When working at height, preventing dropped objects is a critical part of keeping people safe. A falling tool can cause serious injury, damage equipment, and disrupt operations.
Tool tethers play an important role in dropped object prevention by helping to secure tools while they are being used at height. However, for a tool tether to perform effectively, it must be thoroughly tested to ensure it can withstand the forces it may experience during normal use and in the event of a dropped tool.
This is where Safe Working Load (SWL) testing becomes essential.
The Safe Working Load (SWL) refers to the maximum load a tool tether is designed to support during normal use, in accordance with the manufacturer’s guidance.
Understanding the load rating of a tool tether is important because using equipment beyond its intended capacity can increase the risk of failure and compromise safety.
When selecting a tool tether, always ensure that:
A tool lanyard may appear strong enough to support a tool when it is hanging stationary. However, the forces generated when a tool is dropped can be significantly greater than the tool’s actual weight.
Testing helps manufacturers understand how their products perform under controlled conditions and provides confidence that the equipment is suitable for its intended purpose.
Effective testing helps to:
For organisations implementing a dropped object prevention programme, selecting tested and appropriately rated equipment is an important part of risk management.
To understand how tool lanyards are tested, it is useful to understand the difference between static and dynamic loads.
A static load is a force that is applied gradually and remains constant.
For example, a spanner hanging from a tool lanyard creates a static load. Static testing measures how a product performs under a steady force and helps assess its strength and load-bearing capability.
A dynamic load occurs when a force is applied suddenly, such as when a tool is dropped and the lanyard arrests the fall.
These forces can be significantly greater than the tool’s actual weight. Dynamic testing helps simulate real-world dropped tool incidents and assesses how a lanyard performs under sudden loading and shock forces.
At Leading Edge Safety, every structurally rated tool lanyard, tether, belt, tool bag and holster undergo rigorous dynamic and static testing to assess performance under real-world working-at-height conditions.
To simulate a dropped tool incident, we attach the product to a solid 10kg test mass and subject it to a 4-metre free fall (Fall Factor 2).
The test is designed to replicate the shock loads generated when a dropped tool is suddenly arrested by a tethering system. No shock absorber is used during testing, ensuring the full impact force is transferred through the product.
For heavy-duty products rated up to 50kg, the test mass is increased to 100kg and the same 4-metre drop test is repeated.
As part of our quality checks, selected product samples are tested three times using the same item to ensure durability and reliable performance. To pass, the product must remain fully functional and show no signs of damage or structural weakness.
Our static testing programme consists of two stages.
First, a load of 0.55kN (approximately 55kg) is applied and held for three minutes. The product must support the load without releasing or failing. For heavy-duty products rated to 50kg, the load is increased to 5.5kN (550kg).
The product then undergoes a destructive pull test to verify that it exceeds its stated Safe Working Load and meets our performance requirements.
All certified Leading Edge Safety height safety products are designed with a 47:1 safety factor.
We deliberately over-engineer our products to exceed the demands of real-world working environments, helping to improve durability, determine safe working life and deliver dependable performance when it matters most.
Correct connector loading is critical to the performance of any tool tethering system.
Karabiners achieve their maximum strength when loaded along their major axis. Loading a karabiner across its width can significantly reduce its strength and affect overall system performance.
It is vital to load the karabiner along its length, never across its width.
Preventing falling objects is an important part of safe working at height.
The Work at Height Regulations 2005 require employers to take appropriate steps to prevent materials, equipment and objects from falling where they could cause injury.
When planning work at height, organisations should consider:
Depending on the task, control measures may include:
The most appropriate solution will depend on the findings of the risk assessment and the nature of the work being carried out.
Selecting the correct tool tether is just as important as choosing a tested product.
Factors to consider include:
Always ensure the tool weight falls within the manufacturer’s recommended load rating.
Frequently used tools may benefit from lightweight tethering solutions that minimise fatigue and improve usability.
Environmental factors such as moisture, UV exposure, chemicals, heat and abrasive surfaces can affect the lifespan of tethering equipment.
Choosing a product suitable for the environment can help maximise performance and longevity.
The method used to secure the tool should be appropriate for both the tool and the task being carried out.
A properly secured connection helps reduce the risk of dropped objects and improves user confidence.
Regular inspection is an important part of any tool tethering programme.
Before each use, users should visually inspect their equipment for signs of damage or excessive wear.
Remember to check for:
Any equipment showing signs of damage should be removed from service and disposed of sustainably
Learn more about PPE Inspection.
Understanding how damage occurs can help extend the service life of tethering equipment.
Common causes include:
Using a lanyard outside its intended load range can place unnecessary strain on components.
Long-term exposure to harsh environments can affect materials and reduce product lifespan.
Repeated contact with sharp edges may cause cuts, abrasions or wear.
Improper storage can expose equipment to unnecessary damage between uses.
Small defects can develop gradually. Regular inspections help identify issues before they become more serious.
Testing helps manufacturers assess the performance, durability and strength of tool tether under controlled conditions.
Static testing measures performance under a steady load, while dynamic testing evaluates performance under sudden loading conditions such as a dropped tool event.
No. Tool tethers should only be used in accordance with the manufacturer’s guidance and recommended load ratings.
A visual inspection should be carried out before use, with additional inspections completed in accordance with company procedures and manufacturer recommendations.
Dropped objects can cause serious injuries, equipment damage and operational disruption. Effective prevention measures help reduce these risks and support safer working practices.
Tool tethering is one part of a wider dropped object prevention strategy.
A successful programme includes:
When combined, these measures can help reduce risk and create a safer working environment for everyone on site.
Having the right equipment is only part of an effective dropped object prevention strategy.
Training helps workers understand:
Our Tool Tethering Training Courses are designed to support safer working practices and help organisations strengthen their dropped object prevention programmes.
Leading Edge is a UK based height safety training provider and PPE manufacturer. From small teams to multinational blue-chips, we empower people to work safely at height across a wide range of industries. Copyright 2026 Leading Edge Safety. All Rights Reserved.
