Service Life and Inspection Requirements – Fall Protection Equipment

Issue Date: 2026

 Service Life and Inspection Requirements – ZERO Fall Protection Equipment [PDF]

1. Scope

This document defines the service life limitations, inspection requirements, and withdrawal criteria for ZERO® fall protection equipment.

This document applies to all ZERO® products used for work at height and shall be read in conjunction with the relevant product Instructions for Use (IFU) and applicable regulatory requirements.

2. Compliance and Governing Standards

ZERO® fall protection equipment shall be used, inspected, and maintained in accordance with applicable standards, including:

• AS/NZS 1891 – Industrial fall-arrest systems and devices
• EN 365 – Personal protective equipment against falls from a height

In accordance with these standards:

• Equipment shall undergo periodic examination by a competent person at intervals not exceeding 12 months
• More frequent inspection intervals shall be applied where required due to frequency of use, environmental exposure, or risk profile
• Inspections shall be carried out in accordance with ZERO® product instructions and applicable legislation

Where specified by ZERO®, inspection, servicing, or recertification shall be undertaken by an authorised service centre.

3. Definitions

Competent Person

A person with the appropriate training, knowledge, and experience to perform inspections and assess the condition of fall protection equipment.

Service Life

The maximum period during which a product may remain in service, subject to passing inspection and remaining fit for purpose.

Date of Manufacture (DOM)

The date marked on the product by the manufacturer.

4. General Service Life Principles

The actual service life of fall protection equipment is dependent on:

• Usage intensity and application
• Environmental conditions including UV exposure, chemicals, moisture, and temperature
• Storage, transport, and maintenance practices

ZERO® defines maximum service life limits where applicable. These limits do not guarantee usability for the full duration. Products shall be withdrawn earlier if inspection criteria are not met.

5. Service Life Classification

5.1 Textile Products

Includes harnesses, lanyards, ropes, and any load-bearing textile components.

• Maximum service life: 10 years from Date of Manufacture (DOM)
• Products may remain in service only if they continue to pass inspection

Note: Textile materials are subject to degradation and may require withdrawal significantly earlier depending on conditions of use.

5.2 Mechanical Products (No Textile Components)

Includes metallic devices such as connectors, anchors, and hardware with no textile elements.

• No predefined maximum service life
• Products may remain in service provided they:

1. Pass inspection
2. Show no signs of damage, deformation, corrosion, or functional impairment
3. Remain fit for intended use

5.3 Mechanical Products with Non-Serviceable Textile Components

Includes products where textile elements are integral and cannot be replaced, such as sealed Self-Retracting Lifelines (SRLs).

5.4 Mechanical Products with Serviceable Textile Components

Includes products where textile elements can be replaced independently of the mechanical system.

Textile Components:

• Maximum service life: 10 years from Date of Manufacture (DOM)
• Must be replaced if:

1. Inspection criteria are not met, or
2. Maximum service life is reached

Mechanical Components:

No predefined maximum service life
May remain in service subject to passing inspection and remaining fit for purpose

6. Inspection Requirements

All ZERO® fall protection equipment shall:

• Be inspected prior to each use by the user
• Undergo periodic examination by a competent person at intervals not exceeding 12 months

Inspection frequency shall be increased where the following apply:

• Equipment is used in harsh environments
• Equipment is subject to high usage
• Regulatory or site-specific requirements apply

Inspection records shall be maintained in accordance with applicable standards and organisational requirements.

7. Damage, Contamination, and Removal from Service

Equipment shall be immediately removed from service if any of the following conditions are identified:

• Cracks, deformation, or structural damage
• Excessive wear, abrasion, corrosion, or mechanical malfunction
• Cuts, fraying, burns, or fibre degradation in textile components
• Exposure to chemicals, paints, or contaminants that may affect integrity
• Evidence or suspicion of shock loading or fall arrest

Where there is any doubt regarding the condition of equipment, it shall be withdrawn from service.

Assessment shall be carried out by a competent person to determine whether:

• The product may be returned to service following approved maintenance, or
• The product must be permanently withdrawn and disposed of

Repairs shall only be performed by ZERO® or an authorised service provider.

8. Fall Arrest Events

Any equipment subjected to a fall arrest event shall be immediately removed from service and shall not be reused unless explicitly authorised in writing by ZERO® following inspection.

9. Limitation of Service Life

The stated service life represents the maximum allowable period under ideal conditions.

ZERO® does not guarantee product performance for the full duration of this period.

Operational, environmental, or maintenance factors may reduce the actual service life.

Issued by:

ZERO® Height Safety (NZ/AU) Limited