Whether you’re relocating heavy machinery, installing industrial equipment, or managing a factory move, rigging safety is crucial for project success. At Reef Rigging, we’ve seen how simple oversights can lead to costly delays, equipment damage, and serious injuries. Here are the most common rigging mistakes we encounter and practical ways to prevent them.
1. Underestimating Load Weight and Centre of Gravity
The Problem
In factory relocations and machine moving, one of the most dangerous mistakes is guessing equipment weight or ignoring the centre of gravity. A seemingly stable CNC machine or industrial compressor can become hazardous if its weight distribution isn’t properly assessed.
The Solution
- Always verify manufacturer specifications before lifting
- Calculate the actual centre of gravity, especially for asymmetrical machinery
- Add rigging hardware weight to your calculations
- When in doubt, use a higher capacity crane than initially planned.
2. Using Damaged or Wrong Slings
The Problem
Whether lifting a milk tank for a dairy installation or moving steel beams for construction, using worn slings or incorrect configurations can lead to catastrophic failure. We often see slings stretched beyond safe angles or damaged slings still in use due to time pressure.
The Solution
- Inspect all slings before each use – remove any with cuts, burns, or excessive wear
- Never exceed a 60-degree angle from horizontal
- Match sling capacity to load weight with proper safety factors
- Keep different sling types separate and clearly labelled.
3. Ignoring Site and Weather Conditions
The Problem
South African weather can change rapidly, especially during summer thunderstorms. Wind loading on large industrial equipment or steel structures becomes dangerous quickly. Poor ground conditions at construction sites can also compromise crane stability.
The Solution
- Check weather forecasts and establish clear wind limits for operations
- Assess ground conditions thoroughly – use crane mats where necessary
- Plan for seasonal weather patterns, particularly afternoon storms on the Highveld
- Have contingency plans ready for weather delays.
4. Poor Communication between Team Members
The Problem
During complex operations like boiler installations or production line moves, miscommunication between crane operators, riggers, and spotters causes accidents. Hand signals get confused, radio batteries die, or multiple people give conflicting instructions.
The Solution
- Designate one signal person per operation
- Use standardised hand signals that everyone understands
- Conduct pre-lift briefings with the entire team
- Test radios before starting and keep spare batteries ready
- Never assume – always confirm instructions are understood.
5. Exceeding Crane Capacity
The Problem
Pressure to complete factory relocations quickly or work with available equipment can lead to overloading. This is especially risky when working at extended boom lengths or ignoring deductions for rigging hardware.
The Solution
- Study load charts carefully – capacity changes with boom angle and extension
- Account for all deductions including block weight and rigging
- Never exceed 85% of rated capacity for standard lifts
- Consider dynamic forces from sudden stops or starts
- If approaching limits, get a larger crane.
6. Rushing or Skipping Equipment Inspections
The Problem
In industries like food and dairy where production schedules are tight, there’s temptation to skip thorough inspections. This allows damaged shackles, worn hooks, or faulty safety latches to go unnoticed until failure occurs.
The Solution
- Implement mandatory daily visual inspections
- Schedule detailed periodic inspections per manufacturer requirements
- Tag and immediately remove any defective equipment
- Keep inspection records updated and accessible
- Foster a culture where anyone can stop work for safety concerns.
7. Inadequate Load Control
The Problem
Uncontrolled loads during lifting are particularly dangerous in confined spaces like compressor rooms or when installing tall equipment like silos. Without proper taglines or guide ropes, loads can swing unexpectedly.
The Solution
- Always use taglines for load control, especially in confined spaces
- Plan load paths to avoid obstacles and personnel
- Control lifting speeds to minimise swing
- Never allow workers under suspended loads
- Position tagline handlers safely away from crush zones.
Real-World Application
These aren’t just theoretical concerns. When Reef Rigging replaced equipment in Clover’s constrained compressor room, proper planning for confined space rigging prevented accidents despite challenging conditions. Similarly, our work dismantling 190-tonne Krupp cranes at 80-metre heights required meticulous attention to weather conditions and load control.
Creating a Safety Culture
Preventing rigging mistakes requires more than rules – it needs commitment from everyone involved:
- Training: Ensure all riggers have proper certification and regular refreshers
- Planning: Develop detailed lift plans for complex operations
- Communication: Hold daily safety briefings before work begins
- Documentation: Keep comprehensive records of inspections and incidents
- Empowerment: Anyone should feel able to stop unsafe work.
Safe rigging isn’t about working slowly – it’s about working smart. By recognising these common mistakes and implementing proper procedures, you can complete projects efficiently whilst protecting your team and equipment.
At Reef Rigging, we’ve successfully completed projects ranging from dairy plant installations to factory relocations by putting safety first. Every lift, whether it’s a routine machinery move or complex steel erection, deserves the same attention to safety fundamentals.
Remember: there’s always time to do it safely, because the cost of an accident far exceeds any deadline pressure.
Need experienced Rigging Professionals for your next Project?
Contact Reef Rigging for crane hire, machine moving, and complete rigging solutions across South Africa. We’re fully accredited by the Specialised Carriers and Rigging Association, ensuring your project meets the highest safety standards.