Safe Sling Operations: Proper Lifting Practices

Manual Lifting & Material Handling
English (NZ)

The Problem

Slings are essential for safe lifting operations, but they can become a major risk when misused. Selecting the wrong type of sling, skipping inspections, or handling them incorrectly can result in dropped loads, injuries, or fatalities. Today, we’ll go over how to select, inspect, and use slings correctly to prevent incidents and ensure safe lifting on-site.

Identify the Hazards

  • Load Failures: Overloading slings, using damaged equipment, or uneven loading can cause the load to drop.

  • Worker Injuries: Twisted, tangled, or damaged slings can snap under pressure.
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  • Environmental Risks: Wind, uneven ground, or nearby obstacles can destabilise the load during the lift.

Safety Practices and Preventative Measures

A. Sling Selection

Choose the right sling based on:

  • Load Weight and Size: Confirm that the sling’s rated capacity is suitable for the task.

  • Sling Type:

    • Single-leg slings: For single-point lifts.
    • Multi-leg slings: For distributing the weight across multiple points.
    • Adjustable slings: For loads of varying sizes.

  • Sling Material: Match sling type to the environment and the load (e.g., high heat, sharp edges).

B. Pre-Lift Assessment

  • Measure or estimate the load’s weight and size.
  • Assess site conditions: wind, ground slope, and obstacles.
  • Plan the lift route and discuss it with the lifting team.

C. Critical Sling Inspection Points

Inspect slings before every use for:

  • Cuts, frays, or wear (webbing slings).
  • Broken wires or rust (wire rope slings).
  • Missing or unreadable ID tags showing rating and specs.
  • Twists, knots, or signs of melting/burning.

Action: Remove any sling with visible damage from service and report it to your supervisor.

D. Safe Lifting Procedures

Positioning:

  • Balance the load evenly.
  • Avoid sharp bends, twists, or tangles.
  • Ensure all attachment points are secure.

Test Lift:

  • Raise the load slightly off the ground to check balance and stability.

Lifting the Load:

  • Lift slowly and under control.
  • Use tag lines to guide the load and keep clear of suspended loads.
  • Stay alert for sudden shifts or instability.

Lowering and Storage:

  • Lower slowly and avoid crushing slings.
  • Store slings properly to prevent wear and damage.

E. Essential Safety Rules

Never:

  • Exceed the sling’s rated working load limit (WLL).
  • Use slings that are frayed, cut, burnt, or chemically damaged.
  • Tie knots in slings.
  • Pull slings trapped under a load.
  • Rush the lift—always take your time.

Always:

  • Check the sling’s WLL and condition before use.
  • Use edge protection when lifting sharp-edged loads.
  • Follow the manufacturer’s instructions for safe use.
  • Ask a supervisor if you are unsure about any lift.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

At a building site last year, a synthetic sling with worn stitching was used to lift a 900 kg load. Halfway through the lift, the stitching gave way and the load fell, narrowly missing two workers. This could have been prevented with a proper inspection before the lift.

Employee Responsibilities

  • Inspect slings before every lift.

  • Tag and report damaged slings immediately.

  • Use correct rigging techniques and lifting procedures.
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  • Check the load weight and the sling’s WLL before starting.

Employer Responsibilities

  • Supply properly rated and maintained slings and lifting gear.

  • Train workers on sling selection, inspection, and safe lifting practices.

  • Remove defective slings from use and replace them promptly.
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  • Conduct ongoing training and competency checks.

Discussion & Questions

  • "What signs of damage should we look for during sling inspections?"
  • "How do you check that a sling is rated correctly for the load?"
  • "When is it necessary to use tag lines during a lift?"
  • "How do we protect slings when lifting sharp-edged loads?"

Encourage workers to share examples and suggestions.

Commitment/Action Plan

From today, let’s commit to inspecting every sling before use, checking WLLs, and lifting safely. If you have any doubts about a sling’s condition—don’t use it. Report it and get it replaced.

Wrap-Up

Safe lifting is about more than just moving a load—it’s about preventing accidents and protecting lives. Proper sling selection, inspection, and handling help make sure everyone goes home safely. Thanks for taking safety seriously.

Standards Overview

WorkSafe New Zealand requires lifting gear and slings to be used, inspected, and maintained in accordance with the Health and Safety at Work (General Risk and Workplace Management) Regulations 2016 and AS/NZS 4497 (for synthetic slings) or AS 1666 (for fibre and wire rope slings).

  • Slings must be inspected before each use.

  • Damaged or defective slings must be removed from service.

  • Lifts must not exceed the sling’s working load limit (WLL).
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  • Only trained persons may perform or supervise lifting operations.

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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Last Updated:
April 28, 2025