The Importance of Harness Systems When Working on Boom Lifts

Working at height presents significant risks to operators and remains one of the leading causes of workplace injuries and fatalities in New Zealand. When using boom lifts and other elevated work platforms (EWPs), proper safety measures are essential to protect workers. Among these safety measures, harness systems play a crucial role, particularly when operating boom-type EWPs. Working at heights training and EWP training both include instruction on using harnesses. This article explores why harness systems are not just recommended but mandatory when working on boom lifts and how proper implementation can save lives, improve productivity, and reduce costs associated with workplace accidents.

Understanding Boom Lift Hazards

Boom lifts, including self-propelled, truck-mounted, and trailer-mounted varieties, present unique risks compared to other EWPs such as scissor lifts. The articulating or telescopic boom design creates movement patterns that can result in sudden jerking, particularly when the platform hits an obstacle or experiences a levelling system failure. Additionally, the extended reach capability means operators can be working at significant heights and distances from the main structure, increasing the risk of catapulting in case of platform movement.

According to WorkSafe New Zealand’s Best Practice Guidelines for EWPs, these hazards make harness systems an absolute necessity, not an optional safety feature, when operating boom-type platforms.

Legal Requirements for Harness Systems

In New Zealand, the Health and Safety at Work Act 2015 places responsibility on businesses to ensure worker safety. Specifically for boom lifts, operators must wear a properly fitted harness with an appropriate lanyard when operating:

• Truck-mounted boom lifts
• Self-propelled boom lifts
• Trailer-mounted boom lifts
• Vertical masts (where recommended by the manufacturer)
• Any boom-type lift with a knuckle or pivot arrangement
• Any machine where a risk assessment indicates it is necessary.

Failing to comply with these requirements not only puts workers at risk but can also result in significant penalties, including fines up to $600,000 for individuals who are PCBUs (Person Conducting a Business or undertaking) or officers and up to $3 million for companies.

Proper Harness System Components

An effective harness system for boom lift operations consists of several key components:

Full-Body Harness

A full-body harness compliant with AS/NZS 1891.1 (Industrial Fall-Arrest Systems and Devices) is required. This distributes fall forces across the shoulders, thighs, and pelvis, minimising injury risk if a fall occurs.

Appropriate Lanyard

The lanyard should incorporate a short energy absorber or utilise a self-retracting lifeline (SRL) that is fit for purpose. When using an adjustable lanyard, it should be set to the shortest practical length to restrain the operator inside the platform. The lanyard length should be selected based on the platform size of the specific EWP being used.

Certified Anchor Point

All harnesses must be attached to a certified anchor point within the work platform. These anchor points should be as close to the platform floor as possible and must be capable of withstanding forces generated during a fall arrest situation.

Benefits of Proper Harness Systems

Reduced Risk of Serious Injury and Fatality

The primary benefit of using a harness system is preventing falls from the platform. If the platform suddenly moves or tips, the harness keeps the operator inside the work basket, dramatically reducing the risk of fatal injuries. This protection is particularly vital when operating at significant heights where falls would likely be fatal.

Increased Worker Confidence and Productivity

When operators know they’re properly secured, they can focus on their work rather than worrying about safety risks. This increased confidence translates directly into improved productivity and work quality. Workers who feel secure are less likely to rush tasks or make errors due to anxiety about height.

Reduced Business Costs

The financial implications of workplace accidents are substantial. Direct costs include:

• WorkSafe investigations and potential fines
• Increased insurance premiums
• Medical expenses and compensation
• Equipment damage.

Indirect costs are often even higher:

• Lost productivity during investigations
• Replacement worker training and reduced efficiency
• Reputational damage affecting business opportunities
• Legal expenses.

By implementing proper harness systems, businesses can significantly reduce these potential costs while demonstrating commitment to worker safety.

Training Requirements for Harness Systems

Using a harness system effectively requires proper training. Operators must understand:

• How to correctly wear and adjust the harness
• How to inspect harness equipment before use
• Proper attachment to certified anchor points
• Emergency procedures if an incident occurs

One way to demonstrate competence is through the NZQA Unit Standard 23229 Use a Safety Harness for Personal Fall Prevention When Working at Height, or a combination of Unit Standard 17600 (Explain Safe Work Practices for Working at Heights) and Unit Standard 25045 (Employ Height Safety Equipment in the Workplace).

Rescue Planning

An often overlooked aspect of harness use is rescue planning. If an operator becomes suspended in their harness after an incident, a rapid rescue is critical to prevent suspension trauma, which can occur when blood pools in the legs due to restricted movement while hanging.

Every workplace using boom lifts should have a documented rescue plan that includes:

• Methods for lowering the platform using ground controls
• Secondary retrieval options if primary systems fail
• Contact procedures for emergency services
• First aid protocols for suspended workers
• Regular rescue drills to ensure preparedness.

Common Misconceptions About Harness Systems

“The Guardrails Provide Enough Protection”

While guardrails are essential safety features, they alone cannot prevent ejection during sudden platform movements or collisions. Guardrails and harness systems work together to provide comprehensive protection.

“Harnesses Restrict Movement and Reduce Productivity”

Modern harness systems are designed for comfort and mobility. When fitted correctly and used with appropriate lanyard lengths, operators maintain freedom of movement while gaining critical safety protection.

“Short Jobs Don’t Require Harnesses”

The duration of work has no bearing on the requirement to use harness systems in boom lifts. Accidents can happen at any time, regardless of how brief the elevated work may be.

Conclusion

Harness systems are a critical safety requirement when operating boom lifts, providing essential protection against the unique risks these platforms present. Beyond meeting legal obligations, proper implementation of harness systems delivers significant benefits to both workers and businesses. By ensuring operators are properly equipped, trained, and supported with clear rescue protocols, companies can improve safety outcomes while enhancing productivity and avoiding costly workplace accidents.

For businesses, investing in quality harness equipment and training represents not just compliance with regulations, but a commitment to worker well-being that ultimately contributes to business success. The small investment in proper harness systems pales in comparison to the potential costs, both human and financial, of failing to protect workers at height.