Equipment failure is something that no crew wants to encounter, especially when it can be prevented. 90% of crane accidents are caused by human error, leading to roughly 42 fatalities every year. In most cases, the warning signs were there before the incident. They were just missed.
Knowing how to spot these early warning signs is one of the most effective ways to reduce risk, avoid downtime, and help prevent injury and death on the job site. For safety managers, maintenance teams, and field crews, this practical, everyday awareness keeps people safe and projects moving forward.
Key Takeaways:
- Lifting and rigging failures are often the result of wear and tear on equipment. Some of this wear and tear can be prevented.
- Knowing the signs of damage to look for in equipment is essential to keeping operations safe and running smoothly.
- Improper use, environmental exposure, and storage can all affect how long gear lasts.
- When in doubt, it’s always better to take a piece of equipment out of service than to risk using it.
Common Causes of Lifting and Rigging Failures
Most causes of rigging failure are predictable. They come from the same handful of issues seen across jobsites every day. These are a few of the common ones:
- Overloading equipment beyond its Working Load Limit (WLL)
- Using the wrong type of gear for the lift
- Wear and tear from repeated use without proper inspection
- Environmental damage (corrosion, extreme temperatures, moisture)
- Improper storage or handling
Signs of Wear and Damage to Look For
A good lifting equipment inspection isn’t complicated, but it does require consistency. Quick visual checks before use and more detailed inspections at regular intervals are critical. Most early warning signs are easy to spot if you know what you’re looking for and take the time to check. Here are some of the most common indicators:
Wire rope: Look for broken wires, “birdcaging,” kinks, crushed sections, corrosion, rust buildup, flat spots, and uneven wear. These are classic signs of damaged wire rope, and they often show up well before a failure occurs.
Chain slings: Look for stretching, elongated links, cracks, nicks, gouges, bent and/or twisted links, and excessive wear at contact points.
Synthetic slings: For synthetic web slings, it’s important to check all the components of the material. Look for fraying or cuts in the fibers, burn marks, melted area, discoloration from chemical exposure, and stuff or brittle texture.
Hardware (hooks, shackles, fittings): Look for bent hooks or widened throats, worn pins or threads, cracks at stress points, and missing or illegible identification tags.
Factors That Accelerate Failure
Even high-quality equipment can fail early on if it’s exposed to the wrong conditions or used incorrectly. Here are some of the most common factors that lead to premature equipment failure.
Improper Usage
If you’re using gear for purposes other than what it was designed for, it won’t perform the way you expect. This is one of the fastest ways to shorten its lifespan. Some examples of this include shock loading, side loading hooks, using undersized or mismatched components, and ignoring load angles and tension changes.
Environmental Exposure
Weather and jobsite conditions matter more than many crews realize. Cold temperatures can make materials brittle. Heat can weaken synthetic fibers. Moisture can lead to corrosion. And chemicals can degrade both metal and synthetic materials. This is why it’s important to keep equipment protected from the elements.
Storage and Handling
Storage and handling also play a role in how long equipment lasts. Gear thrown in a gang box or exposed to the elements between uses will wear out faster. Proper storage goes a long way in preventing unnecessary damage.
Repairable vs. Unsafe Gear
Not all damaged gear needs to be scrapped, but how can you tell when it’s time to retire a piece of gear for good? Some issues are able to be fixed with proper lifting equipment repair, including:
- Replacing worn fittings
- Re-terminating wire rope assemblies
- Proof testing after repair
But other conditions mean it’s time for the gear to be officially retired, such as:
- Cracked or broken metal components
- Severely worn or deformed links
- Significant wire rope damage
- Missing identification or load rating tags
When in doubt, it’s always better to remove equipment from service. A questionable piece of rigging is never worth the risk.
Why You Shouldn’t Ignore “Minor” Signs
Small issues don’t stay small for long. What looks minor during a rushed pre-use check can quickly escalate into a serious incident. Ignoring early warning signs is one of the most common contributors to rigging-related accidents.
This is where Toolbox Talks can help make a difference. Regular, brief safety conversations help crews stay sharp, reinforce what to look for, and create accountability on the jobsite. When everyone knows the warning signs, problems can get caught earlier.
Is It Time for an Inspection?
If you’re seeing any of these warning signs, or if it’s been a while since your last inspection, it’s time for a closer look. Professional lifting equipment inspection goes beyond quick visual checks. It requires trained eyes, proper testing, and clear documentation to help you stay compliant and confident in your gear.
At Olsen Chain & Cable, inspections are built around real-world use, not simply checklists. By identifying problems early and recommending the right lifting equipment repair when possible, we can help you avoid costly failures. Schedule an inspection with Olsen Chain & Cable today.
Statistic source: https://www.oshaoutreachcourses.com/blog/crane-safety-statistics/
