Proper Fit Is Essential in Fall Protection
Understanding and complying with OSHA’s new rule on properly fitted PPE in construction.
- By Vivek Vishal, Susan Silver
- Jun 30, 2025
In the construction industry, fall hazards are a significant concern, making the safety of workers paramount. One of the key components to ensuring safety on construction sites is the use of properly fitting Personal Protective Equipment (PPE) for fall protection. Recently, the Occupational Safety and Health Administration (OSHA) finalized a crucial revision to the PPE standard for the construction industry. This new ruling mandates that all PPE must properly fit each affected employee, enhancing safety measures and setting new standards for inclusivity and worker protection.
The revised OSHA rule amends 29 CFR 1926.95, which outlines the criteria for PPE in the construction industry. Specifically, OSHA updated Section 1926.95(c) to state that construction industry employers must ensure that all personal protective equipment is of safe design and construction for the work to be performed and is selected to ensure that it properly fits each affected employee. This ruling addresses long-standing issues of improperly sized fall protection equipment, which can lead to new safety risks and discourage its use due to discomfort.
Potential Hazards of Improperly Sized Fall Protection Equipment
Improperly sized fall protection equipment can be detrimental in multiple ways:
- Ineffectiveness in Protection: Oversized harnesses or protective clothing can be caught in machinery, leading to severe injuries. Similarly, improperly fitting harnesses can fail to provide adequate fall protection.
- Creation of New Hazards: Excess material in harnesses can lead to tripping or entanglement, further endangering workers.
- Discouragement of Use: Discomfort from ill-fitting fall protection gear can cause workers to avoid wearing PPE, increasing their risk of injury.
This ruling aims to mitigate these risks by ensuring fall protection equipment is both effective and fits comfortably, thereby encouraging consistent use.
The New OSHA Ruling
Effective January 13, 2025, OSHA’s new rule explicitly requires that fall protection PPE must properly fit construction workers. OSHA stated in the proposed rule that improperly fitting PPE can be uncomfortable for the wearer, which in turn can lead workers to modify or disregard the PPE and become vulnerable to hazards. This revision aligns the construction industry’s standards with those already in place for general industry. The rule is a response to growing awareness and advocacy for more inclusive and effective protective measures, ensuring all workers have access to PPE that fits their specific body dimensions.
The updated standard includes specific language that mandates employers to provide fall protection PPE that properly fits their workers. The new rule amends the old PPE standard, 29 CFR 1926.95(c), by explicitly requiring all gear to fit correctly. This requirement addresses the inadequacies of the former “one-size-fits-all” approach taken by some employers, promoting more tailored solutions that accommodate the diverse physical characteristics of the workforce.
The implementation of this new rule will require significant adjustments within the construction industry. Companies will need to review and possibly revise their procurement practices to ensure a range of fall protection PPE sizes is available. Additionally, training processes may need to be updated to educate workers on the importance of proper fit and how to select and maintain the right PPE.
Fall Protection Equipment
One of the most critical aspects of PPE in construction is fall protection. Properly fitting harnesses are essential for preventing falls and ensuring worker safety. A well-fitted harness can significantly reduce the risk of injury and improve worker confidence on the job. Common fall protection equipment includes:
- Full-body Harnesses: These distribute the forces of a fall across the body, minimizing injury. They should fit snugly but comfortably.
- Shock-Absorbing Lanyards: These devices reduce the impact force during a fall by extending slightly to absorb energy.
- Self-Retracting Lifelines (SRLs): These provide mobility and fall protection by automatically retracting and locking in the event of a fall.
- Anchor Points: These are secure attachment points for fall protection equipment, ensuring that the worker remains tethered in case of a fall.
The new OSHA ruling emphasizes the importance of ensuring that all these components fit correctly, thereby enhancing their effectiveness in fall protection.
To comply with OSHA’s new rule, construction companies should proactively adjust their PPE strategies. A standout method is stocking a variety of sizes for essential fall protection gear—full-body harnesses, shock-absorbing lanyards, and self-retracting lifelines (SRLs)—shifting away from the outdated “one-size-fits-all” approach. Leading firms are collaborating with PPE manufacturers to provide harnesses with adjustable straps and D-ring placements, accommodating diverse body types, from petite frames to workers needing heavy-duty options exceeding the standard 310-pound capacity. This ensures compliance while improving comfort and encouraging consistent use.
Beyond harnesses, companies are diversifying lanyard and SRL sizes, tailoring lengths to job needs—shorter for confined spaces, longer for greater mobility—while meeting OSHA’s 1,800-pound force limit. Some are introducing on-site fitting stations or mobile PPE vans stocked with multiple sizes, allowing workers to select snug, comfortable gear before working at heights. This hands-on tactic minimizes downtime and aligns with the rule’s focus on proper fit. These efforts reflect a broader push for inclusive safety, reducing fall hazards and boosting worker morale, proving that meeting OSHA standards can also enhance productivity and workplace confidence.
Training and Compliance
Employers play a pivotal role in enhancing workplace safety. A comprehensive safety program is essential for protecting employees, maintaining productivity, and complying with regulations governing fall protection. Training workers on the importance of proper fit and how to select and maintain the right fall protection PPE is crucial for ensuring compliance with the new OSHA ruling.
Conclusion
The new OSHA ruling on properly fitted PPE in the construction industry marks a significant step forward in ensuring the health and safety of workers. By mandating that PPE must properly fit, OSHA addresses longstanding safety concerns and promotes a more inclusive work environment. As the construction industry adapts to these changes, it is essential to prioritize the proper fitting of fall protection PPE to enhance worker safety and foster a safer and more productive work environment.
This article originally appeared in the June 2025 issue of Occupational Health & Safety.