What the latest height safety standards mean for building owners, designers and workers at height
Falls from height remain one of the leading causes of serious injury and fatalities across Australian workplaces, particularly in construction, maintenance and building services. In response to ongoing risks and evolving building practices, two critical Australian Standards have been updated:
- AS 5532:2025 – Manufacturing requirements for single-point anchor devices used for harness-based work at height
- AS/NZS 1891.4:2025 – Personal equipment for working at height: Selection, use and maintenance
These updates represent the most significant changes to height safety standards in over a decade. They introduce clearer guidance, more realistic testing requirements and improved accountability across the design, manufacture, installation and ongoing maintenance of fall protection systems.
If you are a building owner, facility manager, designer, installer or anyone working at height, these changes directly affect how height safety systems are specified, installed and managed.
AS 5532:2025 – Manufacturing requirements for single-point anchors
AS 5532 governs how single-point anchors used for fall arrest are designed, tested and certified. The 2025 revision strengthens the standard by aligning testing more closely with real-world installation conditions and modern roof structures.
Key changes under AS 5532:2025
Mandatory substrate-specific testing
Single-point anchors must now be tested on the actual substrate they are intended to be installed into, such as metal roof sheeting or concrete. This replaces reliance on laboratory-only testing and ensures anchors perform as expected once installed on site.
Expanded support for modern roof structures
The updated standard addresses limitations in earlier versions by supporting installation on a wider range of timber and steel purlin roof types. This improves access to compliant anchor solutions for trades such as solar installers, roof maintenance crews and façade contractors.
Dynamic and static load testing requirements
Anchors must meet both dynamic and static performance criteria:
- Dynamic load testing to 15kN, conducted both inline and across the roof sheeting
- Static load testing to 15kN in both directions
- Where an anchor is rated for two users, two separate dynamic drop tests must now be performed on the same anchor
Energy-absorbing anchor testing clarified
Energy-absorbing anchors now have specific testing requirements. These tests account for the reduced load transferred into the structure due to the energy absorption mechanism, allowing testing on lighter gauge roof materials while still maintaining safety outcomes.
Improved traceability and certification
Anchors must be batch tested and fully traceable, with documentation available to verify compliance. This improves accountability across manufacturing, installation and ongoing inspection processes.
AS/NZS 1891.4:2025 – Selection, use and maintenance of fall arrest systems
AS/NZS 1891.4 focuses on how fall protection systems are selected, installed, used and maintained throughout their service life. The 2025 update provides clearer structure and guidance to ensure systems are both compliant and practical in real-world environments.
Key changes under AS/NZS 1891.4:2025
Clearer distinction between system types
The standard now more clearly defines the differences between fall arrest systems, restraint systems and rope access systems. This helps designers, employers and workers select the most appropriate system for each task and risk profile.
Working on inclined or slippery surfaces
Where a worker relies on the height safety system to maintain footing on steep or slippery surfaces, the system must now incorporate:
- A secondary, independent connection, or
- A passive fall protection system, such as a guardrail
This change addresses the increased risk of slips where footing cannot be maintained without assistance from the system.
Updated inspection and recertification requirements
- Permanently installed fall arrest devices must undergo compliance inspections annually
- PPE and removable equipment must be inspected every six months
For anchors with multiple fasteners, ongoing annual pull testing is no longer required, provided specific documentation is available. These anchors must still be proof tested at the time of installation.
Single-fix anchors unchanged
Anchors that rely on a single fixing must continue to be pull tested every 12 months.
Pull testing duration and rating updated
- Pull tests are now conducted for 30 seconds, rather than three minutes
- Minimum test load increased to 7.5kN, up from 6kN
Training and competency emphasis
The standard reinforces the requirement for formal training and competency verification for anyone installing or using fall protection systems.
System design and documentation requirements
Designers must provide comprehensive documentation as part of the project handover, including:
- System layouts
- Anchor specifications and load ratings
- Installation details
- Ongoing inspection and maintenance requirements
What these changes mean for existing buildings
The introduction of the 2025 standards does not mean that previously compliant systems are suddenly unsafe. As with all standards updates, a transition period applies.
In some cases, systems designed under earlier versions of the standards may not fully align with the updated requirements. During the transition period, these differences may be noted as recommended upgrades rather than immediate non-compliances. Over time, and once the transition period concludes, upgrades may be required to maintain full compliance.
Practical actions to take
For installers and contractors
- Confirm that anchors and fall arrest devices are manufactured and tested in accordance with AS 5532:2025
- Ensure installation teams are formally trained and competent under the updated standards
- Understand proof testing requirements at the time of installation
For designers, project managers and building owners
- Specify compliant anchor systems supported by certification and traceable testing documentation
- Engage installers who are knowledgeable and experienced with the 2025 standards
- Ensure height safety systems are fully documented, including layouts, load ratings and maintenance plans
- Understand ongoing inspection and maintenance obligations under AS/NZS 1891.4:2025
Supporting safer work at height
The 2025 updates to AS 5532 and AS/NZS 1891.4 are designed to improve safety outcomes by aligning height safety systems with modern building practices and real-world conditions. By improving clarity, accountability and consistency across the industry, these standards help ensure that people working at height are better protected, now and into the future.
If you would like advice on how these changes affect your building, project or existing height safety system, the Anchor Safe team is here to help. Our specialists can assist with system design, compliance assessments, upgrades and ongoing maintenance in line with the latest Australian Standards.
Contact us today to discuss how we can help keep your teams protected at height.