In high-risk environments such as construction, mining, and industrial maintenance, rigging plays a critical role in lifting, moving, and securing heavy loads. But when rigging is done incorrectly, the consequences can be severe and range from equipment damage and project delays to life-threatening accidents.

At Bunzl Safety & Lifting, we believe that every lifting operation should begin with safety, and that starts by understanding what not to do.

1. Using the Wrong Rigging Equipment for the Task

One of the most common and dangerous rigging errors is selecting equipment that isn't suited for the specific lift. For example, using slings with insufficient load capacity, or hardware that isn’t rated for the working load limit (WLL), can compromise the integrity of the lift. Similarly, using hooks, shackles, or turnbuckles that don’t match the load configuration or environmental conditions can lead to imbalance or failure. Choosing the correct rigging gear is essential for compliance and safety on the jobsite.

2. Failing to Inspect Equipment Before Use>

Rigging gear wears down over time and sometimes that wear is invisible until it’s too late. Many incidents occur because workers either skip the pre-use inspection or perform only a cursory visual check. Slings can fray, chains can stretch, and hooks can become deformed. Without a proper inspection process, these hazards go unnoticed until failure occurs mid-lift.

Regular inspection of lifting and rigging equipment is a non-negotiable step in safe rigging. All lifting gear should be visually checked for damage, deformation, corrosion, and wear before every use. More detailed, periodic inspections by trained personnel are required by Australian Standards and should be logged for compliance.

3. Improper Sling Angles and Load Positioning

Even when the right equipment is chosen, improper use can render it unsafe. One of the most overlooked mistakes in rigging is incorrect sling angle configuration. If slings are attached at steep angles, the tension in each leg increases dramatically, potentially exceeding their rated capacity. This issue is especially dangerous because the load may appear secure, when in fact the sling is overstressed and prone to sudden failure.