SLING OUT OF HARM'S WAY

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SLING OUT OF HARM'S WAY
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RECOIL ACCIDENTS

• Two fatal recoil accidents in the past few years.
• Many fatal accidents and non-fatal injuries in
  the past few years as a result of recoil,
  rigging, and come-a-long accidents.
• Significant number associated with longwalls.

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MAINTENANCE

• The process of scheduling and performing
  preventative maintenance activities on wire ropes
  and chains should be reviewed-especially in
  preparation for a longwall move!

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F-bar with Guards
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Removing Shield from Face
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COAL MINE FATALITY January 3, 2004 A 44-year
old longwall shearer operator with 26 years of
mining experience was fatally injured while
attempting to advance a longwall shield. The
longwall face was being mined through a setup
room containing cementatious "cutable" cribs.
These cribs failed, causing many of the shields
to fully collapse. To advance the longwall,
chains were attached from the collapsed shields
to the panline. Using two adjacent shields to
push the panline, the collapsed shield was pulled
forward with the attached chains and the shield's
double-acting ram. Miners were positioned on each
of the three affected shields to manually operate
them. During this process, the chain hook broke.
The remaining part of the hook and the chain
assembly recoiled, striking the miner operating
the collapsed shield in the head.
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• BEST PRACTICES
• Ensure that chain assemblies (rigging) are rated
  for the loads being pulled. Consult the chain
  manufacturer to determine chain assembly rated
  capacities and also required de-ratings due to
  the geometry of the final rigging arrangement.
• Ensure persons are positioned in a safe location
  before tension is applied when dragging or towing
  equipment with chains, wire rope, or any other
  rigging.
• Ensure that chains and hooks are properly
  attached or rigged.
• Evaluate pillar strength and design before second
  mining areas containing unusual circumstances,
  such as setup rooms.

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• Miners must think about how to do the task
  safely.
• All miners involved must be properly trained.
• Take the necessary time to find and use the
  correct tools.
• We must assure that miners are not unfamiliar
  with the task, job, or equipment. Persons take
  on tasks or are assigned tasks that they are not
  trained and/or equipped to perform.
• Supervisors and miners must communicate when
  there are near misses. People dont want others
  to know about near misses. They become
  embarrassed because they had erred due to
  inexperience, rushing, use of poor judgment, or
  had their thoughts elsewhere. Just because you
  didnt get hurt does not mean that the next
  person will be as lucky.

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SLINGS

• Chain Slings
• 2. Wire Rope Slings
• 3. Synthetic Web Slings

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THE FIRST ONE I CAN FIND METHOD
SOMETIMES CHAINS ARE NEEDED TO ACCOMPLISH
SOMETHING QUICKLY, LIKE TOWING A DISABLED VEHICLE
OR DRAGGING SOMETHING OUT OF THE WAY. WHEN TIME
IS A FACTOR, SELECTION AND INSPECTION ARE STEPS
SOMETIMES EASILY OVERLOOKED.
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• USE SLINGS OF
• ADEQUATE
• AND !

SIZE
STRENGTH
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METAL/NONMETAL MINE FATALITY- On April 29, 1998,
a 39-year old bull dozer operator with 15 years
of mining experience was fatally injured while
attempting to tow a truck that had become stuck.
He backed the dozer to the rear of the truck and
attached a chain. In the process of pulling the
truck out, the chain broke and struck the dozer
operator in the temple. He received severe head
injuries and died several days later.
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• COAL MINE FATALITY - September 9, 2003
• A 36-year old utility person with 4 years of
  mining experience was fatally injured at a
  surface coal mine. The victim and a co-worker
  were using two pick-up trucks to assist moving
  the power cable for an electric shovel that was
  being repositioned. One of the trucks lost
  traction in a muddy area and a nylon tow rope was
  attached to a hook on the truck's front end. The
  toe rope was then attached to a hook on the back
  of the second pick-up. On the first attempt to
  pull the truck, the metal hook broke loose from
  the hitch of the front truck, pierced the
  windshield of the rear truck and struck the
  victim's head.

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• BEST PRACTICES
• Use only tested and approved mechanisms for
  pulling or towing.
• Obtain approval of manufacturer for modifications
  to original towing equipment.
• Ensure employees are properly instructed on
  proper towing practices.
• Ensure vehicles have sufficient traction for
  surface conditions.
• Conduct audits (observations) of specific tasks
  to ensure proper techniques are employed and
  tools/materials are maintained.
• Never exceed the rated capacity of a tow vehicle
  or towing equipment.
• Use hands-on training specific to the individual
  task.
• Communicate prepare pre-task check of materials
  and techniques for every application.

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• Known hazards tend to become routine which tends
  to promote complacency. This complacency may not
  allow us to acknowledge the hazards or identify
  changes that can affect our safety.
• Supervisors and miners must observe/evaluate/deter
  mine the assignment in progress.

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TAKE INTO ACCOUNT

• WEIGHT OF LOAD
• SHAPE OF LOAD - avoid sharp edges (use pads)
• HOW TO HOOK UP LOAD - avoid dragging rigging from
  under the load

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Sling Tags

• Be familiar with manufacturers recommendations
  for use and identification methods for rated load
  capacity and test dates.

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• Never overload a sling! 
• Remember, the wider the sling legs are spread
  apart, the less the sling can lift!
• 
  

1000 lbs Lift Capacity
707 lbs Lift Capacity
500 lbs Lift Capacity






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• Reeving through connections to load increases
  load on connections fitting by as much as
  twice.DO NOT REEVE!

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NEVER SHOCK LOAD A SLING!
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COAL MINE FATALITY June 9, 2003 A 49-year old
supervisor with 29 years mining experience was
fatally injured when he was thrown from the
elevated bucket of a Simon-Telect 42-foot aerial
bucket truck. The victim and two other miners
were dismantling a de-energized electrical
substation on the surface area of an underground
mine. To secure a steel "I-Beam" structure, a
nylon rope was attached between the bucket of the
aerial lift and the steel structure. After the
steel structure was disconnected from the
substation, the rope broke, causing the aerial
bucket to shift suddenly, throwing the victim out
of the bucket. The victim fell 28 feet 11 inches
to the ground. The steel "I-Beam" structure then
rolled onto the raised frame of the aerial bucket
truck.
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• BEST PRACTICES
• Use appropriate fall protection, including safety
  harnesses and safety lines, where there is a
  danger of falling.
• Use equipment for its intended purpose and within
  the design specifications of the manufacturer.
• Conduct pre-operational checks on equipment prior
  to operation and ensure that outriggers and
  equipment are ready for intended use.
• Size ropes/slings for maximum load applications
  and protect them from being cut when a load is
  applied.
• Ensure that all workers are properly trained in
  the task to be preformed, such as hoisting,
  rigging, equipment design capabilities, etc.

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COAL MINE FATALITY November 9, 2004 A
55-year-old company president, with 30 years of
experience, was fatally injured when he was
crushed between a front end loader and a
tractor-trailer truck. The end loader was being
moved into position to allow the victim to
connect a steel cable from it to the truck. The
end loader was going to be used to pull the
tractor-trailer up the haul road, and was stopped
a short distance from the truck. While the victim
was connecting the cable to the truck, the end
loader inadvertently rolled back and crushed him
against the truck.
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• BEST PRACTICES
• Ensure that haulage equipment is compatible with
  all conditions and haulage road grades at the
  site.
• Ensure that vehicles have sufficient traction for
  surface conditions.
• Avoid pulling or pushing of vehicles as a routine
  practice.
• Ensure employees are properly instructed on
  proper towing procedures.
• Monitor work habits routinely and examine work
  areas to ensure that safe working procedures are
  being followed.
• Caution miners to avoid the hazards presented by
  pinch points.

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CONNECTIONS

• The load capacity of the sling is determined by
  its weakest component.
• Match size and working load limit of attachments
  to sling.

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METAL/NONMETAL MINE FATALITY March 24, 2003 A
46-year-old supervisor with 8 years mining
experience was fatally injured on the surface at
an underground stone mine. A crane was lifting
steel plates that were to be used as conveyor
belt take-up weights. The victim was positioning
the plates when the rigging failed and the plates
crushed him
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• BEST PRACTICES
• Discuss work procedures and identify all hazards
  associated with the work to be performed along
  with the methods to properly protect persons.
• Establish safe work procedures that require all
  personnel to be positioned where they are not
  working under suspended loads.
• Train all personnel in safe work procedures.
• Use rigging that is free of defects and designed
  to safely lift the load.

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IMPROPER USE OF CHAINS

• KNOTTED loading wont be along axis
• TWISTED
• BOLTED TOGETHER

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METAL/NONMETAL MINE FATALITY January 13,
2003 A 62-year-old supervisor with 26 years
mining experience was fatally injured at a cement
plant. The victim was standing 9 feet above
ground level at a door opening discussing the
progress of repairs with another foreman standing
outside on a concrete pad at ground level. The
victim was leaning on the top chain handrail that
was installed across the door opening. Apparently
as the victim exerted outward pressure against
the chain, the chain link slipped off the grab
hook attachment on the removable end of the chain
causing him to fall 9 feet to the concrete pad.
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• BEST PRACTICES
• Ensure that safety chains or handrails are
  properly installed, regularly examined and
  properly maintained, and are capable of
  supporting the weight of a person who might fall
  or lean on them.
• Design the installation of safety chains to
  ensure the termination points remain securely
  attached when they are in place.

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Wire Rope Clips
RIGHT WAY FOR MAXIMUM ROPE STRENGTH
WRONG WAY CLIPS STAGGERED
WRONG WAY CLIPS REVERSED
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EXAMINATIONS

• Examine sling and anchorage points prior to each
  use for damage and wear!

POSSIBLY THE MOST CRITICAL STEP IS THE VISUAL
INSPECTION OF RIGGING EQUIPMENT!
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Chain Sling Inspection Items

• Links that are bent, stretched, cracked, or
  gouged.

Bent
Wear and Stretch
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Wire Rope Sling Inspection Items

• Broken wires, kinking or other distortion,
  corrosion, and wear.

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REMOVAL CRITERIA
MORE THAN ONE BROKEN WIRE AT TERMINATION
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Synthetic Sling Inspection Items

• Melting, cuts, broken stitching, and stretching.

BROKEN STITCHING
MELTING AND CHARRING
One manufacturer warns Strap is permanently
damaged when exposed to temperatures in excess
of 200F. Avoid muffler and hot exhaust systems.
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To assist operators in determining if a sling is
stretched, many manufacturers incorporate a red
core warning system inside of the sling. When
this red wear cord can be readily seen upon
inspecting the sling, the sling has been
stretched and is to be removed
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BUNCHING
PINCHING
FOLDING, BUNCHING OR PINCHING OF SYNTHETIC SLINGS
WILL REDUCE THE RATED LOAD
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HOOKS
Never use a hook whose throat opening has been
increased, or whose tip has been bent. Hooks
should not be side loaded, back loaded, or tip
loaded.
Side Loaded
Back Loaded
Tip Loaded
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• Note A latch will not work properly on a hook
  with a bent or worn tip.

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SHACKLES
Angle loads must be applied in the bow. Many
shackles incorporate guide markings to check the
angle of side pull.
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METAL/NONMETAL MINE FATALITY May 15, 2003 A
51-year-old master welder with 30 years mining
experience was fatally injured in a shop at a
surface stone mine. The victim was fabricating a
screen tower section. Using an overhead bridge
crane, he was positioning the 3-beam, right side
component for assembly. While the victim was
standing on the bottom beam, communicating with
the crane operator and positioning a chain sling,
the load shifted and fell, crushing him.
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• BEST PRACTICES
• Discuss work procedures and identify all hazards
  associated with the work to be performed along
  with the methods to protect personnel.
• Require all personnel to be positioned to prevent
  them from being exposed to any hazards.
• Never perform work on or have unstable
  structures/fabrications freestanding.
• Secure loads before unhooking them.
• Arrange the rigging to prevent shifting of the
  load being lifted. Balance the load by placing
  the crane or hook block directly above the load's
  center of gravity.

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Other Suggestions
Use sheave wheels or pads to pull around
corners. Use tow bars when possible.
30 CFR 77.1607 (u) Tow bars shall be used to
tow heavy equipment and a safety chain shall be
used in conjunction with each tow bar.
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Equipment with winches should be equipped with
guarding for the operator.
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COAL MINE FATALITY - On Friday, September 3,
1999, a preparation plant mechanic and another
employee were using a material hoist to lift a 55
gallon drum to the third floor of the preparation
plant. When the mechanic reached out to guide the
suspended drum to the third floor, a corroded
railing gave way and he fell approximately 50
feet to the ground floor of the preparation
plant.
30 CFR 77.210 (c) Taglines shall be attached to
hoisted materials that require steadying or
guidance.
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• For every 300 near miss accidents, there will be
  29 minor accidents. And for every 29 minor
  accidents, there will be one serious accident.
  If we encourage people to report near miss
  accidents, we can expect minor accidents to be
  reduced and possibly the serious accident will be
  eliminated.

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Non Fatal Accident CONSTRUCTION ACCIDENT BLINDS
MANA Texas man is a lucky to be alive after a
construction accident involving a large hook.
The hook was attached to a backhoe when it hit
Gail Cook in the left temple and eye back in
December. X-rays show how it lodged in Cook's
head, stopping within millimeters of his brain.
Surgeons in San Antonio were able to remove the
hook. But both optic nerves were severed. The
accident has left Cook blind, but also thankful
to be alive.USA, Action News
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• Non Fatal Accidents
• Employee was removing the wire ropes from the
  drag drum when a 2 inch nylon sling broke and
  recoiled striking them in the head, knocking them
  unconscious.  The wire rope tugger was being used
  to pull the rope slack toward the rear of the
  machine when the nylon sling appears to have been
  cut by the threads of an inch and a half bolt on
  the drum clamp.
• Three employees were working to pull the tailgate
  drive back.  The gob plate was attached to the
  shield with chains.  As they started to pull, one
  of the chains broke and struck the employee in
  the face, causing a fracture to the cheek and a
  laceration requiring stitches.

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• Near Miss Accident
• Some information we have on pulling equipment may
  help others.  We had a coal hauler stuck at the
  stockpile, we used a rubber tire dozer and a 2"
  cable choker 10' long to pull the coal hauler
  out.  The operator in the coal hauler was
  accelerating to assist the rubber tire dozer, as
  the coal hauler began to move it suddenly lunged
  forward.  The forward momentum of the coal hauler
  allowed it to hit the rear of the rubber tire
  dozer.  When the coal hauler hit the rubber tire
  dozer it caused the rubber tire dozer to lunge
  forward.  The 10' cable choker acted as a large
  rubber band allowing the two machines to slam
  together twice before the operators could react
  and get their machines stopped.  We now require a
  20' choker to be used when one machine is pulling
  another machine.  Thus allowing operators more
  time to react to the unexpected.

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CONCLUSIONS

• Maintain Communications!!
• Stay Clear!! All persons MUST be in a safe
  location!!

Remember, the longer the sling, the wider the
recoil radius!
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QUESTIONS

• Do you think that an individuals actions should
  be reviewed in accident investigations?
• Do you think that an individuals actions are a
  common denominator for some of our most recent
  accidents?
• If so, how do we fix this?
• How can we motivate people to make the correct
  choices?
• Any other comments or suggestions?

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Any person with questions, or would like to make
additional comments/suggestions, please contact
MSHAs District 9 office at Bob
Cornett Email Cornett.Bob_at_DOL.GOV Al
Davis Email Davis.Allyn_at_DOL.GOV Mailing
Address Mine Safety and Health
Administration Coal Mine Safety and Health P.
O. Box 25367 DFC Denver, CO 80225 Telephone 3
03-231-5458 Fax [phone]