1. Indoor Cranes— The Case of the Broken Sling
P O W E R P O I N T ® T R A I N I N G
Change notes pg #1. Handout document is not customizable word doc.
Target Audience: This session relates to crane safety. It is primarily intended for those who operate or may work with indoor cranes on a regular basis.
Learning Objectives: This training session deals with crane safety. It can be used in conjunction with a complete training session on crane safety, or it can be used as refresher training.
Background for the Trainer:
This training session presents a case study of an actual accident inspected and documented by the Occupational Safety and Health Administration (OSHA). The case presented in this training session is:
Accident:
Report ID:
Inspection:
You may choose to present this training information in a lecture format or make the training presentation interactive by engaging your class in discussions that will help them identify facts of the case, potential causes of the accident, and future accident prevention measures. In either case, students will benefit by learning from a real-life scenario.
Before beginning your training session, print and make copies of the one-page Case Study Student Handout, which is provided on the disc. The Case Study Student Handout can be used as a worksheet during the training session or as a take-away reminder once the training session is complete.
Also, print and make copies of the Case Study Quiz, which is provided on the disc as a fully customizable Word document. The students can take the quiz at the end of the training session in order to help reinforce the information presented. Note that the same quiz is included at the end of this PowerPoint presentation as actual slides to review in class.
Consider taking pictures of cranes and slings used in your workplace. You can add these pictures to the presentation by inserting them into existing slides or creating new slides.
Make sure the trainees understand the message as you go along. Ask questions periodically to test their understanding.
Speaker’s Notes:
Welcome everyone. Today we will conduct a case study of an actual accident investigated by the Occupational Safety and Health Administration (OSHA). This is an actual tragic workplace accident that had real-life implications for the worker, the worker’s family, co-workers, and the employer. The Case Study may be disturbing and may even involve a fatality.
The purpose of this training session is to teach and reinforce the importance of crane and sling safety in our workplace in order to prevent tragic accidents. In particular, it deals with how to select, inspect, and care for slings. The intention is to learn from the accident and take steps to prevent a similar accident from changing our lives.
Indoor Cranes—
The Case of the Broken Sling

2. Let’s Talk About Cranes
Operators must be trained
Observe and adhere to recommended capacity
Conduct daily inspections
Hooks must have safety latch or clip
Follow safe hoisting practices
Develop and use hand signals
Background for the Trainer:
Bring a copy of your company’s crane operating procedures.
Speaker’s Notes:
Because of the potential hazards associated with their use, only trained and authorized employees are permitted to operate cranes.
Never load a crane beyond its rated capacity. The capacity must be clearly marked on each side of the crane. The markings must be legible from the ground.
Inspect cranes daily to make sure operating mechanisms are working properly. Check the hoist chains/ropes for signs of wear, twisting, or other distortion. Cranes must undergo a thorough inspection at least annually.
Hooks must have a safety latch or clip, which prevents the sling from falling out of the hook if it becomes twisted or goes slack. If the safety latch is missing or broken, do not use the crane until the latch is replaced or repaired.
Follow safe practices when hoisting. Do not suddenly accelerate or decelerate. Make sure the load does not contact any obstructions. Never leave the crane controls when the load is suspended. Keep all workers away when lifting.
Develop a system of hand signals for use in your workplace. Use a spotter to help guide loads when necessary. Use guide ropes when needed to help place loads in tight areas.

3. Take a Look at the Facts Employee using a small crane
Lifting 1,200-pound pipe
Nylon strap rated at 2,585 pounds
Nylon strap in good condition
Background for the Trainer:
Training Option: Pass out the Case Study Student Handout. You may have the students read the accident description to themselves before discussing it in the class, or you may use the bullet points on the slide and the speaker’s notes below to describe the accident.
Speaker’s Notes:
The employee is using a small crane in this case.
He is lifting a 1,200-pound pipe from a table to a storage rack.
He is using a nylon lifting strap that is rated at 2,585 pounds.
According to the employee, the nylon strap is in good condition.

4. Take a Look at the Facts (cont.)
The strap breaks
Pipe falls on employee’s feet
Both feet are fractured
Speaker’s Notes:
The nylon strap breaks.
The pipe falls on the worker’s feet.
Both feet suffer fractures.
© Business & Legal Reports, Inc. 0908

5. What Do You Think Went Wrong?
What do you think caused the strap to break?
What can make a sling susceptible to breaking?
What type of hitch do you think was used?
Did the employee inspect the strap before using it?
When lifting, how far away from the load should you be?
Background for the Trainer:
Use the questions on this slide to elicit discussion.
Training options: After reviewing this slide and the accident description, give the class 5 to 10 minutes to discuss the accident description in small groups, or ask the students to try to determine some of the facts, potential causes, and possible prevention measures. In either case, use the Case Study Student Handout as a way to encourage discussion as you go through this presentation.
Speaker’s Notes:
Let’s take a few minutes and, using the Case Study Student Handout, work in groups to try to determine the facts of the accident, potential causes of the accident, and possible prevention measures. Then we will review the Case Study together in class.
Consider some of the questions on this slide when discussing the Case Study in your groups.

6. Let’s Review the Causes
Sharp edges nearby
Sling not properly stored or cared for
Sling not inspected before use
Crane operator standing too close to the load
Background for the Trainer:
Try to get the trainees to put themselves in the place of the person in the Case Study. What would they have done in this case? Point out how a near miss can turn into a catastrophe in the presence of emergencies. In this case, the worker probably did not inspect the sling very well before using it, and he was standing too close to the load when lifting it.
Speaker’s Notes:
Although the inspection report does not specifically say why the sling broke, a few possible causes seem likely:
Sharp edges can damage slings and cause them to fail. Although the pipe being lifted did not have sharp edges, the operator may have bumped into or slid against a sharp edge that cut the sling. Sharp edges can be found on tables, racks, machinery, and equipment.
The sling may have been damaged because it was not stored or cared for properly. For example, if the sling was stored on the ground, it could have been damaged by water, run over by forklifts, and even crushed when other loads were placed on top of it. In addition, the strap could have been used in an overcapacity lift at some point, which will stretch the sling and make it more likely to break.
Although the operator states that the nylon strap was in good condition, apparently it was not because it broke despite carrying a load that was well under the sling’s capacity. Slings must be inspected by a qualified crane operator each day before they are used.
The employee was standing too close to the load while it was being lifted. Crane operators must always be aware of the potential for a falling load, a load moving in an unexpected direction, and even a sling breaking. Crane operators must keep themselves and other employees at a safe distance from the load.
Can you think of any other causes that may have contributed to this accident?

7. Sling Inspections Daily visual inspections Annual thorough inspections
Chains – examine links, welds, cracks, length
Wire rope – look for broken strands, kinks, bird caging, corrosion
Background for the Trainer:
Bring any written procedures your company has for crane and sling operations – specifically for sling inspections.
Show pictures of slings being inspected in your workplace.
Bring examples of slings used in your workplace to demonstrate an inspection.
Bring examples of the inspection logs used in your workplace.
Speaker’s Notes:
Slings must undergo a visual inspection each day, before use, by a trained and authorized crane operator. Any slings with obvious damage must be removed from service immediately.
A thorough sling inspection must be conducted at least annually. This inspection must be documented. During the thorough inspection, every inch and every link of the sling will be inspected.
Inspect chain slings for signs of link wear, defective welds, deformed links, increased link length, and overall chain length.
Inspect wire rope slings for broken strands, kinks, signs of crushing, unusual wear, cuts, bird caging, or signs of corrosion.

8. Sling Inspections (cont.)
Metal mesh – look for broken welds, wire damage, distortion
Fiber rope – look for wear, rotting
Synthetic web – look for burns, snags, punctures, tears
Speaker’s Notes:
Inspect metal mesh slings for broken welds, wire damage, signs of corrosion or distortion, such as one side of the mesh being longer than the other side.
Inspect fiber rope slings for signs of wear, broken fibers, rotting, or distortion, such as increased overall length.
Inspect synthetic web slings for signs of heat or chemical burns, snags in the webbing, punctures, tears or cuts, and broken stitches.
© Business & Legal Reports, Inc. 0908

9. Keys to Sling Safety Never: Load slings beyond capacity
Shorten slings with knots, bolts, etc.
Use damaged or defective slings
Always:
Securely attach slings to the load
Store slings properly
Look for the label
Protect slings from sharp edges
Background for the Trainer:
Bring any written procedures your company has for crane and sling operations—specifically the safe use and storage of slings.
Show pictures of slings used and stored properly in your workplace.
Speaker’s Notes:
Never load slings beyond their rated capacity. Remember that slings at an angle are subjected to an increased load because of horizontal and vertical forces. For example, if you were to lift a 1,000 pound load with two slings that are both hanging vertically, then each would be subjected to 500 pounds of load. If you were to lift that same load and the slings were at an angle of 45 from vertical, each sling would be subjected to 707 pounds of load (500 pounds of vertical load and 207 pounds of horizontal stress).
Never shorten a sling by tying a knot, inserting a bolt, etc. When lifting a load in this condition, additional stress is put on the knotted area or the chain links that contain the bolt. This extra stress could result in failure of the sling during a lift.
Never use damaged or defective slings. Tag them “out of service” and have them repaired or destroyed and replaced.
Make sure the sling is securely attached to the load as well as to the crane’s hoist hook. Hooks on both the crane and the slings must have spring-loaded safety clips that are working properly. If using a basket or choker hitch, make sure the load is balanced before lifting so the load does not slip out of the hitch.
Store slings properly to protect them from damage. Put them away by hanging them up on a wall or designated storage area. Do not leave slings on the ground where they can be run over by forklifts or where other loads might be set on top of them. Do not allow slings to be exposed to water, welding sparks, chemicals, or other materials that could damage them.
Slings must always be labeled with their rated capacity and length as well as some type of identification number so the sling can be referenced in inspection records.
Protect all slings, including chains, cable, rope, or mesh, from sharp edges on the load being lifted as well as sharp edges on nearby objects that could be struck against during the lift.

10. Don’t Let it Happen to You
Inspect slings before each use
Protect slings from sharp corners
Use slings with adequate capacity
Keep slings in good condition
Never use a damaged sling
Stay clear of the load
Speaker’s Notes:
Let’s take a look at what we can do to prevent a similar incident from happening at our facility.
Visually inspect slings before each use.
Protect slings from sharp corners on nearby equipment or machines as well as sharp corners on objects being lifted.
Make sure the sling you use has adequate capacity for the load. Also consider the horizontal stress being placed on the load when the sling is at an angle.
Keep slings in good condition by storing them off the floor and protecting them from water, chemicals, welding sparks, etc.
Never use a damaged sling. Send it out for repair or destroy the sling and then discard it.
Keep yourself and other nearby employees well away from the load when it is being lifted. Never stand under a load.
Are there any questions?
Thanks for your attention.

11. Quiz 1. When inspecting a chain sling, name two things to look at.
2. What must be on a sling’s label?
3. Why is an angled sling subjected to more load than a vertical sling?
4. What should you do if you discover that a sling is damaged?
Background for the Trainer:
Remind employees that the quiz is to encourage further discussion and to help you, the trainer, be sure that everyone understands what was discussed.
Print copies of the quiz for participants to take on their own, or go over the questions as part of the training session.

12. Quiz (cont.)
5. Name two things that can damage slings when they are stored improperly.
6. When inspecting a synthetic web sling, name two things to look for.
7. How can you avoid being struck by a falling load?
8. Who is permitted to operate cranes?
© Business & Legal Reports, Inc. 0908

13. Quiz Answers
1. Q. When inspecting a chain sling, name two things to look at.
A. Links, welds, cracks, length
2. Q. What must be on a sling’s label?
A. Capacity, identification number
3. Q. Why is an angled sling subjected to more load than a vertical sling?
A. Horizontal forces put additional stress or load on the sling

14. Quiz Answers (cont.)
4. Q. What should you do if you discover that a sling is damaged?
A. Tag the sling “out of service”
5. Q. Name two things that can damage slings when they are stored improperly.
A. Water, solvents, corrosives, welding sparks, run over by forklift, crushed by another load
© Business & Legal Reports, Inc. 0908

15. Quiz Answers (cont.)
6. Q. When inspecting a synthetic web sling, name two things to look for.
A. Burns, snags, punctures, tears
7. Q. How can you avoid being struck by a falling load?
A. Stay well away from the load when lifting
8. Q. Who is permitted to operate cranes?
A. Only trained operators
© Business & Legal Reports, Inc. 0908