Rigging work demands unwavering precision. One misstep, whether in calculation, configuration, or communication, can shift a load off balance, damage critical assets, or jeopardize the safety of everyone on site. The distinction between a controlled lift and a serious incident often comes down to the most easily overlooked details.
Preparation, not luck, drives successful outcomes. Safe rigging starts with thorough planning, technical knowledge, and disciplined execution at every stage. Crews depend on clearly defined procedures and properly matched equipment to maintain control through every lift phase.
This guide presents seven foundational rules for safe and effective rigging. Each principle reflects widely recognized industry standards rooted in mechanical construction and man basket safety protocols.
Together, these practices establish a clear, practical framework for reducing risk, safeguarding personnel, and ensuring operational stability on the job site.
- Know the Load Weight
Every hoisting and rigging task begins with one fundamental question: What is the exact weight of the load? This number influences every decision, from equipment selection to load path planning. Proceeding without it introduces unnecessary risk.
In hoisting and rigging, approximation is never acceptable. Exceeding equipment capacity not only jeopardizes gear integrity but also creates instability, increases the likelihood of uncontrolled movement, and raises the potential for personnel injury. Even experienced teams occasionally rely on visual estimates or prior assumptions. Yet, these practices can prove dangerous under real-world conditions.
To determine weight accurately:
- For steel pipes, use the following formula:
Weight = π × Diameter × Length × Wall Thickness × Unit Weight
- For HVAC units, refer to official manufacturer specifications.
- For compressed gas cylinders, confirm whether the cylinders are full or empty and include the cage weight in total calculations.
No load should be lifted without confirmed weight data matched against the rated capacity of every rigging component. When documentation is unavailable, operations must be put on hold until proper figures can be verified. This simple verification step is a first line of defense against preventable failures.
- Select the Correct Hitch
The hitch serves as the critical connection between the sling and the load. Stability during lifting depends on this connection remaining secure under stress, angle, and movement. Misapplication often results in partial engagement, slippage, or shifting mid-lift — consequences that leave little opportunity for correction once the lift begins.
Each hitch configuration distributes weight differently:
- Vertical Hitch: Lifts directly upward; appropriate for balanced, single-point loads
- Choker Hitch: Encircles the load; effective for round or consistent shapes but insufficient for loosely stacked materials
- Basket Hitch: Offers balanced distribution; ideal for grouped or bundled items
A single choker used on a stacked pipe may secure only the lower portion of the load, leaving top sections vulnerable. In this case, a double-wrap basket hitch provides greater containment and reduces the likelihood of slippage.
Proper rigging practices start here. The correct hitch configuration ensures better control, improved safety, and a more stable lifting environment. Rigging teams must anticipate how the load will respond throughout the lift and choose hitches that accommodate that behavior.
- Account for Sling Angles and Tension
Load tension does not result from weight alone. Sling angles significantly influence force distribution, and failing to account for them can lead to dangerous overload conditions. It is a common misconception that two-leg slings evenly share a load under all circumstances. This only holds true when angles remain close to vertical.
As the angle between the sling and the horizontal decreases, the force applied to each sling leg increases sharply — straining the rig far beyond expected limits. The same applies to associated hardware. Hooks, eyebolts, and shackles experience reduced capacity when pulled off their vertical axis.
Examples of increased tension due to sling angle:
- 60°: ~15% additional force
- 45°: Up to 41% additional force
- 30°: Nearly double the load
Multi-leg slings add further complexity. While three-leg configurations typically balance well, four-leg slings often shift the load onto only two legs, with the remaining pair acting as stabilizers.
Overlooking these dynamics increases the risk of equipment overload, even when load weight remains within published limits. Proper rigging practices demand awareness of how tension builds, distributes, and shifts under varying angles and rigging geometry.
- Match the Sling to the Job
Sling selection should be based on more than capacity alone. Material composition, environmental exposure, load surface conditions, and lift geometry all factor into choosing the right type. An ill-suited sling may not fail immediately, but it may reduce control, cause damage, or degrade over time, compromising future reliability.
Each sling type brings unique considerations:
- Synthetic Web Slings: Lightweight and flexible; excellent for polished or fragile surfaces. Vulnerable to cutting, heat, and chemical damage.
- Synthetic Round Slings: Offer similar surface protection and flexibility. However, internal damage may go undetected.
- Wire Rope Slings: Provide rigidity and temperature resistance. Prone to wear at contact points, especially around sharp edges.
- Alloy Steel Chain Slings: Exceptionally durable and suitable for harsh environments. It can damage sensitive surfaces due to weight and stiffness.
Personnel lifts involving man baskets call for alloy steel chain slings marked with clear identification tags. Tags must always remain readable and list manufacturer details, rated capacity, and sling type. Any sling lacking this information or showing signs of wear, knots, or deformation must be taken out of service.
Sling choice directly impacts rigging safety. Selecting the correct sling ensures control, protects the load, and preserves equipment integrity over time.
- Inspect Hardware Before Every Use
Rigging hardware does not fail without warning. Signs of fatigue, corrosion, distortion, and wear often appear during inspection — provided that inspection occurs. Even high-quality components can degrade after repeated exposure to stress, temperature, and misuse.
A thorough inspection should evaluate:
- Hooks: Check for bent tips, deformed latches, throat wear, or visible cracks.
- Shackles: Ensure proper pin fit, intact threads, and absence of stretch or gouging.
- Eyebolts: Confirm shoulder seating and alignment. Avoid use for angular lifts unless specifically rated.
- Wire Rope Clips: Follow the correct orientation. Place the saddle on the live end of the rope to maintain grip.
Lifting and rigging procedures rely on hardware that functions without compromise. Each component must display clear manufacturer identification. If markings are missing or unreadable, the part is considered unserviceable.
This level of scrutiny is especially critical for man basket applications, where hardware integrity is directly linked to personnel safety. OSHA standards require that all rigging hardware used for suspended lifts pass inspection immediately before use to support overarching rigging safety standards.
- Guard Against Sharp Edges
Slings remain one of the most vulnerable elements in any rigging and lifting setup. Contact with unprotected sharp edges can lead to rapid deterioration or sudden failure, often without visible warning. The risk increases significantly under load as tension amplifies friction and pressure at the contact points.
Preventing damage requires proactive measures:
- Apply padding at all sling-to-load contact areas.
- Use commercial corner protectors to reduce direct pressure.
- Increase bend radius by blocking sharp bends, particularly with wire rope.
- Visually inspect edges and surfaces before attaching slings.
Synthetic slings are especially susceptible to tearing and fiber damage. Even mildly abrasive surfaces can cause long-term wear if left unaddressed.
One failure can end an otherwise routine lift. Edge protection takes minimal time to implement but plays a major role in maintaining the integrity of hoisting and rigging systems over time.
- Focus on the Final Moments
While thorough preparation sets the stage for a safe lift, execution ultimately determines the outcome. Many lifting and rigging failures occur during the lift itself as hidden flaws in configuration, communication, or environmental awareness surfaces.
A disciplined final check should include:
- Lifting the load several inches to confirm sling position and balance.
- Adjusting any misaligned or shifting rigging components.
- Attaching tag lines to control movement and prevent spin.
- Clearing all personnel from the lift zone.
- Verifying that all PPE requirements are met, including gloves, hard hats, and eye protection.
Equally important is the communication protocol. A single, designated signal person should direct the lift, and all crew members should be trained in consistent signals and procedures. Mixed commands or miscommunication significantly increase risk.
Personnel lifts introduce further safety obligations. OSHA requires a trial lift, visible identification tags, and the use of full-body harnesses tied to an independent anchorage point. No suspended platform should operate without full verification and documentation.
This final moment represents the culmination of all proper rigging practices and planning. Skipping one step in the process can negate the effectiveness of every safeguard in place.
Work Safer and More Securely With Lakeshore Industrial
Rigging and lifting operations demand a combination of precision, discipline, and the right tools. From selecting slings to executing man basket lifts, every decision affects safety. Effective results depend on the consistent execution of well-established lifting and rigging procedures.
Lakeshore Industrial supports teams that take rigging safety seriously. Our safety man baskets and rigging equipment meet the highest industry standards, are built for reliability, tested for strength, and designed for real-world conditions.
When the lift begins, trust the gear that’s engineered to perform. Request a quote today!