Safe rigging requires technical knowledge, the right equipment, and disciplined practice on every lift. Whether you are an experienced rigger looking to reinforce best practice or a site manager wanting to understand the fundamentals, these ten proven tips will help you promote safer rigging operations on every project.
Tip 1: Always Determine the Load Weight Before Rigging
The rated capacities of rigging equipment and cranes are meaningless if you don’t know the weight of the load you are lifting. For known equipment, use the manufacturer’s stated weight. For unknown loads, calculate from the material density and dimensions, or verify by weighing. Never assume a load is within capacity — confirm it. If the load weight is close to or exceeds the available capacity, stop and reassess rather than proceeding at risk.
Tip 2: Choose the Correct Rigging Hitch for Your Load
A rigging hitch is the method of attaching the sling to the load. The three basic hitch types are the vertical hitch (a single leg sling in a straight pull), the choker hitch (where the sling encircles the load and passes through its own eye), and the basket hitch (where the sling cradles the load with both ends attached overhead). Each has different effective capacities and different applications. Using the wrong hitch type for the load can result in the load slipping, rotating, or falling during the lift.
Tip 3: Understand How Sling Angles Affect Tension
One of the most important but frequently overlooked facts in rigging is the effect of sling angle on tension. As the angle between the sling and the vertical decreases (i.e., as the sling becomes more horizontal), the tension in the sling increases dramatically for the same load weight. At 60° from vertical, sling tension is approximately 200% of the load weight per leg — meaning a 2-tonne load creates 4 tonnes of tension in each sling leg. Always calculate sling tension based on the actual rigging angle, not just the total load weight.
Tip 4: Choose the Right Sling for Your Load
Different sling types suit different applications. Synthetic web slings are gentle on sensitive surfaces and lightweight. Synthetic round slings offer high strength-to-weight ratios and conform to irregular shapes. Wire rope slings are the workhorse of heavy industrial rigging — strong, abrasion-resistant, and available in a wide range of capacities. Alloy steel chain slings are suitable for high-temperature environments and rough or abrasive loads where synthetic materials would be damaged. Match the sling type to the load characteristics and site conditions.
Tip 5: Inspect All Rigging Equipment Before Every Use
Rigging equipment must be inspected before each use for damage, wear, and deterioration. Wire ropes show broken wires and kinks. Web slings show cuts and UV degradation. Shackles show loose pins and corrosion. Chain slings show stretch and cracked links. Any equipment that shows damage must be removed from service immediately. Do not use equipment that lacks a current load test certificate — it may be uncertified for a reason.
Tip 6: Protect Rigging Equipment from Damage During Use
Sharp edges on loads cut through slings — particularly synthetic web slings — with alarming speed. Always protect slings from sharp edges using edge protectors, corner pads, or softeners. Avoid dragging slings across abrasive surfaces. Keep slings away from heat sources and acids. Protect wire rope slings from crushing loads. The cost of properly protecting equipment is always less than the cost of replacing a condemned sling or managing a dropped load.
Tip 7: Know and Respect Equipment Capacity Limits
Never exceed the rated capacity of any rigging equipment or crane. Never assume that a small overload is acceptable — the safe working load already incorporates a safety factor, and exceeding it removes that factor entirely. If a lift is at or near capacity, source equipment or a crane with greater capacity rather than proceeding at the limit.
Tip 8: Clear the Area and Establish Exclusion Zones
Keep all non-essential personnel out of the area beneath and around the suspended load and the crane’s operating radius. Dropped objects and crane tip-overs do not give warning — by the time someone realises there is a problem, it is already too late to take avoiding action. Exclusion zones must be maintained throughout the operation, not just during the initial lift.
Tip 9: Use One Banksman and Standardised Signals
One person — the banksman — gives all signals to the crane operator. Standardised hand signals or agreed radio commands are used. The crane operator responds only to those signals. If signals become unclear or ambiguous, the operator stops and holds until communication is re-established. Multiple people giving competing signals is a recipe for disaster.
Tip 10: Never Stand Under a Suspended Load
This is the most fundamental rule in rigging — and one that is still violated regularly on industrial sites across South Africa. No personnel should stand under a suspended load at any time, for any reason. The banksman guides the load from a position beside it, not beneath it. Ground personnel stay clear of the load’s travel path. There are no exceptions.
Reef Rigging applies these safety principles on every project. Learn about our health and safety approach or contact the team for professional rigging services across South Africa.
Frequently Asked Questions: Safe Rigging Practices
What is the most important safety rule in rigging?
Never stand under a suspended load — this is the most fundamental rule in rigging and cannot be overstated. Beyond this, the most important overall principle is to plan every lift before you execute it. Rigging incidents are almost always traceable to inadequate planning, use of uncertified or damaged equipment, or poor communication between team members. Addressing all three through systematic planning, equipment management, and clear communication protocols eliminates the vast majority of rigging hazards.
What happens if you exceed a sling’s safe working load?
Exceeding a sling’s safe working load removes the safety factor that the rating is designed to provide. The sling may not fail immediately, but it has been subjected to loads it was not designed to carry, potentially damaging its fibres or wire strands in ways that are not immediately visible. A sling that has been overloaded must be condemned and destroyed — it cannot be returned to service. In a worst case, overloading causes immediate catastrophic failure, resulting in a dropped load.
What is a choker hitch and when should it be used?
A choker hitch is formed by passing the sling around the load and through its own eye (or a choker ring), then hooking the running end to the crane hook. The sling cinches tight around the load when tension is applied. Choker hitches are used when the load has no suitable lift points and needs to be gripped by the sling. The capacity of a sling in a choker hitch is lower than in a vertical hitch — typically 75% of the vertical hitch capacity — because of the additional stress imposed at the choker point. Always apply the correct capacity derating when using a choker hitch configuration.