Alloy Steel Chain Sling Inspection and Safety
The Problem
Alloy steel chain slings are essential tools used for lifting and moving heavy loads on New Zealand worksites. However, if damaged or improperly inspected, they can fail—causing dropped loads, serious injuries, or fatalities. The good news? Most of these failures are preventable. Today, we’ll cover how to properly inspect chain slings, identify hazards, and take appropriate action to ensure everyone's safety.
Identify the Hazards
- Dropped Loads – Sling failure under stress due to cracks, stretching, or corrosion.
- Structural Damage – Twisted or bent links, weakened hooks, or heat damage.
- Improvised Repairs – Use of incorrect bolts or missing identification tags.
- Environmental Effects – Exposure to heat, rust, or overloading reduces sling strength.
Safety Practices and Preventative Measures
Visual Inspection for Damage
- Look for cracks, nicks, gouges, or deformities along the chain assembly.
- Pay special attention to master and coupling links.
Rust and Corrosion
- Identify any visible corrosion which weakens the sling.
- Action: Remove from service and have it assessed before reuse.
Twisted or Bent Links
- Spot even slight twists or bends.
- Action: Do not use—tag and report for removal.
Heat or Flame Damage
- Look for discolouration, melting, or any signs of heat exposure.
- Action: Remove immediately from service.
Elongation or Stretching
- Elongation is a sign of previous overloading or internal fatigue.
- Action: Remove the sling from service immediately.
Hooks and Rings
- Check for stretching, twisting, or deformities.
- Replace immediately if damaged.
Improvised Repairs
- Look for repairs using non-manufacturer approved methods (e.g., bolts or shackles).
- Action: Tag out and remove from service.
Sling Identification Tag
- Ensure the tag is legible and includes serial number, rated capacity, and length.
- Action: Do not use if tag is missing or unreadable.
Follow Manufacturer Guidelines
- Always inspect and maintain chain slings according to the manufacturer’s instructions.
Remove Damaged Slings from Service
- Tag and isolate any damaged slings.
- Inform your supervisor and follow your organisation's removal/replacement procedures.
Real-Life Case or Scenario
On a construction site in Auckland, a chain sling with a visibly twisted link was used to lift a heavy steel beam. The sling failed mid-lift, dropping the load. Luckily, no one was injured, but the incident caused costly delays. This could have been prevented with a basic pre-use inspection.
Employee Responsibilities
- Inspect alloy steel chain slings before every use.
- Report damaged slings immediately.
- Never use slings with missing tags, makeshift repairs, or visible damage.
Employer Responsibilities
- Provide training on safe inspection and handling of chain slings.
- Ensure only qualified repairs are completed.
- Replace and tag out defective equipment immediately.
Discussion & Questions
- “What types of chain damage have you seen during inspections?”
- “What’s your process when you find a damaged sling on-site?”
Encourage workers to share past experiences and near misses.
Commitment/Action Plan
Let’s commit to inspecting each alloy steel chain sling before every use. If you find damage, tag it, report it, and do not use it. A quick inspection could prevent a serious incident.
Wrap-Up
Safe sling use is everyone’s responsibility. Inspections, maintenance, and proper use ensure loads are lifted safely and workers stay protected. Thank you for staying vigilant and committed to safety.
Standards Overview
Under the Health and Safety at Work (General Risk and Workplace Management) Regulations 2016:
- Lifting equipment must be inspected regularly and kept in safe working condition.
- All damaged or defective slings must be removed from service immediately.
- Employers and workers must ensure lifting gear is suitable for the task and safe to use.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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