Qingdao Haosail Machinery Co., Ltd.

In the "lifeline" of lifting and hoisting operations, rigging plays an irreplaceable role. It is the core hub connecting heavy objects and equipment, and a crucial barrier protecting personnel safety and project progress. However, according to a report from the State Administration for Market Regulation, improper operation or use of rigging was one of the main causes of crane machinery accidents from 2018 to 2020. From material handling in workshops to the construction of mega-projects, the selection, use, and maintenance of rigging cannot tolerate any negligence. This article will combine real-world cases and industry standards to outline the core points of rigging safety.

I. Understanding the Rigging Family: "Exclusive Partners" for Different Scenarios

Ribing is not a collective term for a single product, but rather a "large family" encompassing multiple categories such as wire rope slings, synthetic fiber slings, and lifting chains. Different rigging types have significant performance differences; accurately matching them to the specific scenario is the first step to safe operation.

1. Wire Ropes: The "Core Support" of Heavy Industry

As the most widely used type of rigging, wire ropes, with their high strength and impact resistance, are the first choice for heavy industrial applications such as metallurgy, shipbuilding, and bridge construction. During the construction of the Three Gorges Dam, a rigging company developed a cable crane system using high-strength special wire ropes, successfully achieving high-precision hoisting of a 320-ton steel box girder. However, its shortcomings are also obvious: it is prone to rusting in humid, coastal, and corrosive environments, requiring regular application of rust inhibitors; when in contact with sharp objects, the surface wires are easily scratched and broken, requiring the use of corner protectors or padding.

2. Synthetic Fiber Slings: The "Flexible Guardian" for Light-Load Operations

Compared to metal rigging, synthetic fiber slings offer advantages such as light weight, portability, and corrosion resistance, making them highly favored in scenarios requiring high surface protection for workpieces, such as food processing and electronic equipment manufacturing. In humid seafood processing workshops or chemical storage areas with acidic or alkaline media, synthetic fiber slings can effectively prevent the corrosion problems associated with metal rigging. However, it is particularly important to note that these types of rigging have poor heat resistance and are prone to softening and failure when the operating environment temperature exceeds 80℃. Their use in high-temperature environments such as welding operations is absolutely prohibited.

3. Lifting Chains and Magnetic Lifting Devices: "Customized Solutions" for Special Needs

Lifting chains are forged from alloy steel, exhibiting outstanding wear resistance and high-temperature resistance, making them suitable for long-term lifting of heavy machinery components. Magnetic lifting devices (divided into electromagnetic chucks and permanent magnet chucks) are widely used for transporting magnetic materials such as steel and wire coils due to their "non-contact gripping" advantage. However, the safety hazards of permanent magnet lifting devices require high vigilance. Data from a magnetic testing center shows that the safety performance qualification rate of permanent magnet lifting devices sampled from 2013 to 2018 was only 4.7%, with nearly one-fifth having a measured suction force less than half of the rated value.

II. Fatal Hidden Dangers: Overlooked Misconceptions in Rigging Use

Most accidents caused by rigging are not due to product quality issues, but rather stem from a sense of complacency during operation. The following three typical misconceptions must be constantly guarded against.

1. Deliberate Removal of Safety Devices: Trading Life for "Efficiency"

The anti-disengagement device on a crane hook is the last line of defense against falling heavy objects, but some workers remove it for convenience. In June 2021, a tragedy occurred in a company's galvanizing workshop because of this: the crane hook was not fully engaged with the lifting ring, and the lifting device detached during transport, striking the operator. According to the "Rules for Periodic Inspection of Lifting Machinery," hooks with malfunctioning anti-disengagement devices are considered substandard products and are absolutely prohibited from use.

2. Hidden Overloading: Overestimated Load Capacity

The rated load of rigging is the safety red line, but in actual operations, "makeshift" use is common. Some companies reuse wire ropes from scrapped cranes after splicing them together, while others forcibly lift when the magnetic lifting device is not in sufficient contact with the workpiece—the wire coil falling accident at a wire factory in July 2018 was caused by a gap between the magnetic lifting device and the protruding part of the wire coil, resulting in insufficient suction. It is important to clarify that the load-bearing capacity of rigging decreases with wear and corrosion; seemingly "perfect" rigging may harbor hidden dangers.

3. Neglecting Routine Inspections: Small Defects Lead to Major Accidents

Wear, deformation, and other defects in rigging need to be detected promptly through regular inspections. National standards have clear quantitative requirements for the amount of wear and deformation of hooks; for example, the wear on the dangerous section of a forged hook must not exceed 10% of its original size. However, in practice, many companies skip routine inspections, only stopping use of rigging when obvious cracks appear, undoubtedly creating hidden dangers for accidents.

III. Scientific Management: Making Rigging Safety "Controllable and Traceable"

Only by managing the entire lifecycle of rigging can safety risks be fundamentally avoided. Based on industry practice, it is recommended to establish standards from three dimensions: selection, use, and maintenance.

1. Three Selection Principles: Full Matching of Load, Environment, and Workpiece

- Load Priority: Select rigging with a rated load capacity based on the weight of the object, and allow for a safety margin of at least 20%. Overloading is strictly prohibited.

- Suitable Environment: Select lifting chains for high-temperature environments, synthetic fiber slings for corrosive environments, and special steel wire ropes for high-altitude and large-span operations.

- Workpiece Fit: Use padding for workpieces with sharp edges and corners, select anti-slip rigging for workpieces with smooth surfaces, and customize special lifting equipment for irregularly shaped workpieces.

2. Four Operational Steps: Inspection, Standardization, Monitoring, and Storage

1). Before Lifting: Visually inspect the rigging for wear, cracks, and deformation. Magnetic lifting rigs must be tested for suction power; any defects must be immediately removed from use.

2). During Lifting: Adjust the rigging angle to ensure even force distribution, avoiding one-sided stress. Oblique pulling and lifting are strictly prohibited. 

3). During Operation: Observe the rigging status in real time through the monitoring system. Stop operation immediately if wind speed exceeds limits or load is abnormal.

4). After Storage: Rigging must be cleaned and dried before storage. Avoid contact with sharp objects and corrosive media. Wire rope rigging should be neatly coiled to prevent knots.

3. Long-Term Mechanism: Establishing a "Ribing Identity File"

Each set of rigging is numbered and registered, recording factory information, usage scenario, inspection records, and scrapping time, achieving full lifecycle traceability. Especially in large-scale projects, such as the cable system customized by Juling Rigging for the Three Gorges Bridge, real-time monitoring of rigging operation data through a digital management platform provides precise assurance for safe operations. Safety Reminder: Rigging is a consumable item and there is no such thing as "lifetime use." When the number of broken wires in wire rope rigging reaches the specified standard, synthetic fiber slings are damaged, or hooks are permanently deformed, they must be scrapped immediately and must not be repaired and reused.

From small-scale hoisting in workshops to mega-projects spanning canyons, the safety of rigging is always the bottom line in engineering construction. Whether it's company management or frontline operators, everyone should keep the scientific selection and standardized use of rigging firmly in mind. Only in this way can this "lifeline" truly safeguard safety and support development. If you have any questions about rigging selection for specific scenarios, please contact us; we will provide you with customized solutions.