Understanding rigging failure causes and the steps you can take to avoid them
When rigging fails, the consequences can be severe. From crushed equipment to critical injuries, a single mistake in a lift can ripple across an entire jobsite. In Alberta and across Canada, rigging-related incidents continue to highlight the importance of proper training, regular rigging inspections, and safe practices.
The good news is that most accidents can be prevented. By understanding the leading rigging failure causes and applying proven rigging safety tips, crews can reduce risks and keep lifting operations safe and compliant.
1. Overloading Equipment
One of the most common rigging failure causes is exceeding the rated Working Load Limit (WLL) of slings, shackles, or hooks. This typically occurs when the weight of the load is not verified or when sling angles are improperly calculated, increasing tension beyond safe limits.
How to prevent rigging accidents: Always determine the total load weight, including all rigging hardware, and confirm the capacity of each component. Use manufacturer charts to account for variables like sling angles and hitch types.
2. Improper Equipment Selection
Not all rigging gears are interchangeable. Using the wrong type of sling, hitch, or below-the-hook device can compromise the integrity of a lift, especially if equipment has been modified or fabricated without engineering oversight.
Rigging safety tip: Choose hardware rated for the specific application and lifting environment. Avoid non-OEM components and makeshift assemblies. If in doubt, consult a qualified lifting specialist.
3. Inadequate Pre-Use Inspections
Rigging hardware is exposed to constant stress and wear. Skipping rigging inspections can allow damage such as frayed slings, bent hooks, or corrosion to go unnoticed until failure occurs mid-lift.
How to prevent rigging accidents: Perform pre-use inspections before every lift. Look for deformation, cracks, corrosion, and missing labels. If identification tags are missing or unreadable, equipment should be removed from service until properly inspected and verified safe for use.
4. Lack of Training and Certification
Untrained or inexperienced riggers may not know how to calculate sling angles, identify defective gear, or maintain proper load control. These gaps in knowledge put the entire crew at risk.
Rigging safety tip: All personnel involved in rigging should be properly trained and deemed competent. Practical, hands-on training combined with theoretical instruction ensures riggers can safely handle lifting equipment and make sound decisions on the jobsite.
5. Poor Load Control
Even when properly rigged, a load can become unstable due to shifting contents, environmental conditions, or lack of tag lines. Improper control during hoisting or travel can result in swung loads, dropped material, or struck-by injuries.
How to prevent rigging accidents: Plan for load control before lifting. Use tag lines, spreader bars, or multi-leg slings to distribute forces evenly. Always consider wind and path of travel when planning lifts.
6. Lack of Sling Protection
Slings in contact with sharp or abrasive surfaces face a high risk of cutting or tearing. Synthetic web and round slings are especially vulnerable, and failure at a contact point can result in a total load drop.
Rigging safety tip: Always usesling protection like wear pads, corner protectors, or sleeves when lifting around edges or rough materials. Even small edge radii can damage synthetic slings without proper protection.
7. Ignoring Load Structural Integrity
A poorly built crate or a container with shifting contents can collapse or tip mid-lift even when rigged correctly. Lifting operators must account for the load’s internal stability, not just its weight.
How to prevent rigging accidents: Inspect containers or fabricated loads for structural soundness. Stabilize partially filled vessels and verify that lifting points are engineered for the forces of the lift.
8. Lack of Communication on the Jobsite
Rigging operations demand coordination. Miscommunication between the operator, rigger, and signal person can lead to missed cues, unsafe movements, or premature lifting.
Rigging safety tip: Establish and enforce standardized hand signals and clear communication protocols. Conduct pre-lift meetings to review roles, hazards, and emergency procedures.
Building a Safer Future
Rigging safety starts well before the crane lifts a load. From proper lifting gear maintenance and thorough rigging inspections to clear communication and reliable sling protection, every step matters.
By addressing these common rigging failure causes, crews can significantly reduce risks, protect workers, and ensure compliance.
For more rigging safety tips, support with lifting gear maintenance, and high-quality rigging solutions, contact Titan Supply. We are your trusted partner in helping you prevent rigging accidents and keep your jobsite safe.