Harness Up, Power Up: Using Fall Harnesses with the SafeLift Exosuit

In physically demanding industries like warehousing, distribution, and logistics, protecting workers from injury is a top priority — especially those operating at height. Traditionally, fall harnesses have played a critical role in these environments, helping protect against fall-related injuries. 

Worn securely around the torso, shoulders, and legs, and connected via a D-ring to a lanyard or lifeline, these systems are designed to catch a worker mid-fall, distribute impact forces across their body, and keep them upright for safe rescue. When properly used, fall harnesses are a time-tested, reliable safeguard.

However, while fall harnesses protect workers during slips or falls, they do nothing to address the risk of strains and injuries caused by repetitive lifting or lowering motion. That’s where new technology like the SafeLift™ exosuit comes into play. Designed to offload up to 40% of strain from a user’s lower back during lifting and lowering movements, the exosuit can reduce the risk of lower back musculoskeletal injuries by up to 85%, as well as lessen overall strain and fatigue. 

So — what happens when you combine fall harnesses with exosuits?

You create a new standard of personal protective equipment: one that delivers comprehensive protection from both sudden falls and the chronic physical demands of manual labor. Fall harnesses and exosuits aren’t competing technologies — they’re complementary solutions that, when used together, elevate worker safety and performance to a whole new level.

After extensive research and testing, we have confirmed that the SafeLift exosuit is compatible with fall arrest harnesses from all major manufacturers, allowing it to empower your associates with the benefits of lift assistance, even at height.

How It Works: Layering for Safety and Support

When discussing exosuit deployment with customers, we often receive questions about combining fall protection with exosuit technology in order to take advantage of the best of both systems. The most common concerns are:

• Should the harness fit over or under the exosuit?
  
  
• Will the exosuit interfere with the tethering system, or with workers' mobility?
  
  
• Can a worker wear both all day without discomfort?

The SafeLift exosuit has a low-profile, form-fitting design that fits comfortably over most standard fall harnesses without compromising range of motion, meaning it can be worn easily while still allowing access to key anchor points. It does not interfere with the dorsal D-ring or chest strap, ensuring full compliance with fall arrest systems. When combining systems, workers should first don their fall harness normally, adjusting for a firm fit. Once they’re in their harness, they can then put on their SafeLift exosuit.

The SafeLift exosuit is made from lightweight, breathable materials, so it moves with the body — meaning workers can attach lanyards and perform high-mobility tasks without restriction, even while wearing a fall harness.

Layering the PPE like this ensures that neither system interferes with the other. Your team can benefit from SafeLift’s reduction in back strain without compromising fall arrest functionality or sacrificing comfort.

Verifying Compatibility

To ensure the SafeLift exosuit could be safely worn alongside fall arrest equipment, Verve Motion contracted with Intertek Group — the world’s largest testing laboratory for consumer goods — to evaluate the SafeLift exosuit's performance when used with standard fall protection systems.

Intertek conducted a comprehensive assessment that included:

• A risk analysis to identify any potential hazards introduced by wearing the exosuit with fall protection gear.
  
  
• A regulatory review of OSHA 1910.140 (Personal Fall Protection Systems) and ANSI/ASSE Z359.11-2014.
  
  
• Physical testing of the SafeLift exosuit in combination with two representative fall protection harnesses, following the ANSI/ASSP Z359.11-2021 standard.

Both of the harnesses tested — Safewaze FS185 and Honeywell Miller Titan II T4507/UAK — feature a central dorsal attachment point and sub-pelvic strap. Testing confirmed that the SafeLift exosuit does not reduce the effectiveness of these fall protection systems in any way.

NOTE:  While we can recommend specific fall harnesses, they and any other harness selection should be evaluated by the EHS team for appropriateness in your specific application and environment.

Additionally, the exosuit’s carry handle must be removed by Verve Motion before use with fall arrest systems. This prevents workers from accidentally attaching their arrest tether directly to the exosuit, which would compromise the functionality of the fall harness.

Choosing the Right Harness

To ensure optimal fit and comfort, we recommend selecting a fall protection harness with the following features:

• Low-profile anchor pad. Adjust the pad to the highest possible position.
  
  
• Minimal bulk. Avoid extra features, like positioning rings or padding, that aren’t essential for your workers’ needs.
  
  
• Lightweight, streamlined design. Helps ensure optimal exosuit fit for user comfort and proper adjustment.

These models have been found to minimize overlap and ensure easy integration with the SafeLift exosuit:

• 3M — Protecta P50
  
  
• Werner — LiteFit
  
  
• FallTech — Contractor
  
  
• Guardian — Series 1
  
  
• MSA — Workman
  

If your facility uses a different model of fall harness, please reach out to us with questions.

Empowering Your Workforce, Safely

Companies shouldn’t have to target one aspect of workers' safety at the expense of another. By pairing fall harnesses with the SafeLift exosuit, we’re expanding the envelope so workers gain:

• Protection against sudden falls.
  
  
• Assistance in lifting heavy or repetitive loads.
  
  
• Reduced musculoskeletal strain.
  
  
• Greater compliance with safety protocols.
  

Have questions about exosuits and PPE, or need guidance on harness selection? Our team is here to help ensure safe and effective deployment of SafeLift across every application, including elevated work.

SafeLift helps keep your teams protected on every level. Reach out to the Verve Motion team to learn more.