Best Zipline Safety Checklists for DIY Harness Setups and Portable Rigging Systems

Ziplining offers an exhilarating rush, but the thrill only stays fun when the gear is rock‑solid. Whether you're rigging a backyard line for kids, a summer camp adventure, or a temporary course for an event, a thorough safety checklist is your first line of defense. Below are two focused checklists---one for DIY harness setups and another for portable rigging systems---to help you keep every ride secure.

Core Safety Principles (Applicable to Both Checklists)

✅ Principle	What to Verify
Load Rating	Every component (rope, carabiners, pulleys, anchor plates, harnesses) must be rated at minimum 10 kN (≈ 2 kips), ideally double the expected maximum load.
Redundancy	Critical load‑bearing elements (e.g., harness straps, anchor points) should have a backup or be double‑checked for redundancy.
Inspection Frequency	Perform a pre‑run visual check before each session and a deep inspection after every 10 hours of use or any incident.
Environmental Conditions	Suspend operation in high wind (> 15 mph), rain, ice, or extreme temperatures that could affect rope strength or hardware.
Training	All operators and riders must complete a short safety briefing and demonstrate proper harness donning, braking, and dismounting.
Emergency Plan	Have a clear rescue procedure, first‑aid kit, and communication device on site.

DIY Harness Setup Checklist

2.1 Harness Selection & Preparation

Fit Test -- Ensure the harness conforms to the rider's body size (adjustable waist and leg loops). No gaps or pinching.
Rating Verification -- Confirm a certified minimum 10 kN load rating; look for CE, UIAA, or ANSI markings.
Condition -- Check for frayed webbing, broken stitching, corrosion on buckles, or any signs of UV degradation.
Labeling -- Attach a label with the date of purchase, last inspection, and next scheduled inspection.

2‑3. Connection Points

Carabiners -- Use locking, screw‑gate carabiners rated ≥ 10 kN. Verify the gate closes fully and locks securely.
Webbing Loops -- If you create a custom harness loop, use high‑strength polyester or Dyneema webbing; double‑sew each stitch.
Backup Connection -- Add a secondary carabiner or a backup knot (e.g., a figure‑eight with a bight) for added redundancy.

2‑4. Braking System

Brake Block -- Choose a friction brake (e.g., a ¾'' PVC pipe or a commercial zipline brake block) sized for the line's diameter.
Attachment -- Secure the brake to the harness with a rated "quick‑release" shackle; test the release under load before each run.
Adjustment -- Verify that the brake can be fine‑tuned (tightened or loosened) without compromising the harness's position.

2‑5. Final Rider Check

Donning -- Rider must double‑check all straps, ensure the harness sits snugly at the hips, and that leg loops are evenly tensioned.
Lock Confirmation -- Perform a "pull test" on the lock---apply a moderate tug to confirm the carabiner gate won't open unintentionally.
Communication -- Establish a clear hand‑signal or verbal cue ("Ready", "Go", "Stop") before releasing the rider.

Portable Rigging System Checklist

3‑1. Anchor System

Anchor Type -- Use ground anchors (spuds, screws, or dead‑man bags) or tree‑based anchors with protective padding.
Load Path -- Ensure the anchor's load is transferred directly into the ground or a massive, healthy tree trunk (minimum 12‑inch diameter, no decay).
Redundant Anchors -- Deploy at least two independent anchors spaced ≥ 3 ft apart; each must be capable of handling the full load alone.

3‑2. Line (Rope/Cable) Inspection

Material -- Choose a static, low‑stretch steel cable (galvanized or stainless) or a high‑strength synthetic rope rated ≥ 10 kN.
Diameter -- For a typical backyard zipline (30‑45 ft), a ⅜‑inch steel cable or ⅜‑inch Dyneema rope suffices.
Surface Check -- Look for rust spots, kinks, broken strands, or frayed ends. Run a tension test with a calibrated load cell if possible.
End Fittings -- Install swaged sockets or cable clamps rated for the line's diameter; tighten to manufacturer torque specifications.

3‑3. Tensioning & Sag Control

Turnbuckle -- Use a high‑strength turnbuckle to set tension; lock the turnbuckle nut after achieving target tension.
Sag Measurement -- Aim for a sag of 2‑3 % of the span (e.g., 1 ft sag on a 40‑ft line) to balance speed and safety.
Check for Stretch -- After tensioning, re‑measure after 5‑10 minutes to account for any settling.

3‑4. Pulley & Brake Assembly

Pulley Rating -- Minimum 10 kN rating, sealed bearings to resist weather.
Mounting -- Secure the pulley to a sturdy post or a dedicated "brake tower" using a rated bearing block or clamp.
Brake Block Installation -- Verify that the brake engages smoothly and holds the rider at a safe speed (typically < 20 mph).

3‑5. Ground Clearance & Landing Zone

Clearance -- Ensure at least 8 ft of vertical clearance from line to ground; any obstacles (branches, protrusions) must be trimmed.
Landing Surface -- Place a soft landing area (e.g., impact‑absorbing mats or a sand pit) extending at least 5 ft beyond the expected stop point.
Side Barriers -- Install temporary barriers or padding on either side if the line passes near walls or fences.

3‑6. Post‑Run Procedures

Loosen Tension -- Release turnbuckle tension gradually to prevent a sudden snap‑back.
Store Gear -- Clean all hardware (wipe moisture, apply a light corrosion inhibitor) before storing in a dry container.
Logbook -- Record date, number of rides, weather conditions, and any maintenance performed. Use this log to schedule the next deep inspection.

Common Pitfalls & How to Avoid Them

❌ Pitfall	🔧 Remedy
Using mismatched ratings (e.g., a 5 kN carabiner with a 10 kN line)	Verify every component's rating; keep a master spreadsheet of part specifications.
Skipping the double‑check (only one person inspects)	Adopt a two‑person sign‑off: one performs the check, the second confirms it.
Over‑tightening turnbuckles -- causing excessive line stress	Use a tension gauge to hit the target sag rather than "tight as possible."
Relying on a single anchor	Always install at least two independent anchors; test each individually.
Neglecting rope rotation (the line twists under load)	Use a rotating swivel or a cable eye that allows free rotation at the anchor points.
Operating in rain or ice	Postpone the run; moisture reduces friction in the brake and can weaken rope strength.

Final Thoughts

Safety is non‑negotiable when you're building a zipline---especially one that relies on DIY harnesses and portable rigging. By treating every component as a critical link in a chain, rigorously following the checklists above, and fostering a culture of double‑checks, you can transform a potentially hazardous setup into a reliable recreational asset.

Remember: the best zipline is the one that never fails. Happy riding, and stay secure!