What to check when specifying shock cords for PPE or harness systems

We are proud to be the UK’s go-to supplier of shock cords for a wide range industries here at Ibex Ropes Marina, with well over a century of supplying them to customers all over Britain, for countless applications. So, if you are ever specifying shock cords for PPE or harness systems, you may already know that there are very strict requirements for these cords to meet. You will need to look closely at the materials, the compliance requirements, the way the cords can be adapted to the end use, and the ongoing checks that keep them safe and reliable. Each of these areas directly affects how the cords perform when put under strain, and how well they protect the wearer in critical applications.

Material performance and durability

To begin with, you will need to evaluate the base materials of the shock cord before anything else, as this dictates how well it will handle repeated loading, abrasion, and exposure to the elements. The core is usually made of natural or synthetic rubber (we only supply natural rubber here at Ibex Ropes Marina), and you will need to check the tensile strength, elongation properties, and recovery rate. The outer sheath, often polyester or polypropylene, provides protection to the core, so you will need to ensure it has high abrasion resistance, UV stability, and resistance to moisture. If your equipment will be used outdoors, this becomes even more important to preserve the life of the cord.

You will also need to consider how the cord responds to long-term stress and fatigue. If your harness systems are used on a daily basis, the cords must retain their elasticity after thousands of cycles of stretching. Some cords are treated with coatings to enhance resistance against oils, chemicals, or saltwater. This may be essential if your industry involves offshore work, chemical handling, or other environments that are frequently exposed to corrosive substances.

Safety standards and compliance

When specifying shock cords for PPE or harness systems, you will need to check that they meet the relevant safety standards. In the UK and Europe, cords used in fall arrest and restraint systems must conform to standards such as EN 354 for lanyards or EN 566 for slings, depending on the application. Therefore, it is strongly advisable to review test certificates from the manufacturer to confirm compliance. These tests typically cover tensile strength, elongation, and breaking load, all of which are critical to the safety of the end user. Without this official certification, you cannot have peace of mind that the cords will perform appropriately under load – when lives are at stake.

At this stage, it is also a good idea to think about traceability and quality assurance. Reputable manufacturers provide batch numbers and documentation so that you can track exactly which production run your cords came from. This allows you to verify that they have been produced under controlled conditions and audited processes. In high-risk environments, this documentation can demonstrate that your cords are compliant and backed by a reliable quality management system.

Customisation for fit and function

Different harness systems have different design requirements, and you will need to consider how your shock cords can be tailored to meet those needs. Length and diameter are the most obvious factors, as they determine how the cord integrates with the rest of the system. It is important to make sure that the cord provides the right amount of stretch without compromising support. In some cases, cords may be pre-terminated with hooks, loops, or other fittings, which can make it even easier to integrate. This is one of the reasons why it is so vital to specify the right configuration at the outset – it can save time and prevent errors during assembly.

Colour coding and labelling may also be valuable for your application. If your team uses multiple types of cords for different tasks, coloured sheaths or printed markers can help to quickly identify the right cord.

Inspection and maintenance requirements

Once your shock cords are in service, you will need to ensure that there are clear inspection and maintenance routines, and that these are rigorously followed. Visual inspections should be carried out before every use, with your team checking for fraying, cuts, or loss of elasticity. If the sheath is damaged at any stage, it is possible that the core may degrade rapidly, so your staff need to be highly proactive in immediately removing any compromised cords from service.

You will also need to establish replacement intervals based on the level of use and the environment, as even the most durable cords can degrade over time – depending on the circumstances of their use. The way your team stores cords has a big impact as well. Keeping them away from direct sunlight, chemicals, and sharp edges reduces premature wear. In short, taking a proactive approach to maintenance extends the life of your cords, reduces costs for your business, and keeps your workforce safe.

These are all the essential points covered – and if you ever need any help or more specific advice on shock cords and their applications in harnesses and safety equipment, that is exactly where we can help here at Ibex Marina Ropes. We have unrivalled experience with shock cords, and serve a wide range of sectors across the UK and beyond, including aerospace, military and defence, subsea and offshore, and sport and leisure – just to name a few.

To speak to one of our team for help and advice, or to make an enquiry, call us today on +44 (0)1706 360 363. We are here to help!