Common Challenges in Heavy Equipment Rigging and How to Overcome Them

Rigging heavy equipment is a high-risk job that requires precision, awareness, and adherence to safety protocols. However, even experienced riggers may overlook critical steps, leading to unsafe lifts, equipment damage, and potential injuries.

To help you avoid these costly mistakes, we consulted the Lifting Specialists at California Specialized Logistics, LLC experts, who have witnessed firsthand the most frequent rigging failures during site visits, inspections, and consultations.

Here are six common rigging challenges they frequently encounter, along with practical ways to overcome them and ensure every lift is safe and successful.

1: Uncertain Load Weight

As a rigger, you must know the load’s weight to ensure it stays within the working load limit (WLL) of the rigging equipment. While this may seem straightforward, determining a load’s weight isn’t always easy.

Some ways to verify a load’s weight in industrial rigging services include:

• Checking the bill of lading or shipping documentation
• Reviewing engineering drawings or design plans
• Using an industrial scale, load cell, or dynamometer
• Referring to manufacturer specifications or catalog data
• Calculating the weight, ensuring all rigging components (slings, hooks, hardware) are included

2: Lack of Equipment Inspection or Inspection Knowledge 

Neglecting to inspect heavy equipment rigging and installation for damage, defects, or wear can put your team at serious risk. Without proper knowledge and routine inspections, Heavy equipment rigging failure becomes more likely, leading to unsafe lifts and potential accidents. To ensure a safe work environment, it’s crucial to stay proactive in inspecting and maintaining your rigging gear.

How to Address This Issue:

• Conduct Frequent Inspections: Perform hands-on checks daily or before each shift.
• In high-risk environments, inspections should be conducted before every use.
• Ensure riggers know what to look for during inspections to identify potential issues early.
• Provide training and visual references (charts, posters) to help workers recognize damaged or unsafe equipment.
• Train employees to meet ASME B30.26 (Rigging Hardware) and ASME B30.9 (Slings) standards.

3: Unknown Sling or Hardware Capacity

Using rigging equipment without knowing its Working Load Limit (WLL) puts you and your team at serious risk. If the WLL is missing or unreadable, you must remove the equipment from service immediately to prevent accidents and equipment failure.

Best Practices for Rigging Heavy Equipment Safely:

• Always check that WLL markings are clearly visible on all rigging equipment.
• If the WLL is missing or illegible, do not use the equipment—replace it or consult your supervisor.
• For equipment like spreader bars or below-the-hook lifting devices, ensure the capacity label is prominently displayed before use.
• Some components, such as eye bolts or master links, may not have a WLL marked directly. In these cases, use manufacturer-provided charts to determine their safe load capacity.
• Keep WLL reference charts easily accessible to all riggers to prevent misuse of equipment.

4: Use of Improperly Fabricated or Modified Below-the-Hook Devices

Using makeshift or improperly fabricated heavy rigging equipment compromises safety and increases the risk of equipment failure. These devices do not comply with ASME B30.26 standards because their Working Load Limit (WLL) and Design Factor cannot be verified without proper load testing.

Common Issues That Put You at Risk:

• Using lifting devices built from scratch without proper load testing.
• Modifying or welding existing equipment, weakening its structural integrity.
• Replacing components with non-OEM (original equipment manufacturer) parts, which may not meet safety standards.

How You Can Prevent This:

• Always use certified and tested below-the-hook lifting devices.
• Never modify or weld lifting equipment without proper approval and testing.
• Verify that all lifting devices have been load-tested and inspected before use.
• Report any makeshift or modified devices immediately to ensure compliance and workplace safety.

5: Failure to Use Proper Sling Protection

Slings must be protected from sharp corners, edges, and protrusions to prevent wear and tear. Synthetic slings (web and round slings) are especially vulnerable.

What Can Happen Without Proper Protection?

• Equipment failure and failed lifts due to sling cuts and abrasions.
• Injury or fatalities caused by sudden sling breakage.
• Higher replacement costs for frequently damaged slings.
• Damage to the load, particularly with wire rope or chain slings.

How You Can Prevent This:

• Always use edge protection when lifting sharp or abrasive loads.
• Inspect slings before and after each use for signs of wear.
• Follow manufacturer recommendations on sling protection methods.

6: Failure to Maintain Load Control

Maintaining proper load control is essential to prevent tipping, swinging, or loss of balance.

Key Factors That Affect Load Control:

• Wind and environmental conditions that may cause instability.
• The center of gravity is shifting unexpectedly.
• Incorrect lifting equipment or sling hitch selection.
• Lack of taglines to stabilize the load during movement.
  

How You Can Prevent This:

• Use tag lines to control the load during lifting and lowering.
• Evaluate wind conditions and surroundings before a lift.
• Ensure the load’s center of gravity is properly aligned before rigging.
  
• By staying informed and following these best practices, you can increase workplace safety, prevent equipment failures, and ensure successful lifts.

Conclusion

Preventing common rigging mistakes enhances workplace safety and operational efficiency. By addressing these six common issues, riggers can reduce risks and improve lifting procedures.

For expert industrial rigging services, heavy equipment rigging, and installation, training, inspections, and consultations, contact California Specialized Logistics, LLC—your trusted industry professional!