1. SLING OUT OF HARM'S WAY
Coal Mine Safety and Health
District 9

2. 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.
Coal Mine Safety and Health
District 9

3. 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!
Coal Mine Safety and Health
District 9

4. Coal Mine Safety and Health
District 9

5. F-bar with Guards

6. Removing Shield from Face

7. 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.

8. 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.
Coal Mine Safety and Health
District 9

9. 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 don’t 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 didn’t get hurt does not mean that the next person will be as lucky.
Coal Mine Safety and Health
District 9

10. SLINGS
Chain Slings
2. Wire Rope Slings
3. Synthetic Web Slings

11. 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.

12. SIZE STRENGTH ADEQUATE AND ! USE SLINGS OF Coal Mine Safety and Health
District 9

13. 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.

14. 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.

15. 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.
Coal Mine Safety and Health
District 9

16. 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/determine the assignment in progress.
Coal Mine Safety and Health
District 9

17. 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

18. Sling Tags
Be familiar with manufacturer’s recommendations for use and identification methods for rated load capacity and test dates.

19. Never overload a sling! 1000 lbs Lift Capacity 707 lbs Lift Capacity
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

20. Coal Mine Safety and Health
District 9

21. Reeving through connections to load increases load on connections fitting by as much as twice.DO NOT REEVE!
Coal Mine Safety and Health
District 9

22. NEVER SHOCK LOAD A SLING!

23. 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.

24. 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.
Coal Mine Safety and Health
District 9

25. 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.

26. 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.
Coal Mine Safety and Health
District 9

27. CONNECTIONS Match size and working load limit of attachments to sling.
The load capacity of the sling is determined by its weakest component.
Match size and working load limit of attachments to sling.
Coal Mine Safety and Health
District 9

28. 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

29. 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.
Coal Mine Safety and Health
District 9

30. IMPROPER USE OF CHAINS KNOTTED – loading won’t be along axis TWISTED
BOLTED TOGETHER

31. 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.

32. 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.
Coal Mine Safety and Health
District 9

33. Wire Rope Clips RIGHT WAY FOR MAXIMUM ROPE STRENGTH
WRONG WAY: CLIPS STAGGERED
WRONG WAY: CLIPS REVERSED

34. 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!
Coal Mine Safety and Health
District 9

35. Chain Sling Inspection Items
Links that are bent, stretched, cracked, or gouged.
Bent
Wear and Stretch

36. Wire Rope Sling Inspection Items
Broken wires, kinking or other distortion, corrosion, and wear.

37. MORE THAN ONE BROKEN WIRE
REMOVAL CRITERIA:
MORE THAN ONE BROKEN WIRE
AT TERMINATION
OBJ 4 - b

38. 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 200°F. Avoid muffler and hot exhaust systems.

39. 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
Coal Mine Safety and Health
District 9

40. BUNCHING
PINCHING
FOLDING, BUNCHING OR PINCHING OF SYNTHETIC SLINGS WILL REDUCE THE RATED LOAD

41. 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

42. Note: A latch will not work properly on a hook with a bent or worn tip.

43. SHACKLES
Angle loads must be applied in the bow. Many shackles incorporate guide markings to check the angle of side pull.

46. 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.

47. 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.
Coal Mine Safety and Health
District 9

48. Other Suggestions Use sheave wheels or pads to pull around corners.
Use tow bars when possible.
30 CFR § (u) Tow bars shall be used to tow heavy equipment and a safety chain shall be used in conjunction with each tow bar.
Coal Mine Safety and Health
District 9

49. Equipment with winches should be equipped with guarding for the operator.
Coal Mine Safety and Health
District 9

50. 30 CFR § 77.210 (c) Taglines shall be attached to hoisted
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 § (c) Taglines shall be attached to hoisted
materials that require steadying or guidance.

51. For every 300 near miss accidents, there will be 29 minor accidents
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.
Coal Mine Safety and Health
District 9

52. Non Fatal Accident CONSTRUCTION ACCIDENT BLINDS MAN A 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

53. 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.
Coal Mine Safety and Health
District 9

54. 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.
Coal Mine Safety and Health
District 9

55. Remember, the longer the sling, the wider the recoil radius!
CONCLUSIONS
Maintain Communications!!
Stay Clear!! All persons MUST be in a safe location!!
Remember, the longer the sling, the wider the recoil radius!
Coal Mine Safety and Health
District 9

56. QUESTIONS:
Do you think that an individual’s actions should be reviewed in accident investigations?
Do you think that an individual’s 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?
Coal Mine Safety and Health
District 9

57. Bob Cornett Email: Cornett.Bob@DOL.GOV
Any person with questions, or would like to make additional comments/suggestions, please contact MSHA’s District 9 office at:
Bob Cornett
Al Davis
Mailing Address: Mine Safety and Health Administration
Coal Mine Safety and Health
P. O. Box DFC
Denver, CO
Telephone:
Fax:
Coal Mine Safety and Health
District 9