Common Rigging Mistakes and How to Avoid Them | Advantage Rigging

Posted by Advantage Rigging on 20th Oct 2025

Common Rigging Mistakes and How to Avoid Them | Advantage Rigging

If your rigging isn’t right, nothing else matters. Bad habits on the job site turn into bent hooks, damaged loads, and worst-case scenarios. The good news? Most rigging mistakes are predictable—and preventable. Here’s a straight-shooting guide to the errors we see most often and how to fix them before they cost you time, gear, and safety.

Quick Takeaways (for your toolbox)

  • Know your Working Load Limit (WLL) and never guess.

  • Choose the right sling for the load, hitch, and angle.

  • Protect slings from sharp edges, heat, and pinch points.

  • Tag it, inspect it, and retire it when it’s done.

  • Communicate: one qualified signal person, clear plan, no surprises.

1) Ignoring the Working Load Limit (WLL)

The mistake: Lifting based on “what we did last time” instead of what the tag says. Overloading risks sling failure, distorted hooks, and dropped loads.

How to avoid it

  • Read the tag. WLL is not a suggestion—it’s the maximum load under ideal conditions.

  • Factor in hitch type (vertical, choker, basket) and sling angle (more on that below).

  • Remember: Attachments have limits, too. Hooks, shackles, and master links each have their own WLL. The system is only as strong as its weakest link.

Pro move: Keep a laminated WLL chart in the gang box. If the tag is missing or unreadable, take that sling out of service.

2) Bad Sling Angle Math (or no math at all)

The mistake: Rigging a basket or two-leg hitch at “whatever looks right” and forgetting that sling angle reduces capacity. A 60° angle is not the same as 30°—and the load penalty is real.

How to avoid it

  • Use an angle or load-factor chart. Lower angles (flatter slings) increase tension on each leg.

  • When in doubt, increase the angle (make slings more vertical), add a third or fourth leg, or bump up sling size/grade.

  • Make sure the load is level. Uneven leg lengths shift weight and spike tension on a single leg.

Rule of thumb: Tension on each sling leg = (Load ÷ Number of Legs) × Load Factor for the angle.

3) Wrong Sling for the Job

The mistake: Using web slings near sharp steel, chain slings in a corrosive chemical wash, or wire rope slings on delicate, finished surfaces. The tool might pick the load—but you’ll pay for it in sling life, rework, or both.

How to avoid it

  • Chain slings (Grade 80/100/120): Best for rugged, high-temp, or shock-load environments. Easy to inspect and repair.

  • Wire rope slings: Great for abrasion and heat; moderate flexibility; good all-purpose choice.

  • Synthetic web slings: Lightweight, non-marring, but need edge protection.

  • Round slings: High capacity for their weight; excellent on finished surfaces; also edge-protection required.

Match the sling to:

  • Load weight and geometry

  • Hitch method (vertical/choker/basket)

  • Surface condition (sharp edges? finished paint?)

  • Environment (heat, chemicals, moisture, UV)

4) Skipping Edge Protection

The mistake: Throwing slings over plate steel, I-beams, or sharp tank edges without protection. One cut and the lift is compromised.

How to avoid it

  • Use corner protectors, sleeves, softeners, or DICA-style edge guards on every sharp contact point.

  • Move from bearing contact to rolling/contact-spreader where possible (use shackles, softeners, or lifting points to re-route sling paths).

  • Inspect sleeves and guards just like slings. If they’re crushed, cut, or glazed from heat, replace them.

5) Choker Hitches Done Wrong

The mistake: Choking too tight on a fragile load, or too loose on a smooth, round surface so the sling slips.

How to avoid it

  • For chokers, reduce WLL according to the manufacturer’s chart.

  • Use double-wrap chokers on smooth, round loads to prevent slipping.

  • Where possible, use engineered lifting points (swivel hoist rings, pad eyes) instead of choking the load body.

6) Lifting Off Unknown or Weak Attachment Points

The mistake: Hooking to thin sheet, small eye bolts, or unknown weldments. If the anchor fails, the system fails.

How to avoid it

  • Use rated lifting points sized for the load and direction of pull.

  • If you must use temporary attachment, have a qualified person design and verify the pad eye or rigging lug.

  • Check thread engagement on eye bolts (1× diameter minimum for full capacity in steel).

  • Avoid side-loading standard eye bolts; use shoulder eye bolts or swivel hoist rings designed for angular loads.

7) Misusing Hooks, Latches, and Shackles

The mistake: Side-loading hooks, running slings in the wrong spot of a shackle, or removing safety latches because they’re “in the way.”

How to avoid it

  • Hooks: Load should sit in the bowl/pocket, not on the tip or latch. Avoid side loads; use a clevis or master link to align the pull.

  • Latches: Keep them in place and functional; latches aren’t load-bearing, but they prevent unhooking.

  • Shackles: Put the pin through the hardware and the sling in the bow when you can. If two slings must share a shackle, they go in the bow—never stack hardware on the pin. Torque pins to spec.

8) Poor Load Control and Tagline Use

The mistake: Letting the load spin or sail in the wind because “we’ll catch it when it comes down.” That’s how hands get where they shouldn’t.

How to avoid it

  • Use taglines to control rotation and swing—especially on long or flat loads.

  • Plan pick points for balance. Pre-lift a few inches to confirm level before going up.

  • Keep hands off pinch points; use push/pull tools where needed.

9) Neglecting Inspections and Records

The mistake: Using “the green sling” because it’s nearby, even though it’s glazed or cut. No tag, no paperwork, no idea when it was last checked.

How to avoid it

  • Pre-use checks every lift: tags legible, no cuts, kinks, broken wires, crushed links, distortion, or heat damage.

  • Frequent and periodic inspections by a qualified person, documented.

  • Retire criteria:

    • Chain: 10% wear, stretched links, bent/deformed components, or failed latch = remove from service.

    • Wire rope: Broken wires per lay, birdcaging, kinks, crushed sections, or severe corrosion.

    • Synthetic: Cuts, snags, holes, abrasion, chemical damage, melted/glazed fibers, UV brittleness, illegible tags.

If a sling fails inspection, tag it out and scrap it. No “one more lift.”

10) Heat, Chemicals, and the Environment

The mistake: Treating every job like room temperature and dry. Heat weakens synthetics; some chemicals attack nylon and polyester; cold can make hardware brittle.

How to avoid it

  • Check temperature ratings for slings, hooks, and chain grades.

  • Choose polyester over nylon around certain chemicals and hydrocarbons; use chain for high-heat.

  • Keep weld spatter off slings; use protection blankets or relocate the sling path.

11) No Lift Plan, No Signal Plan

The mistake: “We’ll figure it out at the crane.” That’s when confusion creeps in—multiple people giving signals, riggers guessing at weight, and nobody watching the blind side.

How to avoid it

  • Write a simple lift plan: load weight, center of gravity (estimated is better than ignored), sling selection, hitch, angles, pick points, travel path, and set-down area.

  • Assign one qualified signal person. Everyone else zips it unless there’s a stop signal.

  • Do a dry run: choke up, lift a few inches, assess level and balance, then proceed.

12) Treating Training as “One and Done”

The mistake: New hires get a quick overview, then it’s back to work forever. Standards evolve. Crews change. Bad habits spread.

How to avoid it

  • Provide initial and refresher training for riggers, signal persons, and lift directors.

  • Use tailgate talks to review one topic a week (angles, chokers, edge protection, inspection, etc.).

  • Keep quick-reference guides in the job box and a QR code that links to your rigging charts.

Field Checklist: 10 Questions Before You Pick

  1. What’s the load weight and center of gravity?

  2. Which hitch are we using—and why?

  3. What’s our smallest sling angle? (Check the load factor.)

  4. Are slings/hardware rated for this pick? (WLL ≥ required load.)

  5. Any sharp edges or pinch points? (Edge protection in place.)

  6. Are tags legible and gear inspected?

  7. Are we using the right attachment points?

  8. Do we have taglines and a path clear of obstructions?

  9. Who is the signal person? (Everyone else knows the plan.)

  10. What’s the set-down strategy?

Print it. Use it. Make it habit.

When to Upgrade Your Gear

If you’re fighting the same problems—nicked web slings, under-sized chain, spinning loads—your gear might not match your work.

Consider:

  • Grade 100 or 120 chain slings for higher capacity with smaller, lighter legs.

  • Adjustable chain slings with grab hooks for faster leg length equalization.

  • Synthetic round slings with built-in wear indicators for quick inspection.

  • Swivel hoist rings to eliminate side-loading of eye bolts.

  • Purpose-built edge protection to extend sling life.

Need help choosing? That’s what we do.

Final Word

Rigging isn’t about being lucky—it’s about being disciplined. Use the right gear, at the right angles, on the right attachment points, with the right plan. Do that consistently and your lifts get safer, faster, and cheaper.

Shop Trusted Rigging Gear

  • Chain Slings: Built to order, inspected, and assembled in America.

  • Hooks & Shackles: Industry-trusted brands with clear WLL markings.

  • Synthetic & Wire Rope Slings: From light duty to heavy picks.

  • Edge Protection & Accessories: Protect your investment—and your crew.

Browse compliant rigging gear at advantagerigging.com

480-502-2225 | info@advantagerigging.com
1482 W Scott Ave Suite 101, Gilbert, AZ 85233

Note: Always follow current OSHA/ASME requirements and your site’s written procedures. If a tag is missing or a condition is questionable, remove the gear from service and consult a qualified person.