Custom Rigging Solutions: When “Standard” Doesn’t Cut It
Walk through almost any industrial facility, construction site, shipyard, or manufacturing plant and you’ll find a common theme: no two lifts are exactly alike.
While standard slings, shackles, hooks, and lifting hardware are designed to handle a wide range of applications, some lifting challenges demand something more. Oversized loads, unusual shapes, limited lift points, clearance restrictions, and specialized environments can quickly turn a routine lift into a complex engineering challenge.
When standard rigging solutions no longer provide the safest or most efficient option, custom rigging solutions can help bridge the gap.
Why Standard Rigging Isn’t Always Enough
Standard lifting equipment is designed around common load configurations and predictable lifting conditions. However, many industries regularly encounter situations that fall outside those parameters.
Examples include:
- Large fabricated components
- Heavy machinery with off-center centers of gravity
- Precast concrete structures
- Modular construction sections
- Industrial vessels and tanks
- Aerospace or defense components
- Specialized maintenance lifts in confined spaces
In these situations, using standard equipment may create challenges such as:
- Uneven load distribution
- Excessive sling angles
- Limited attachment points
- Damage to the load
- Reduced control during lifting
- Increased setup time
Rather than forcing a lift to fit available equipment, custom rigging solutions are designed around the specific requirements of the load.
What Is a Custom Rigging Solution?
A custom rigging solution is any lifting device, sling assembly, spreader beam, lifting frame, or below-the-hook device engineered to safely handle a unique lifting application.
Examples include:
Custom Spreader Beams
Spreader beams help distribute load forces across multiple lift points while reducing sling angles. Custom designs can be engineered for unique dimensions, capacities, and attachment requirements.
Lifting Frames
For large or irregularly shaped loads, lifting frames provide multiple pick points and improved load stability throughout the lift.
Engineered Sling Assemblies
Custom wire rope, synthetic, or chain sling assemblies can be designed to accommodate specific load configurations, environmental conditions, and lifting requirements.
Specialized Lifting Devices
Custom hooks, clamps, grabs, lifting lugs, and other below-the-hook devices can be developed for loads that cannot be safely handled using standard rigging hardware.
Safety Must Drive the Design
One of the biggest misconceptions about custom lifting devices is that they are simply fabricated versions of standard equipment.
In reality, properly engineered custom lifting devices require detailed analysis of:
- Load weight and center of gravity
- Load geometry
- Lift point locations
- Sling angles
- Dynamic loading conditions
- Environmental factors
- Applicable safety factors
Industry standards such as ASME B30.20 (Below-the-Hook Lifting Devices) and ASME BTH-1 (Design of Below-the-Hook Lifting Devices) provide guidance for the design, construction, inspection, testing, and operation of engineered lifting devices. These standards help ensure that custom equipment is designed with appropriate structural and mechanical safety margins.
Proof Testing Matters
Custom lifting devices aren’t simply designed and put into service.
OSHA requires special custom-designed grabs, hooks, clamps, and other lifting accessories used in construction applications to be marked with their safe working load and proof-tested to 125% of their rated capacity before use.
This testing helps verify that the device performs as intended and provides confidence that the equipment can safely withstand its rated load.
The Risks of “Making Something Work”
When a unique lifting challenge arises, some organizations are tempted to modify existing equipment or fabricate an in-house lifting device without formal engineering review.
While these solutions may appear to save time initially, they often introduce significant risks:
- Unknown load paths
- Improper load ratings
- Lack of documentation
- Missing inspection criteria
- Compliance concerns
- Increased liability exposure
Industry experts frequently identify homemade or modified lifting devices that lack proper engineering documentation, identification, testing, or inspection requirements.
When personnel safety and critical loads are involved, assumptions are never an acceptable substitute for engineering.
Benefits of a Custom Rigging Solution
When designed correctly, custom lifting equipment can deliver significant advantages:
Improved Safety
Equipment is designed specifically for the load and lifting environment.
Greater Efficiency
Faster setup times and simplified lifting procedures can help reduce downtime.
Better Load Control
Properly engineered lift points improve balance and stability during the lift.
Reduced Product Damage
Custom devices can protect finished surfaces and sensitive components.
Repeatability
For recurring lifts, custom equipment creates a standardized and documented lifting process.
Working with the Right Partner
Developing a custom rigging solution requires more than fabrication capability. It requires engineering expertise, lifting experience, inspection knowledge, and an understanding of applicable OSHA and ASME requirements.
The right partner will work through the entire process:
- Evaluating the lift
- Reviewing load characteristics
- Developing engineered concepts
- Providing calculations and documentation
- Manufacturing the device
- Conducting proof testing when required
- Supporting inspections and ongoing use
The result is a lifting solution designed specifically for the application—not a compromise.
When the Lift Demands More
Every lift presents unique challenges. While standard rigging equipment handles the vast majority of lifting operations, there are times when “good enough” simply isn’t good enough.
When load geometry, capacity requirements, safety concerns, or operational constraints push beyond the limits of standard equipment, a custom rigging solution can provide the safest and most effective path forward.
At CERTEX, we work with customers across construction, manufacturing, energy, marine, infrastructure, and industrial markets to help solve complex lifting challenges. Whether it’s a custom spreader beam, engineered lifting frame, specialized sling assembly, or a fully engineered below-the-hook device, our team can help develop a solution designed specifically for your application.
Have a lift that doesn’t fit the standard playbook? Contact your local CERTEX team to discuss a custom rigging solution engineered for your project.
