Hovair Systems

Understanding Rigging Equipment: A Guide for New Operators

When was the last time you watched a skyscraper under construction? The seamless lift and placement of enormous steel beams seem almost magical, but in reality, they rely on skilled operators and the precise use of rigging equipment. Rigging is the backbone of nearly every large-scale construction, heavy manufacturing, and shipping project. Without the right lifting and rigging equipment—and knowledge of how to use it effectively—projects can come to a halt, or worse, result in costly accidents and injuries.

Rigging involves more than just hooking up a load to a crane; it requires a keen understanding of the equipment, procedures, and, most importantly, the safety protocols that keep every lift controlled and secure.

For new operators, learning the different types of rigging equipment and understanding best practices for handling heavy machinery lifting equipment is essential. Even seasoned professionals recognize that the complexity of rigging demands continual education and focus on safety. That’s why investing in high-quality rigging equipment, like those provided by material handling experts, is critical.

Hovair Systems provides high-quality material handling equipment designed to enhance safety, efficiency, and precision in every rigging operation.

In this guide, we’ll cover the essentials of rigging equipment, from understanding the various types and their uses to mastering the safety protocols that protect both operators and equipment. We’ll also look at best practices in lifting and handling large loads to ensure smooth and safe operations.

1. What is Rigging Equipment?

Rigging equipment includes the tools and machinery necessary to lift, move, and secure heavy loads. From industrial lifting straps to shackles, slings, and hoists, rigging equipment is designed to hold, lift, and move items weighing thousands of pounds. The equipment needs to be reliable, strong, and often specifically rated to handle high-capacity loads.

For new operators, understanding each piece of rigging equipment—and how they work together to create a stable, secure lifting environment—is essential for safe handling. In many cases, operators work with equipment such as cranes, air-bearing pallets, and heavy-duty industrial turntables. Each tool serves a unique function and must be used according to industry standards and regulations.

2. Types of Rigging Equipment and Their Uses

a. Slings

Slings are flexible lifting devices made from chains, wires, or synthetic fibers. They are used to secure loads to cranes or hoists, making them one of the most common tools in material handling equipment.

  • Wire Rope Slings: Known for their strength and durability, wire rope slings are typically used for heavy-duty applications, especially when a load has rough or sharp edges.
  • Chain Slings: Made from metal chains, these slings are ideal for heavy-duty loads and are often used in industrial settings where loads might have sharp edges.
  • Synthetic Slings: Made from materials like polyester or nylon, synthetic slings are lighter than metal options and are used for more delicate or smooth-edged loads to prevent surface damage.

b. Shackles and Hooks

Shackles and hooks are essential connectors in any rigging setup. They provide the attachment point between slings, chains, and the load.

  • Shackles: These metal U-shaped devices have a removable pin and are used to connect slings to other lifting equipment.
  • Hooks: Available in various styles, including eye hooks, clevis hooks, and swivel hooks, hooks enable operators to securely attach loads to rigging systems. Safety latches on hooks help prevent accidental detachment of the load.

c. Hoists

Hoists are mechanical devices used to lift and lower heavy loads. They come in several types, each suited to different applications.

  • Chain Hoists: These use a chain to lift and are available in both manual and electric models. They’re commonly used for moving heavy machineryin confined spaces.
  • Wire Rope Hoists: These are often chosen for heavier loads and are typically used in industrial settings where larger loads must be lifted frequently.

d. Air Bearings and Pallets

Air bearings are specialized material handling equipment that use compressed air to lift and move heavy loads with minimal friction. They are ideal for operators who need to transport massive loads across floors without using cranes.

e. Spreaders and Lifting Beams

Used to support the weight of long, horizontal loads, spreaders and lifting beams distribute the load’s weight across multiple points, reducing the risk of bending or other types of damage.

3. Key Safety Practices in Rigging Operations

Essential rigging equipment for heavy lifting operations

Every rigging operation comes with inherent risks, and that’s why strict adherence to safety standards is non-negotiable. Rigging accidents are often preventable if operators follow best practices and use equipment appropriately.

a. Conduct Thorough Pre-Use Inspections

Inspecting rigging equipment before every use is one of the simplest yet most effective safety measures. Look for wear and tear, damaged parts, or signs of corrosion. Check the working load limit (WLL) on slings, shackles, and hooks to ensure they match the load requirements.

b. Follow Load Capacity Guidelines

Overloading rigging equipment is a primary cause of accidents in material handling. Ensure the combined weight of the load, lifting attachments, and rigging setup does not exceed the WLL of the rigging components. Remember, using equipment beyond its rated capacity compromises both the safety and lifespan of the tools.

c. Balance Loads Correctly

An unbalanced load can cause the entire rigging system to fail, leading to dangerous situations. The load’s center of gravity should align with the crane’s lifting point, and spreader bars or lifting beams should be used as needed to distribute the load evenly.

d. Secure Loose Parts

Loose parts or poorly secured attachments can result in the load slipping during a lift. Ensure that every component, including shackles and hooks, is fastened securely. Double-check safety latches on hooks to confirm they’re locked in place.

e. Use Proper Lifting Techniques

Maintaining proper lifting angles and using lifting techniques suited to the load type are essential. When lifting with slings, ensure the angle between the sling legs and the horizontal load doesn’t exceed 60 degrees. Higher angles place additional stress on the slings and can lead to failure.

f. Ensure Clear Communication

Effective communication among team members is vital during rigging operations. Hand signals, two-way radios, and standard industry commands help keep everyone on the same page, minimizing the chances of miscommunication.

4. Handling Heavy Machinery and Large Loads Safely

Handling heavy machinery lifting equipment isn’t just about having the right tools; it’s also about implementing effective procedures that protect the load, the equipment, and everyone involved.

a. Understand the Load Characteristics

Every load behaves differently based on its shape, weight distribution, and composition. Analyzing the load beforehand helps operators plan the lift, including the best points for attaching rigging equipment.

b. Prepare the Load Site

A clean, stable area is essential when working with large loads. The lift site should be free of obstacles and any hazards that could interfere with the lift. Clear signage and barriers should be in place to keep unauthorized personnel out of the rigging zone.

c. Follow Rigging Best Practices for Heavy Loads

Handling exceptionally heavy or unusually shaped loads requires careful planning and sometimes additional rigging techniques to ensure stability and safety.

For starters, double-wrapping slings—which involves looping a sling twice around the load—can provide better grip and reduce the risk of slippage. This technique is especially useful for awkwardly shaped or slippery surfaces where a single wrap might not hold securely.

Employing multiple anchor points is another effective practice. By attaching the load to two or more secure points, the weight is distributed more evenly across the rigging system, lowering the stress on any single attachment point and minimizing the risk of failure. This approach is crucial for loads with uneven weight distribution, which can otherwise shift unexpectedly during lifting.

In some scenarios, air pallets or air bearings offer an alternative to traditional hoists, providing added stability and ease of movement. These devices create a thin film of air that lifts the load slightly off the ground, allowing it to be moved with minimal friction.

This is ideal for extremely heavy, fragile, or sensitive equipment that could be damaged or destabilized by a standard lift. By floating the load on air, air pallets and bearings ensure a smoother, more controlled movement with reduced risk of tipping or impact.

5. Common Mistakes New Operators Make—and How to Avoid Them

Starting out in the rigging field can be challenging, especially with a steep learning curve. New operators often make mistakes that could have serious consequences, so let’s examine some common pitfalls and how to avoid them.

  • Rushing Through Inspections: Skipping or rushing equipment checks is a recipe for disaster. Take the time to inspect each piece of rigging equipment
  • Ignoring Load Limits: Pushing equipment past its WLL can cause catastrophic failures. Always respect weight limits, and verify them as part of your preparation.
  • Neglecting Load Balancing: Unbalanced loads create unstable lifting conditions. Always double-check load positioning to align with the equipment’s lifting point.
  • Overlooking Safety Gear: Wearing the proper personal protective equipment (PPE) is essential, including gloves, helmets, and eye protection, to protect from rigging-related injuries.

6. Training and Certification for Safe Rigging Operations

Top safety practices for rigging operations
Image Caption: The seamless lift and placement of enormous steel beams se

Proper training is a non-negotiable aspect of operating rigging equipment safely. Most employers require certification from accredited training providers, and additional on-the-job training is recommended.

a. Certification Programs

Certification programs help new operators understand industry standards, safety protocols, and how to handle material handling equipment confidently. Many certification courses cover topics such as load calculation, proper use of rigging hardware, and inspection procedures.

b. Continuous Education

Rigging practices and equipment evolve, and operators need to stay updated. Periodic refresher courses help experienced operators stay sharp and informed about the latest safety protocols.

Need Rigging Equipment? Here’s Why You Should Choose Us

Ready to get serious about safety and efficiency in your rigging operations? Choosing reliable, high-quality rigging equipment is critical for smooth, successful lifts, and it’s exactly what we offer at Hovair Systems. Our products are designed to withstand the demands of heavy lifting, with durable materials and innovative features that make your job easier and safer. When you browse our selection, you’ll find everything from ergonomic lift tables to heavy-duty air pallets that let you move even the largest loads smoothly.

Whether you’re just starting in the field or are a seasoned pro, using the right rigging equipment makes all the difference. Contact us today to learn more about how our equipment can support your rigging needs with precision and reliability.

Are You Ready to Lift Like a Pro?

What would it feel like to operate with confidence, knowing you have the best rigging equipment and the know-how to handle any load safely? Rigging is a serious responsibility, and choosing the right tools can help you meet that responsibility with success. At Hovair Systems, we understand the demands of heavy machinery lifting, and we’re here to provide equipment that ensures safety, efficiency, and peace of mind.

Browse our full range of rigging and material handling equipment, and let us help you make every lift a safe one.

Scroll to Top