual stiffness, a crunchy texture, or swelling, which are tell-tale signs of water damage and mildew.
2. Stitching: Examine every row of stitches. Look for pulled threads, cuts, or discoloration. Pay close attention to areas where water could get trapped and weaken the thread.
3. D-Rings & Metal Hardware: Check for rust, corrosion, or pitting. Ensure they move freely without any stickiness, which can be caused by rust forming in the mechanisms.
4. Lanyards & Energy Absorbers: Inspect the entire length for cuts, burns, or changes in texture. For shock-absorbing lanyards, check the warning flag and ensure the pack isn't swollen or damp inside.
5. Connectors (Snap Hooks, Carabiners): Ensure the gate opens and closes smoothly and locks automatically. Check for any corrosion, cracks, or distortion that could compromise strength.

Scheduled Professional Inspections

No matter how diligent your daily checks are, they are not enough on their own. 

As required by Canadian safety standards (and the manufacturer), your PPE must undergo a formal inspection by a competent person; someone trained and authorized to identify less obvious damage.

This thorough inspection must be completed at least annually, or more frequently as specified by the manufacturer (e.g., every six months for severe use environments like constant wet conditions). 

These professional inspections are documented and are essential for catching internal corrosion, hidden wear, and other damage that daily checks might miss. This two-step approach ensures every possible risk is identified.

How to Maintain Fall Protection PPE in Wet Conditions

Getting your gear wet isn't the end of the world, but leaving it that way is!

Proper maintenance after exposure to moisture is a simple process that extends the life of your equipment and, most importantly, ensures it remains safe to use. 

Here’s how to do it right.

Cleaning & Drying Best Practices

Cleaning

1. Wipe down metal components with a dry cloth to remove surface moisture and dirt.
2. Use a soft-bristle brush and lukewarm water with a mild soap solution to gently clean the webbing.
3. Rinse thoroughly with clean water to remove all soap residue.

Never use bleach, solvents, or harsh detergents, as they can break down the synthetic fibres and weaken the material.

Drying

1. Hang the harness, lanyards, and other gear in a well-ventilated, clean area away from direct sunlight.
2. Allow it to air dry completely. Do not use forced heat from ovens, radiators, or hair dryers, as excessive heat can severely damage the fibres.
3. Ensure the gear is fully dry inside and out before storage. Trapped moisture leads to mildew and hidden corrosion.

Proper Storage of PPE in Wet Environments

How you store your gear is just as important as how you clean it. Correct storage prevents damage from happening between shifts. 

1. Always store PPE in a cool, dry, and clean environment free from UV light, chemicals, and excessive humidity.
2. Hang harnesses on a wide hook to maintain their shape and allow for continuous airflow.
3. Never store gear while it is still damp or in a sealed container or bag, as this traps moisture and guarantees mildew growth.

Choosing Weather-Resistant Fall Protection PPE

If your crew regularly works in damp Canadian climates, from coastal showers to prairie springs, investing in gear built for the environment is a smart first line of defence.

While all PPE requires care, some equipment is specifically engineered to better withstand wet conditions, offering enhanced durability and an extra margin of safety.

When selecting gear, look for these key features designed to fight moisture:

1. Water-Resistant or Mildew-Resistant Webbing: Many harnesses and lanyards are made from webbing with a tight weave and special coatings that cause water to bead up and roll off rather than being absorbed. This significantly reduces drying time and inhibits the growth of mildew.
2. Corrosion-Resistant Hardware: Look for D-rings, snap hooks, and other connectors made from stainless steel or featuring heavy-duty zinc or chrome plating. These materials fiercely resist rust and corrosion, ensuring the metal components operate smoothly and maintain their strength even after repeated exposure to moisture.
3. Sealed Stitching and Water-Shedding Design: Some harnesses feature sealed or backed stitching, which prevents water from wicking through the needle holes into the inner threads. Designs that minimize pockets where water can pool also help gear dry faster and more thoroughly.

Choosing PPE with these features can reduce long-term maintenance, extend the equipment's service life, and provide greater confidence when working in persistently wet conditions. 

Always check the manufacturer's specifications to confirm the gear is rated for your specific work environment.

Training and Worker Awareness

The most advanced safety gear is only effective if the people using it know how to care for it.

Formal policies are not enough; creating a culture of awareness where every worker can spot and respond to water-related damage is essential for true safety. This requires consistent, practical training that connects directly to their daily reality on the job.

Regular toolbox talks and hands-on training sessions are the best ways to drive this message home. 

Focus these sessions on the real-world challenges of working in rain, snow, and damp conditions. This isn't about theory—it's about giving workers the practical skills they need to protect themselves.

Effective PPE training must cover three core essentials:

1. Inspection: Hands-on practice in performing pre-use checks, specifically teaching crews how to identify the feel of stiff webbing, the look of surface rust, and the smell of mildew.
2. Cleaning & Drying: Demonstrating the correct, hands-on process for cleaning with mild soap and, most importantly, the critical practice of air-drying gear away from harmful heat sources.
3. Emergency Response: Ensuring every worker knows the immediate protocol to follow if their gear becomes saturated or damaged during a shift, including how to formally tag it and remove it from service.

When your entire team can confidently identify risks and take correct action, they become your most valuable asset in preventing equipment failure.

Replacement Criteria and Common Mistakes

Knowing when to retire damaged gear is as critical as knowing how to inspect it. Using compromised fall protection PPE creates a false sense of security with potentially dire consequences. 

Follow these clear, non-negotiable criteria to determine when equipment must be taken out of service.

When to Remove PPE from Service

Immediately tag and remove any fall protection equipment from service if you find any of the following issues:

1. Saturation or Immersion: Gear that has been fully saturated or submerged (unless specifically approved by the manufacturer for such use).
2. Mildew or Mould: Any visible signs of mildew, mould, or fungal growth on the webbing, along with a musty smell.
3. Fraying & Abrasion: Any cuts, tears, frayed edges, or excessive abrasion on webbing or lanyards.
4. Rust & Corrosion: Any rust or corrosion on hardware that does not wipe off easily, or that affects the function of moving parts.
5. Post-Fall Impact: Any equipment that has been subjected to fall arrest forces must be immediately retired, even if no damage is visible.
6. Expiration Date: If the manufacturer has specified a service life, the equipment must be retired on that date, regardless of condition.

What Not to Do

Some mistakes can instantly compromise the integrity of your safety gear. Avoid these common errors at all costs.

1. DO NOT store wet or damp gear. This is the fastest way to guarantee mildew and hidden corrosion.
2. DO NOT skip an inspection, especially after exposure to wet conditions. What you don't find can hurt you.
3. DO NOT use harsh chemicals, bleach, or solvents for cleaning. They destroy the fibres' strength.
4. DO NOT ever attempt to modify, repair, or splice damaged PPE yourself. This must only be done by the manufacturer or an authorized repair facility.

Regulatory Standards and Compliance

Maintaining fall protection PPE in wet conditions is a mandatory requirement under health and safety regulations. It should be an essential component of any fall protection plan.

In Canada, equipment must be designed, inspected, and maintained in accordance with recognized national standards, primarily the CSA Z259 series of standards, which align with broader North American frameworks like ANSI Z359.

These standards provide the benchmark for what constitutes a safe inspection, maintenance, and retirement practice. 

They mandate that inspections be performed by a competent person and that detailed records of all formal inspections and worker training be meticulously documented and kept on file.

This documentation is your proof of due diligence. It demonstrates that your organization has met its legal duty to provide a safe work environment and ensures every piece of equipment has a verifiable history. 

Quick Maintenance Checklist

Follow this simple checklist after any exposure to wet conditions to ensure your gear remains safe and reliable:

1. Inspect Daily: Perform a hands-on check of webbing, stitching, and hardware before each use.
2. Clean Gently: Use only lukewarm water and mild soap with a soft brush.
3. Air-Dry Fully: Hang gear in a shaded, well-ventilated area; never use direct heat.
4. Store Properly: Keep equipment in a cool, dry place and hang harnesses to maintain shape.
5. Replace Immediately: Tag and remove any damaged, expired, or fall-impacted gear from service.
6. Document Everything: Keep detailed records of all formal inspections and fall arrest training.

Conclusion

Working in rain, snow, and damp conditions is common across Canada, making the proper care of your fall protection gear non‐negotiable. 

Moisture attacks the very materials that keep you safe, weakening fibres and corroding metal. 

This isn’t just about equipment longevity; it’s about ensuring that every harness, lanyard, and connector will perform exactly as designed during a fall.

By committing to a disciplined routine of inspection, correct cleaning, thorough air-drying, and proper storage, you do more than just comply with standards. 

You actively protect your crew, prevent unnecessary equipment failure, and build a culture where everyone takes ownership of their safety. The effort you put into maintenance is a direct investment in everyone’s well-being.

Ultimately, knowing how to maintain fall protection PPE in wet conditions is a fundamental skill. Always make wet-weather PPE maintenance a core part of your safety program.