Wire Rope Sling Inspection and Maintenance
The Problem
Wire rope slings are essential for lifting and moving heavy loads on site, but they can also become serious points of failure if not properly inspected and maintained. A damaged or faulty sling can snap, resulting in dropped loads, equipment damage, serious injury, or even fatalities. Today, we’ll talk about the key hazards related to wire rope slings and go over how to inspect them to help prevent incidents.
Identify the Hazards
- Cuts, Kinks, and Crushing: These weaken the rope’s internal structure and reduce lifting capacity.
- Corrosion and Rust: Can degrade the rope internally and externally, weakening the wire over time.
- Frayed or Broken Strands: Individual broken wires reduce overall strength and increase risk of failure.
- Heat Damage: Signs like discolouration or melting indicate high heat exposure that can compromise safety.
- Exposed Inner Core: A visible core is a major indicator that the sling is unsafe for use.
- Loose Fittings: Damaged or unsecured end fittings may fail under load.
Safety Practices and Preventative Measures
Visual Inspection for Damage
- Look for cuts, kinks, crushing, knots, or bird-caging.
- Any visible deformities or misshapen areas are red flags.
Rust and Corrosion
- Inspect for rust or pitting. Corroded slings may need to be removed from service immediately.
Fittings and End Terminations
- Make sure all fittings are tight, undamaged, and not bent or cracked.
Frayed or Broken Strands
- Run a clean cloth along the rope — snags may indicate fraying.
- If you find broken strands, report them to a Competent Person immediately.
Elongation or Stretching
- Watch for any abnormal stretching, which may mean the sling has been overloaded.
Exposed Inner Core
- A visible core is a definite sign the sling should be taken out of service.
Heat or Flame Damage
- Signs include discolouration, melted wires, or other signs of thermal exposure.
Check the Identification Tag
- Ensure the sling has a readable tag showing working load limits and serial numbers.
- Slings must never be used without a legible tag.
Follow Manufacturer’s Guidelines
- Always refer to the manufacturer’s guidance for maintenance, use, and inspections.
Remove Damaged Slings from Service
- If a sling is unsafe:
- Tag it clearly or isolate it so it’s not used.
- Notify your supervisor for replacement or assessment.
Real-Life Case or Scenario
On a recent job, a team used a wire rope sling that had a visible kink. They assumed it wasn’t serious. When the load was lifted, the rope gave way, and the load dropped. Luckily, no one was injured, but it damaged equipment and caused costly delays. This could have been avoided through proper inspection and removal of damaged gear.
Employee Responsibilities
- Inspect wire rope slings before each use.
- Tag and report any damaged or questionable slings.
- Never use a sling if you’re unsure about its condition.
Employer Responsibilities
- Provide training on correct inspection and use of wire rope slings.
- Ensure all lifting gear is compliant with AS/NZS 1666 standards.
- Arrange for regular inspection and replacement of slings as needed.
Discussion & Questions
- “What are some signs of damage you’ve come across during a sling inspection?”
- “Have you ever found a sling in poor condition before use? What did you do?”
Encourage team members to share examples or tips they’ve learned from past jobs.
Commitment/Action Plan
Let’s commit to inspecting all wire rope slings thoroughly before every use. If in doubt, stop and check — it’s better to delay the lift than to risk someone’s life or safety.
Wrap-Up
Wire rope sling failures are avoidable. Taking the time to inspect and maintain them is a small action that makes a huge difference in safety. Thanks for taking this seriously and keeping our site safe.
Standards Overview
WorkSafe New Zealand requires that lifting equipment, including wire rope slings:
- Is inspected regularly before use.
- Is maintained according to the manufacturer’s instructions.
- Is removed from service immediately if defective or damaged.
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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