Spotting wear and tear on used gear: my quick routine

Marking dates on harnesses is a solid move. I’ve tried color-coded tags for quarterly inspections, but honestly, the tape method is more straightforward - less confusion when you’re in a rush. I do wonder, though, how folks keep track of gear that gets shared between crews or shifts. We’ve had issues where a harness goes missing for a week, then turns up with a mystery scuff or two, and no one’s quite sure if it’s still safe.

I’ve found that keeping a logbook helps, but it’s only as good as the people using it. Sometimes, with a big property and rotating teams, things slip through the cracks. Anyone have a system for tracking gear usage that actually sticks? I’m always looking for ways to cut down on those “where’d that go?” moments, especially with the pricier safety equipment.

We tried a sign-out board for harnesses - just a whiteboard by the gear rack. It’s not perfect, but at least you know who had it last when something goes missing or comes back looking rough. Still, stuff slips through, especially on busy days...

It’s not perfect, but at least you know who had it last when something goes missing or comes back looking rough.

Does anyone actually check the board every time, though? I get what you mean about stuff slipping through - on a busy site, half the crew forgets to sign out gear anyway. I’ve seen harnesses tossed back on the rack with busted buckles and nobody says a word. Is there really any way to make sure people actually look things over, or is it just wishful thinking? Maybe tagging harnesses that need inspection could help, but then you gotta trust folks notice the tag.

Honestly, I’ve never seen a sign-out board actually work 100% - especially when everyone’s in a rush to get off the roof before the rain hits. I’ve tried tagging harnesses with bright tape when something looks sketchy, but half the time, folks just grab whatever’s closest and go. What’s helped a bit is doing a quick group check before we pack up. Not perfect, but at least you catch the obvious stuff before it gets buried on the rack.

I hear you on the sign-out board - no matter how organized things start, it always seems to fall apart once the weather turns. I’m pretty detail-oriented, but even I’ve missed stuff when everyone’s in a hurry. Quick group checks sound smart, but how do you make sure people actually pay attention and don’t just go through the motions? Also, does anyone keep a checklist or is it more of a visual scan for frayed straps and cracks? I worry about missing something subtle, especially since I’m still learning what’s “normal wear” versus “replace now.”

- I keep a laminated checklist in the bin - helps when my brain’s fried after a long day.
- For group checks, I make folks call out what they see. If someone’s just nodding along, I’ll ask them to point to a random strap or buckle.
- Subtle stuff’s tricky... if you’re unsure, snap a pic and compare it week to week.
- Frayed edges and deep cracks? Replace. Light fuzz or tiny nicks? Usually fine, but trust your gut if it looks off.
- Honestly, I’ve missed things before - nobody’s perfect. Just try to slow down when you can.

- Laminated checklist’s a solid move. I’ve tried digital apps, but honestly, paper’s faster when you’re tired and your phone’s dead or buried under a pile of gear.
- Group checks - yeah, I get the idea, but sometimes folks just want to get it over with. I’ll admit, I’ve had to call people out for just nodding and not actually looking. Your “point to a random strap” trick is clever. Might steal that.
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Subtle stuff’s tricky... if you’re unsure, snap a pic and compare it week to week.

All in all, your routine’s pretty dialed in. Just don’t let the “replace everything at the first sign of wear” mindset take over - sometimes a little wear is just proof the gear’s doing its job. But yeah, trust your gut if something feels off.

That “point to a random strap” trick cracks me up - reminds me of when I’d ask my kids to find the one tool I actually needed in the garage, just to see if they were paying attention. I’m with you on not tossing stuff for a little fuzz. My old climbing harness looked rough around the edges but was still solid for years. Sometimes a bit of wear just means it’s been put to good use. But yeah, if something feels off, I don’t mess around - better safe than sorry, even if it means double-checking when I’m dead tired.

I get the hesitation to toss gear just for looking a bit worn - sometimes it’s just cosmetic. But I always wonder, is there a specific sign you look for that makes you finally retire something? For me, it’s usually fraying near a load-bearing seam, but I’m never sure if I’m being too cautious.

For me, it’s usually fraying near a load-bearing seam, but I’m never sure if I’m being too cautious.

I get that - fraying at seams is my main red flag too, especially with things like harnesses or straps. But sometimes I’ll keep using something if the wear is only on an outer layer and the core fibers look solid. Does anyone actually cut stuff open to check inside? I’ve always wondered if I’m missing hidden damage.

- Same here - if I see fraying at a seam, I get nervous, but I’ll admit I’ve kept using stuff if the main threads look okay.
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Does anyone actually cut stuff open to check inside?

Cutting stuff open seems a bit extreme unless it’s already at the end of its life. I get the urge to be thorough, but I’d rather rely on a solid visual and tactile check - especially if it’s gear that’s seen a lot of use. If I notice any stiffness, odd stretching, or the fibers start separating, that’s usually my cue to retire it. I’ve seen webbing that looked fine on the surface but felt off when I bent it, and sure enough, there was hidden damage inside. Sometimes, you just have to trust your gut and err on the side of caution.

I do think people toss things a little early sometimes, but honestly, I’d rather be safe than risk a failure when it counts. If there’s any doubt, especially with safety gear, it’s not worth pushing your luck.

- I get where you’re coming from, but sometimes I wonder if a visual and bend test is enough, especially with older stuff that’s seen sun and weather.
- Had a harness that looked totally fine, but after a couple wet/dry cycles it started to feel weird - didn’t see anything until I pulled the stitching apart.
- Curious if anyone’s actually sent gear off for lab testing or destructive testing? I’ve heard mixed things about how reliable those “gut checks” are, especially when UV damage is involved.
- Ever had something pass all your checks but still fail unexpectedly? That’s my worry...

- Been there with gear that *looks* fine but just feels off. I trust my hands more than my eyes half the time, but even then, stuff can surprise you.
- UV is a sneaky one. Had some old webbing that sat on the truck for a summer - looked okay, but when I finally gave it a yank, it tore like tissue paper. Never would’ve guessed from just looking.
- Never sent anything to a lab myself (who’s got the budget for that?), but I have done a few “backyard break tests” on old harnesses and ropes. Results were... not confidence-inspiring. Stuff that passed my usual checks sometimes failed way sooner than I thought it would.
- Gut checks are good, but they’re not magic. If something’s been baking in the sun or soaked through a bunch, I usually just retire it. Cheaper than a hospital bill.
- Honestly, if you’re ever in doubt, toss it. That’s my rule after seeing too many “surprises” over the years.

Gut checks are good, but they’re not magic. If something’s been baking in the sun or soaked through a bunch, I usually just retire it. Cheaper than a hospital bill.

That hits home. I’ve tossed harnesses that looked fine but just felt “off” after a season on the job. Ever notice how UV damage isn’t always obvious till it’s too late? I wonder if there’s a better way to test gear without breaking the bank... Sometimes I wish manufacturers gave more practical guidelines for real-world use, not just lab specs.

Yeah, I hear you on the UV thing. I’ve had harnesses that looked totally fine but just felt brittle or weird after a summer up on hot shingles. Sometimes it’s just a gut call, even if the tags say they’re still in date. Wish there was a cheap way to really check the fibers, but for now, I’d rather be safe than sorry. Manufacturers could definitely do better with real-world advice... lab tests don’t cover half of what we put gear through out here.

Had a harness that was just under two years old, always stored in the shade, but after a brutal August up on black shingles, it started feeling stiff and almost chalky. No visible fraying, and the label looked fine, but it just didn’t sit right. Sent it in for inspection and sure enough, the webbing had started to break down. I agree - real-world use is a whole different beast than what those test labs account for. Sometimes you just gotta trust your hands more than the tag.

- Gotta say, I get the “trust your hands more than the tag” thing, but sometimes I wonder if we’re too quick to toss stuff.
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“No visible fraying, and the label looked fine, but it just didn’t sit right.”

I get what you mean about retiring gear early - sometimes it does feel like overkill. But I’ve seen harnesses that looked fine, then you dig in and find a spot that’s gone stiff or slick after a summer in the truck. Ever notice if certain brands bounce back better after heat or humidity? Or is it just luck of the draw?

I’ve definitely noticed some brands seem to hold up better in humid conditions, but I’m never quite sure if it’s just the way I store them or actual quality differences. I had a Black Diamond harness that got stiff after just one hot summer in the garage, while my Petzl seemed to last longer before showing any real wear. Maybe the material blend makes a difference? Or possibly how tightly the webbing is woven... Curious if you’ve ever tried cleaning or conditioning gear to see if that helps restore flexibility, or if that’s just asking for trouble.