Rigging requires precision. Yet in high-pressure environments, it’s easy for shortcuts, assumptions, or overlooked checks to create hazards. According to Safe Work Australia, rigging-related accidents are often linked to improper load securing, inadequate training, or poor equipment maintenance.
It’s all about moving heavy loads safely and efficiently. But when rigging is done incorrectly, whether due to poor training, rushed work, or simple human error, the consequences can be devastating. We’re talking damaged equipment, costly delays, serious injury, and in the worst-case scenarios, fatalities. The consequences can range from property damage to severe injury, making prevention essential.
Whether you’re a rigger, crane operator, site supervisor or business owner, it’s vital to understand where things often go wrong. Let’s take a look at some of the most common rigging mistakes that lead to accidents, and how to avoid them.
One of the most frequent and dangerous mistakes in rigging is selecting the wrong gear. That includes slings, shackles, hooks, chains, and lifting attachments that aren’t rated for the specific load being lifted.
Common Issues:
Consequences:
How to Fix it: Always check the Working Load Limit (WLL) and ensure all components are compatible. Gear should be inspected for wear and certified for use. Never “guess” or take shortcuts when selecting rigging equipment.
Rigging gear wears out over time. Chains stretch, slings fray, hooks bend. One of the biggest mistakes workers make is skipping pre-use inspections or brushing off damage as “she’ll be right”.
What often gets missed:
Why it’s Dangerous: Damaged or worn rigging can fail without warning, especially under dynamic load conditions.
What to Do: Inspect every piece of rigging before each use. Keep a log of rigging inspections and remove damaged gear from service straight away. The cost of a replacement sling is nothing compared to the cost of a serious incident.
It’s not just what you lift, but how you lift it that counts. A common oversight in rigging is failing to account for the sling angle, the angle between the sling and the horizontal plane.
What goes wrong:
When the angle is too low, the tension on the sling increases significantly, which can exceed the WLL even if the load itself isn’t that heavy.
Best Practice:
Use sling angle charts or lifting calculators to determine the correct setup. Keep sling angles as close to vertical as possible and ensure equal load sharing.
Poor communication on site is a major factor in many rigging incidents, particularly during crane lifts or complex manoeuvres.
Problems include:
In busy or noisy worksites, assumptions and unclear instructions can lead to confusion, and confusion leads to mistakes.
How to Fix it: Use standardised hand signals and/or two-way radios. Have a clear lift plan in place, and make sure everyone involved understands their role before the lift starts.
While many people can “have a go” at tying down a load or attaching a sling, proper rigging requires formal training and certification.
Where this often goes wrong:
In Australia, high risk work licences are required for doggers and riggers, and for good reason. Unqualified workers are far more likely to make dangerous errors.
Solution: Ensure all workers involved in rigging tasks hold the relevant licences and are competent in the specific equipment being used. Invest in ongoing training and refresher courses to keep skills sharp.
This one should be common sense, but it’s still one of the biggest safety breaches seen on-site: lifting loads over people or allowing workers to operate under suspended loads.
Why it’s Dangerous: If the rigging fails, there’s nowhere to run. The risk of serious injury or death is extremely high.
Eliminate this risk by:
In outdoor or exposed sites, like high-rise construction, marine works, or mining, environmental conditions play a huge role in rigging safety.
Risks Include:
Tip:
Monitor wind speeds and weather forecasts. Pause lifts in unsafe conditions. It’s better to delay than to take a risk that could cause major harm.
Rigging accidents are rarely caused by one factor, they’re usually the result of preventable mistakes. By respecting load limits, inspecting equipment, and prioritising training, worksites can dramatically reduce risks. Contact us today for reliable steel products and rigging consultation service that meet safety standards and support safer projects.
How often should rigging equipment be inspected?
Inspect before every use and conduct scheduled inspections to comply with Australian safety standards and manufacturer guidance.
Can weather affect rigging safety?
Yes. Wind, rain, or unstable ground can make loads unstable and hazardous. Suspend work when conditions compromise safety.
Do all riggers need formal training?
Yes. Formal training and appropriate licensing are required for most rigging tasks under Australian law.
What should I do if the rigging gear is damaged?
Remove it from service immediately. Do not repair on site. Tag the item, report it, and have it inspected or replaced by a competent person.
How can companies reduce rigging-related accidents?
Provide accredited training, perform routine equipment inspections, plan lifts, maintain clear communication, and enforce strict compliance with safety regulations.
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