How to Conduct a Height Safety Audit

Introduction

Working at height remains one of the most significant risks across industries such as construction, facilities maintenance, energy, telecommunications, and manufacturing. Falls from height consistently rank among the leading causes of workplace fatalities and serious injuries worldwide. Even in well-managed organisations, the complexity of modern work environments, evolving regulations, and varied equipment make ongoing vigilance essential.

A Height Safety Audit is a structured, systematic review of a workplace’s systems, equipment, and procedures used for working at height. Unlike a quick visual inspection, an audit is comprehensive- it examines not just whether height safety systems exist, but whether they are fit for purpose, compliant, properly maintained, and effectively integrated into daily operations.

The objectives of a height safety audit include:

• Ensuring compliance with applicable legislation, standards, and codes of practice

• Identifying hazards that could lead to injury or death

• Assessing the effectiveness of existing fall protection measures

• Providing a prioritised action plan for improvements

• Demonstrating due diligence to regulators, insurers, and stakeholders

• Fostering a safety culture where risks are understood and proactively managed

When done correctly, a height safety audit reduces risks, prevents accidents, and builds confidence in both the workforce and management.

Understanding the Regulatory Framework

Before you do an audit, it is essential to understand the legal and standards-based framework you are using. The exact requirements depend on your jurisdiction, but some universal elements apply globally.

Key Standards and Legislation

Australia & New Zealand

• AS/NZS 1891 – Industrial fall-arrest systems and devices (Parts 1–4)

• AS/NZS 1657 – Fixed platforms, walkways, stairways, and ladders

• WHS Regulations 2011 – Duties of Persons Conducting a Business or Undertaking (PCBU)

• Codes of Practice for managing the risk of falls

United States

• OSHA 29 CFR 1910 (General Industry) and 1926 (Construction)

• ANSI Z359 Fall Protection Code

United Kingdom

• Work at Height Regulations 2005

• BS EN 795: Protection against falls from height — Anchor devices

Legal Responsibilities

In most jurisdictions:

• Employers/PCBUs must identify hazards, assess risks, and implement controls.

• All height safety systems must be designed, installed, and certified by competent persons.

• Equipment must be regularly inspected and maintained in accordance with the manufacturer’s requirements and relevant standards.

• Workers must be trained and competent.

A height safety audit verifies that these responsibilities are being met and documented.

Planning and Preparation

The quality of an audit depends heavily on how well it’s planned.

a) Determine the Audit Type

• Internal audit – Conducted by your own team to identify gaps before an external review.

• External audit – Conducted by independent, qualified auditors. Provides impartiality and is often more credible with regulators or clients.

b) Set the Scope and Objectives

Decide which areas will be covered:

• Roof access and fall protection systems

• Ladders, stairs, and platforms

• Scaffolding and temporary edge protection

• Mobile Elevated Work Platforms (MEWPs)

• Work positioning and rope access systems

• Emergency and rescue systems

Your objectives might include:

• Full compliance check

• Post-incident review

• Pre-project or pre-maintenance certification

• Insurance or contractual requirements

c) Assemble the Audit Team

Include:

• A competent height safety inspector or auditor

• A representative from the site’s safety team

• Facilities or maintenance personnel

• Worker representatives (they often know practical realities)

d) Gather Documentation

Before the site visit, request:

• System design drawings and certifications

• Installation and recertification records

• Maintenance logs

• Risk assessments and Safe Work Method Statements (SWMS)

• Training records

• Rescue plans

This preparation ensures the audit is focused and evidence-based.

On-Site Inspection & Audit Execution

a) Site Walkthrough

Start with a high-level walkthrough to familiarise yourself with:

• Work areas at height

• Access points

• Traffic patterns

• Weather or environmental conditions that may affect safety

b) Inspection of Fixed Systems

Check each system against applicable standards:

• Anchor points – Location, rating, certification, corrosion, deformation

• Static lines – Tension, integrity, terminations, intermediate supports

• Guardrails and handrails – Height, strength, infill panels, corrosion

• Walkways – Width, slip resistance, free of obstructions

• Ladders – Angle, rungs, cages, fall arrest devices, condition

c) Inspection of PPE

• Harnesses – Stitching, buckles, webbing integrity

• Lanyards – Shock absorber condition, connectors

• Rope systems – Fraying, knots, storage

• All PPE should have inspection tags and current certification.

d) Observation of Work Practices

If work at height is occurring during the audit:

• Are workers tied off correctly?

• Are anchor points appropriately used?

• Is PPE adjusted and fitted correctly?

• Are tools tethered to prevent dropped object hazards?

Risk Identification & Assessment

A good audit doesn’t just list defects—it assesses risk.

a) Hazard Identification

Look for:

• Unprotected edges

• Fragile roof surfaces

• Inadequate clearance for fall arrest

• Improper ladder access

• Poor housekeeping in work-at-height zones

b) Risk Rating

Use a simple matrix:

• Likelihood: Rare, Unlikely, Possible, Likely, Almost Certain

• Consequence: Insignificant, Minor, Moderate, Major, Catastrophic

• Risk = Likelihood × Consequence

c) Applying the Hierarchy of Controls

From most to least effective:

1. Elimination – Remove the need to work at height

2. Substitution – Use drones or extendable tools (for example)

3. Engineering controls – Guardrails, platforms, static lines

4. Administrative controls – Procedures, training, permits

5. PPE – Harnesses, helmets, lanyards

Documentation & Reporting

Your report should include:

• Executive summary – Key findings and recommendations

• Compliance matrix – Against standards and regulations

• Photographic evidence – With annotations

• Risk-rated action list – High, medium, low priority

• Suggested timelines and responsible persons for corrective actions

The report should be clear enough that management can make decisions without needing to decode technical jargon.

Corrective Actions & Follow-Up

An audit’s value comes from acting on it:

• Immediate fixes for high-risk issues (e.g., damaged anchor points)

• Scheduled maintenance for medium-priority items

• Long-term improvements for systemic problems (e.g., redesigning access routes)

Follow up with:

• A verification inspection

• Updated training where necessary

• Revised SWMS or procedures

Training, Awareness & Emergency Planning

a) Training

Ensure:

• All personnel using height safety systems are trained in their safe use

• Training includes theory, practical demonstration, and assessment

• Refresher training is conducted (often annually)

b) Rescue Planning

Rescue plans must:

• Be site-specific

• Include before-the-fall and after-the-fall scenarios

• Assign trained rescuers and equipment

• Be rehearsed regularly

Review & Continuous Improvement

Audits are snapshots in time. Continuous improvement requires:

• Annual or biennial audits

• Reviewing incidents and near-misses

• Updating systems and procedures with technological advances

• Encouraging worker feedback

Conclusion

A height safety audit is not just a compliance exercise—it’s a life-saving intervention. When conducted thoroughly, it:

• Protects workers

• Satisfies legal obligations

• Reduces the risk of costly incidents

• Improves organisational reputation

The best audits combine technical accuracy with practical recommendations and follow-through. Done well, they are an investment in both safety and productivity.