OSHA doesn’t just care if your workers wear harnesses—they care how well they fit. Improper sizing leads to failed inspections, reduced protection during a fall, and liability if injuries occur. Here’s how to avoid that.
How Harness Sizing Works (It’s Not Like Clothing)
Fall protection harnesses aren’t sized like T-shirts or jeans. They’re sized based on:
- Chest girth
- Thigh circumference
- Torso length
- Weight range
The sizing terminology varies by brand (some use S/M/L/XL, others use number ranges), but all reputable harnesses will list:
- A weight capacity (usually 130–310 lbs. including tools and gear)
- A size chart with body measurements
PowerPak offers Universal, S, M, L, XL, and 2XL options from brands like Arresta and Guardian.
Key Rule: You must size based on the worker’s body in full gear - including tool belts, cold-weather clothing, etc.
How to Measure a Worker for Harness Fit
Use a fabric measuring tape or harness-sizing tape to get:
| Measurement Area | How to Measure |
|---|---|
| Chest | Around widest part of chest with arms relaxed |
| Thighs | Around upper leg, just below the groin |
| Torso | From shoulder (trap area) down to hip bone |
| Weight | Fully clothed, with tools if they wear them daily |
Then compare these measurements against the harness manufacturer’s sizing chart. If a worker is between sizes, size up, not down—tightening is easier than overstretching.
OSHA & ANSI Sizing Requirements
OSHA (29 CFR 1926.502):
- Requires that personal fall arrest systems must be used properly
- This includes fitting the user correctly (tight and secure, no loose webbing)
ANSI/ASSE Z359.11:
- Harnesses must be tested for minimum and maximum user weight ranges
- Fit must prevent sliding out, slippage, or improper load distribution during a fall
- Internal injuries due to poor load distribution
- Suspension trauma due to poor circulation
- Increased arrest distance (danger of secondary impact)
Common Size Categories
| Size | Chest (in) | Weight Range (lbs) | Notes |
|---|---|---|---|
| Small | 34"–40" | 130–175 | For smaller-framed workers |
| Medium | 38"–44" | 150–210 | Standard adult fit |
| Large | 42"–48" | 180–250 | Most common field size |
| XL | 46"–52" | 210–300 | Heavier or layered clothing |
| 2XL/3XL | 50"+ | 250–400 | Oversized or heavy gear |
Some brands (like Arresta Silver Series) use Universal Sizing that adjusts for M–XL, but that doesn’t work for all body types or applications.
Fit Check Guidelines (Must-Haves Before Use)
Before each use, confirm:
- Dorsal D-ring sits between shoulder blades
- Chest strap lies flat and at mid-chest (not too high or too low)
- Leg straps snug, no hand gap underneath, but not cutting off circulation
- Webbing lays flat and isn’t twisted
- No excess slack in adjustment straps after fitting
If the harness cannot be adjusted to meet all of the above, it’s the wrong size.
What to Stock per Crew
You should have:
- At least 3 sizes on hand: M, L, XL (or Universal + 2XL)
- Extras in cold weather, when bulky gear affects fit
- Specialty harnesses (e.g., crossover, arc-flash rated, retrieval harnesses) in appropriate sizes for specialty crews
Related Harnesses from PowerPak
- ARRESTA Silver Series Harness - Universal Pass-thru leg straps, fits M–XL, high visibility stitching
- Guardian Harnesses - Multiple Sizes Options for specific fit, comfort, or attachment needs
- Custom Order Harness Kits or Bulk Sizes For outfitting entire crews with mixed sizing or safety plans
Final Reminder: Fit = Safety
Stocking the wrong harness size isn't a minor oversight—it’s a liability. Always:
- Fit-test new hires
- Stock a range of sizes
- Document training on proper fitting
- Inspect harness fit every shift