Rigging is a critical component of lifting operations in industries ranging from construction and manufacturing to energy and maritime. While rigging plays a vital role in moving heavy loads safely and efficiently, it also introduces serious risks when not done properly. For this reason, it’s essential that every operator — whether new to the field or a seasoned professional — understands and follows the fundamentals of rigging safety.
In this article, we’ll explore three core areas every operator should prioritize: key safety principles, common hazards, and the importance of routine inspections.
1. Key Rigging Safety Principles
At the foundation of every safe lift are a few non-negotiable safety principles:
- Know the Load: Always confirm the weight of the load and ensure all equipment used is rated appropriately. Overloading a sling or hoist is one of the most common — and dangerous — mistakes in rigging.
- Use the Right Equipment: Choose slings, shackles, hooks, and hardware that are appropriate for the specific load, environment, and any dynamic forces at play. This includes considering the type of load being lifted, as well as potential hazards like sharp edges that could damage slings. Where applicable, use edge protection or softeners to shield slings from abrasion or cuts when they pass over rough surfaces or edges. Properly selecting and protecting rigging gear ensures safe handling and extends the lifespan of equipment.
- Rigging Angles and Load Tension: Rigging angles significantly affect the tension on lifting slings. As the angle between the sling and the vertical decreases, the load tension on each leg increases exponentially resulting in exceeding the safe working load limit of the rigging assembly. Proper calculation of sling angle is essential to ensure all equipment stays within safe operating limits.
- Clear Communication: Rigging teams must use standardized hand signals, as outlined in the ASME B30.5 standards, or alternative communication tools such as radios to ensure clear, consistent coordination. This is especially critical when visibility is limited or during complex lifts, ensuring all team members are aligned and aware of the lifting operation at all times.
- Never Stand Under a Load: In accordance with OSHA regulations, it is a fundamental safety rule that no person should ever stand, walk, or pass beneath a suspended load. Doing so poses a significant risk of injury or fatality in the event of load failure. Always maintain a safe distance from suspended loads.
2. Common Hazards in Rigging Operations
Even experienced operators can fall victim to preventable rigging hazards. Here are some of the most common:
- Improper Sling Use: This includes using damaged slings, incorrect hitches, or tying knots in synthetic slings which severely compromise the slings integrity and rated capacity.
- Worn or Damaged Gear: Chain slings, wire rope slings, or synthetic web slings exhibiting signs of wear such as fraying, kinking, birdcaging, broken wires, excessive corrosion, or other deformities must be immediately removed from service in accordance with OSHA and ASME B30.9 standards. After which, a qualified person must inspect the sling or rigging gear to determine whether it can be repaired or if it must be permanently removed from use.
- Load Shift or Slippage: Loads that are unevenly distributed, inadequately secured, or improperly rigged can shift suddenly during lifting operations. This creates a serious hazard, increasing the risk of dropped loads, equipment damage, and injury or fatality to personnel within the fall zone.
- Environmental Conditions: Adverse conditions such as inclement weather, poor lighting, and uneven or slippery terrain can significantly impact rigging safety. Wet, icy, or unstable surfaces compromise footing and equipment stability, while limited visibility increases the likelihood of miscommunication, overlooked hazards, and operational errors during lifting activities.
- Lack of Training: A primary contributing factor to rigging-related incidents is a lack of current, comprehensive training. Ensuring all riggers and equipment operators are properly trained and qualified in accordance with applicable OSHA and ASME standards is essential to maintaining a safe lifting environment and mitigating operational risk.
⚠️ According to the U.S. Bureau of Labor Statistics, over a 6-year period, there were 297 crane-related deaths, averaging 42 per year. Over half of these fatalities involved workers being struck by objects or equipment, with many incidents linked to equipment failures.
3. The Importance of Routine Inspections
Routine inspections are the backbone of rigging safety. Equipment should be inspected:
- Pre-Use Inspection: Operators must visually inspect all rigging gear for wear, deformation, or damage. The sling’s identification tag must also be checked to ensure it is present and legible. Any equipment in questionable condition should be immediately removed from service and tagged with an “Out of Service” label, including the reason for removal. Equipment must remain tagged until deemed fit for service, repaired, or marked for destruction by a qualified person.
- Periodically by a Qualified Person: OSHA and ASME standards mandate comprehensive, documented inspections at specified intervals, typically on a monthly or annual basis, depending on the frequency of use.
- After Any Incident: If any lifting gear is subjected to an abnormal loading or impact (shock loading), it must be tagged and removed from service and undergo a comprehensive inspection by a qualified person prior to being placed back into service. Regular inspections are
critical to preventing catastrophic failure and ensuring the safe operation of rigging equipment. These inspections also help maintain the riggings integrity and extend its service life, ultimately reducing downtime and minimizing long-term costs.
Final Thoughts
Rigging safety isn’t just about compliance — it’s about culture. Every lift is an opportunity to reinforce safe practices, protect lives, and uphold professional standards. Whether you’re an operator, supervisor, or safety officer, staying grounded in the fundamentals of rigging safety can make all the difference.
At CERTEX, we’re committed to providing the training, equipment, and expertise to help keep your team safe. If you need assistance with rigging inspections or would like to schedule a safety training session, we’re here to help.
