When lifting heavy loads, even the smallest mistake in your rigging setup can have serious consequences. From damaged equipment and costly delays to serious injuries and legal issues, rigging errors are never minor. However, many of these incidents can be prevented with proper planning, training, and attention to detail.
Whether you’re managing a construction site, working in industrial manufacturing, or overseeing a logistics hub, avoiding these five common rigging mistakes can save your company time, money, and liability issues.
1. Using the Wrong Rigging Equipment for the Job
One of the most common and potentially hazardous errors is selecting the incorrect type of rigging equipment for the job. For example, using synthetic slings when wire rope is necessary, or using rigging hardware with inadequate working load limits (WLL).
Why it’s costly: Equipment mismatch can cause slippage, load shifts, or total failure during a lift. This can damage property or, worse, threaten lives.
How to avoid it:
- Always verify load weight and lifting angle calculations before selecting your rigging equipment.
- Understand the material properties of your slings and fittings (e.g., nylon slings stretch, wire ropes resist heat).
- Follow manufacturer specifications and OSHA guidelines for WLL and configuration.
2. Neglecting Rigging Inspections
Rigging equipment isn’t designed to last forever, especially in tough industrial environments. Unfortunately, many companies ignore regular inspections—either skipping them altogether or only doing them superficially.
Why it’s costly:
Uninspected gear can develop internal wear, frayed wires, corrosion, or fatigue cracks that may go unnoticed until failure occurs during mid-lift.
How to avoid it:
- Establish a documented inspection schedule: pre-use, frequent (daily/weekly), and periodic (monthly/quarterly).
- Train staff to identify issues such as abrasion, cuts, broken wires, elongation, and deformities.
- Immediately remove and tag out any gear that is compromised.
3. Ignoring Load Angle and Sling Tension
Many rigging failures come from misunderstanding how load angle influences sling tension. The larger the angle between the sling and the horizontal, the more tension each leg of the sling experiences—often surpassing the safe working load.
Why it’s costly:
Ignoring angle forces can strain your rigging hardware, causing early failure or snapback hazards.
How to avoid it:
- Always determine sling angle forces with load angle charts or rigging calculators.
- Keep sling angles above 45° whenever possible to lessen stress.
- Consider using spreader bars to keep the lift vertical and distribute the load evenly.
4. Poor Communication Between Rigging Crew and Crane Operator
Even with top-notch equipment and setup, a lift can fail if the rigging crew and crane operator aren’t on the same page. Misunderstood hand signals, unclear instructions, or last-minute changes can lead to disaster.
Why it’s costly:
Miscommunication during lifts can lead to dropped loads, equipment collisions, or injuries—particularly in tight work zones or blind lifts.
How to avoid it:
- Designate a single signal person trained in standard hand signals and certified when required.
- Conduct a pre-lift briefing to review the plan, load weight, path of travel, and contingency measures.
- Use radios or other clear communication tools in noisy or obstructed environments.
5. Overlooking Environmental Factors
Wind, rain, temperature changes, and ground conditions all affect rigging safety. A calm morning lift can turn dangerous with a sudden weather change or unstable footing.
Why it’s costly:
Environmental variables can destabilize equipment, obscure visibility, or cause unexpected stress to the rigging system.
How to avoid it:
- Monitor weather conditions carefully before and during lifts.
- Delay operations during high winds or lightning-prone conditions.
- Ensure ground stability, especially for mobile cranes or on muddy ground.
Lift with Caution, Lift with Confidence
The margin for error in rigging is extremely small. Mistakes can cause life-changing results, but most are avoidable with proper training, communication, and a culture that values safety over speed.
If you’re managing rigging operations, take the time to review procedures, inspect gear, and encourage your crew to speak up when something feels off. Investing in safety today is much cheaper than paying for failure tomorrow.