What Are the Rigging Devices Used to Move Loads: A Comprehensive Guide

Moving heavy loads safely and efficiently is a critical operation across various industries, from construction and manufacturing to shipping and warehousing. Rigging devices serve as the essential tools that make these operations possible. This comprehensive guide explores the various types of rigging equipment, their applications, selection criteria, safety considerations, and best practices to ensure successful load movement operations.

Understanding Rigging Systems and Their Importance

Rigging refers to the specialized equipment and techniques used to lift, lower, and move heavy loads. A properly designed rigging system ensures that loads are moved safely, preventing accidents, equipment damage, and productivity losses. The importance of using appropriate rigging devices cannot be overstated, as improper rigging is one of the leading causes of workplace accidents in material handling operations.

Modern rigging systems combine traditional mechanical advantage principles with advanced materials and safety features. These systems have evolved significantly over the centuries, from simple rope and pulley arrangements to sophisticated mechanical and hydraulic systems that can move loads weighing hundreds of tons with precision.

Key Components of a Rigging System

A complete rigging system typically consists of:

1. Attachment points - where the rigging connects to the load

2. Lifting devices - equipment that provides the lifting force

3. Connecting hardware - components that link various parts of the system

4. Control mechanisms - devices that manage movement and positioning

Each component must be properly selected, inspected, and used according to manufacturer specifications and industry standards to ensure safe operations.

The Three Main Types of Rigging Systems

When discussing rigging equipment, industry professionals typically categorize them into three main types based on their primary function and design:

1. Lifting Rigging

Lifting rigging systems are designed primarily to move loads vertically. These systems include:

• Chain hoists

• Wire rope hoists

• Lever hoists

• Hydraulic jacks

• Cranes and crane accessories

These systems are essential in construction, manufacturing, and warehouse operations where materials need to be elevated to different levels.

2. Horizontal Movement Rigging

These systems facilitate the horizontal movement of loads across floors or other surfaces:

• Skates and rollers

• Trolley systems

• Chain and lever pullers

• Come-alongs

• Winches for horizontal pulling

Horizontal movement rigging is particularly valuable in machine installation, factory relocations, and situations where overhead lifting isn't possible.

3. Positioning Rigging

Positioning rigging systems provide precise control for final placement of loads:

• Turnbuckles

• Chain falls with positioning capabilities

• Rigging screws

• Hydraulic positioning systems

• Specialized alignment tools

These systems are critical in applications requiring exact positioning, such as aligning machinery, installing structural components, or placing delicate equipment.

Understanding which type of rigging system best suits your needs is the first step in selecting the appropriate equipment for your load-moving operations.

Essential Rigging Equipment List and Applications

The following comprehensive rigging equipment list covers the most commonly used devices across industries. Each item has specific applications and considerations for proper use.

Slings: The Versatile Lifting Interface

Slings serve as the flexible connection between the load and the lifting device. They come in several materials, each with unique properties:

Wire Rope Slings

• Applications: Ideal for loads with sharp edges or high temperatures

• Advantages: Excellent strength-to-diameter ratio, abrasion resistance

• Limitations: Can damage delicate loads, susceptible to fatigue failure

Chain Slings

• Applications: Heavy-duty industrial lifting, hot materials handling

• Advantages: Superior durability, heat resistance, easily adjustable

• Limitations: Heavier than alternatives, more expensive

Synthetic Slings

• Types: Nylon, polyester, and specialty materials

• Applications: Delicate loads, finished products, irregularly shaped items

• Advantages: Won't damage finished surfaces, lightweight, conform to load shapes

• Limitations: Vulnerable to cuts, chemicals, and high temperatures

TOP LIFT offers a comprehensive range of slings, including high-quality wire rope slings with certified fittings, Grade 80 and Grade 100 alloy chain slings with superior strength-to-weight ratios, and synthetic slings engineered for specific applications.

Shackles: The Critical Connection Points

Shackles are the crucial connecting links in rigging systems. They join various rigging components securely and safely. The main types include:

Bow Shackles (U-shaped)

• Applications: Multiple attachment points, angular loading

• Features: Wider clearance for multiple connections

D-Shackles (Straight sided)

• Applications: Direct in-line loading applications

• Features: Higher strength-to-size ratio than bow shackles

Screw Pin Shackles

• Features: Pin secured by threading into the shackle eye

• Applications: Temporary connections, frequent reconfigurations

Safety Bolt Shackles

• Features: Bolt with cotter pin or safety wire

• Applications: Critical lifts, permanent installations, overhead lifting

TOP LIFT's shackle collection includes US Type drop forged shackles available in various sizes and finishes, including hot-dipped galvanized and self-colored options, all manufactured to meet stringent safety standards.

Hooks: Load Attachment and Release

Hooks provide a quick way to connect and disconnect loads. Modern hooks incorporate safety features to prevent accidental load release:

Eye Hooks

• Features: Designed to attach to wire rope or chain

• Applications: General purpose lifting applications

Swivel Hooks

• Features: Rotating capability prevents rope twisting

• Applications: Dynamic loads or those requiring positioning during lift

Self-Locking Hooks

• Features: Safety latch or mechanism that prevents accidental opening

• Applications: Overhead lifting, personnel lifting systems, critical loads

Grab Hooks

• Features: Designed to shorten or adjust chain length

• Applications: Chain tensioning, load securement

TOP LIFT's hook offerings include G80 and G100 safety hooks with latch mechanisms, swivel hooks with sealed bearing systems for smooth operation, and specialized hooks for specific industrial applications.

Eye Bolts and Hoist Rings: Load Attachment Points

Eye bolts and hoist rings provide secure attachment points on the load itself:

Regular Eye Bolts

• Applications: Straight vertical pulls only

• Limitations: Significantly reduced capacity when loaded at an angle

Shoulder Eye Bolts

• Features: Shoulder design prevents bending

• Applications: Angular loading conditions

Swivel Hoist Rings

• Features: 360° rotation and 180° pivot

• Applications: Loads requiring positioning during lift, angular loading

Dynamo Eye Bolts

• Features: Machinery mounting with lifting capability

• Applications: Equipment installation and relocation

When selecting eye bolts or hoist rings, it's critical to consider the loading direction and ensure the attachment point can safely handle the applied forces from all potential angles.

Lifting Blocks and Pulleys: Mechanical Advantage

Lifting blocks and pulleys create mechanical advantage, allowing smaller forces to move heavier loads:

Snatch Blocks

• Features: Side-opening design for mid-rope installation

• Applications: Redirecting pulling forces, creating mechanical advantage

Multiple Sheave Blocks

• Features: Several pulleys in a single housing

• Applications: Creating significant mechanical advantage for heavy loads

Traveling Blocks

• Features: Moving block assembly in a tackle system

• Applications: Crane systems, heavy industrial lifting

TOP LIFT's snatch block collection includes models capable of handling loads up to 60 tons, with features like sealed bearings, high-strength alloy steel construction, and safety latches on hooks.

Turnbuckles and Rigging Screws: Fine Adjustment

Turnbuckles and rigging screws allow for precise tensioning and adjustment in rigging setups:

Jaw-Jaw Turnbuckles

• Features: Clevis fittings on both ends

• Applications: Applications requiring pin connections at both ends

Eye-Eye Turnbuckles

• Features: Eye fittings on both ends

• Applications: Wire rope systems, general tensioning

Hook-Eye Turnbuckles

• Features: Hook on one end, eye on the other

• Applications: Quick connection to existing attachment points

Stub-End Turnbuckles

• Features: Threaded ends without fittings

• Applications: Custom installations, specialized connections

TOP LIFT provides Korean standard cable turnbuckles in galvanized finishes with eye-and-eye configurations, designed for optimal tension adjustment in various rigging applications.

Rigging Chain: The Backbone of Heavy Lifting

Rigging chain differs significantly from standard hardware store chain. Properly rated alloy rigging chain features:

Grade 80 Chain

• Features: 800 MPa minimum tensile strength

• Applications: General industrial lifting, load securement

Grade 100 Chain

• Features: 1000 MPa minimum tensile strength

• Applications: When higher strength-to-weight ratio is needed

Grade 120 Chain

• Features: 1200 MPa minimum tensile strength

• Applications: Specialized lifting requiring maximum strength

TOP LIFT offers both G80 and G100 alloy steel chains in various sizes, with corresponding fittings and attachments to create complete chain sling assemblies tailored to specific lifting requirements.

How to Select the Right Rigging Equipment for Your Application

Choosing appropriate rigging equipment requires careful consideration of multiple factors to ensure safety and efficiency:

Load Characteristics Assessment

Before selecting any rigging equipment, thoroughly evaluate:

1. Weight and dimensions - Exact weight and center of gravity location

2. Material composition - Fragility, surface finish requirements

3. Temperature - Hot materials require special consideration

4. Special handling requirements - Hazardous materials, delicate equipment

   
   

Environmental Factors

Consider the environment where the rigging will be used:

• Indoor vs. outdoor - Weather exposure considerations

• Corrosive environments - Chemical exposure, salt water

• Temperature extremes - Both hot and cold affect equipment ratings

• Space constraints - Headroom and clearance limitations

  
  

Safety Factor Determination

All rigging equipment has a Working Load Limit (WLL) or Safe Working Load (SWL) that includes a safety factor:

• Industry standard safety factors typically range from 4:1 to 10:1

• Critical lifts may require higher safety factors

• Never exceed the working load limit of any component

  
  

Compatibility Verification

Ensure all components in your rigging system are compatible:

• Material compatibility - Avoid galvanic corrosion between dissimilar metals

• Size compatibility - Ensure proper fit between connecting components

• Rating compatibility - All components should have appropriate ratings for the load

  
  

Rigging Equipment Inspection and Maintenance

Regular inspection and proper maintenance are essential for safe rigging operations:

Inspection Schedule

Equipment Type	Pre-Use Inspection	Periodic Inspection	Detailed Inspection
Slings	Visual check before each use	Monthly documentation	Annual certification
Shackles	Visual check before each use	Quarterly documentation	Annual testing
Hooks	Check latch and throat opening	Monthly documentation	Annual NDT testing
Blocks & Pulleys	Check free movement	Quarterly lubrication	Annual disassembly
Chains	Check for elongation	Quarterly measurement	Annual certification

Key Inspection Points

For each type of equipment, focus on these critical areas:

Wire Rope Slings:

• Broken wires

• Kinks or bird-caging

• Crushing or flattening

• Corrosion or heat damage

Chain Slings:

• Elongation beyond 3%

• Bent, twisted, or gouged links

• Excessive wear at bearing points

• Cracks or heat damage

Synthetic Slings:

• Cuts, tears, or punctures

• Chemical damage or burns

• Broken stitching

• Excessive abrasion

Shackles and Hooks:

• Deformation or cracks

• Thread damage

• Excessive wear

• Proper safety latch function

  
  

Safety Standards and Regulations for Rigging Equipment

Rigging operations are governed by various international and regional standards:

Key International Standards

• ASME B30.9 - Safety Standard for Slings

• ASME B30.10 - Safety Standard for Hooks

• ASME B30.26 - Rigging Hardware

• ISO 4309 - Wire ropes inspection and discard criteria

• EN 13414 - Steel wire rope slings safety

Regional Regulations

• OSHA 1910.184 (US) - Slings

• OSHA 1926.251 (US) - Rigging equipment for construction

• Machinery Directive 2006/42/EC (EU)

• Work at Height Regulations 2005 (UK)

Training and Certification Requirements

• Qualified rigger certification

• Periodic refresher training

• Equipment-specific training

• Documentation of training

TOP LIFT ensures all its rigging products meet or exceed these international standards, with proper certification documentation available for all safety-critical equipment.

Advanced Rigging Techniques and Configurations

Beyond basic rigging setups, several advanced techniques can enhance safety and efficiency:

Multiple-Leg Sling Arrangements

When using multiple-leg slings, consider:

• Angle factors - As angle from vertical increases, capacity decreases

• Equal load distribution - Ensure all legs share the load evenly

• Appropriate hardware - Use proper master links and connecting hardware

  
  

Tandem Lifting Operations

When two or more lifting devices work together:

• Synchronized movement - Coordinated control systems

• Communication protocols - Clear signals between operators

• Load distribution planning - Engineered lift plans

Load Control Strategies

For precise positioning:

• Tag lines - Non-load bearing ropes for guidance

• Spotters - Dedicated personnel monitoring clearances

• Drift control devices - Mechanical or hydraulic positioning systems

Innovations in Modern Rigging Equipment

The rigging industry continues to evolve with new technologies enhancing safety and efficiency:

Smart Rigging Technologies

• Load monitoring systems - Real-time weight and force feedback

• RFID tracking - Automated inspection and inventory management

• Wireless sensors - Strain and environmental condition monitoring

Advanced Materials

• High-performance synthetic fibers - Stronger than steel with less weight

• Composite components - Corrosion resistance and weight reduction

• Specialty coatings - Improved wear and environmental protection

Ergonomic Improvements

• Lightweight components - Reducing manual handling injuries

• Quick-connect systems - Faster rigging with less physical strain

• Power-assisted tools - Reducing force required for tensioning and adjustment

TOP LIFT stays at the forefront of these innovations, incorporating new technologies and materials into their product offerings while maintaining commitment to proven safety principles.

FAQs About Rigging Devices and Equipment

Q1: What is the difference between Working Load Limit (WLL) and Breaking Strength?

A1: Working Load Limit (WLL) is the maximum load that a piece of rigging equipment is designed to support in general service conditions. It includes a built-in safety factor. Breaking Strength (or Minimum Breaking Force) is the force at which the equipment will physically fail. The safety factor is the ratio between Breaking Strength and WLL. For example, if a sling has a Breaking Strength of 40,000 pounds and a safety factor of 5:1, its WLL would be 8,000 pounds. Never exceed the WLL of any rigging component, as this compromises the safety margin designed into the equipment.

Q2: How do I determine the correct sling angle factor for my lift?

A2: When slings are used at an angle, their effective capacity decreases. To determine the sling angle factor, divide the height (H) of the rigging by the length (L) of the sling leg, then find this ratio in a sling angle chart. Alternatively, you can use the formula: Sling Angle Factor = sine of the angle from horizontal. For example, at a 60° angle from horizontal, the factor is 0.866, meaning a sling rated for 1,000 pounds in straight vertical lift can only support 866 pounds at this angle. TOP LIFT provides comprehensive rigging charts and can assist in calculating the correct specifications for angular lifting operations.

Q3: When should I retire a synthetic sling from service?

A3: Synthetic slings should be removed from service when any of these conditions are present:

• Visible damage to the load-bearing fibers (cuts, tears, or punctures)

• Heat or chemical damage (melted fibers, discoloration, stiffness)

• Damaged or illegible identification tag

• Excessive abrasion (worn or fuzzy surface affecting more than 10% of the width)

• Broken or damaged stitching in load-bearing seams

• Knots in any part of the sling

• Distortion, excessive wear, or damage to end fittings

• Any condition causing doubt about the sling's strength

Regular inspection by qualified personnel is essential for determining when a sling should be retired.

Q4: What are the advantages of using Grade 100 chain over Grade 80 chain?

A4: Grade 100 alloy chain offers several advantages over Grade 80 chain:

• Approximately 25% higher working load limit for the same chain size

• Reduced weight for the same lifting capacity, making handling easier

• Often includes enhanced identification features

• Generally improved wear resistance and durability

• Compatible with specially designed G100 fittings and components

However, Grade 100 chain typically costs more than Grade 80 chain. TOP LIFT offers both G80 and G100 chain systems, allowing customers to select the appropriate grade based on their specific application requirements and budget considerations.

Q5: How do I properly store rigging equipment when not in use?

A5: Proper storage of rigging equipment extends its service life and maintains safety:

• Store in a clean, dry area away from direct sunlight, chemicals, and extreme temperatures

• Hang slings on properly designed racks to prevent kinking, crushing, or damage

• Keep chain and wire rope lightly lubricated to prevent corrosion

• Store shackles, hooks, and other hardware in organized containers to prevent damage

• Never drop equipment from heights onto hard surfaces

• Keep synthetic slings away from heat sources and UV exposure

• Ensure all equipment is clean and dry before storage

• Maintain inventory systems to track inspection dates and certification status

Following these storage practices helps maintain the integrity of your rigging equipment between uses.

Q6: What special considerations apply when lifting irregularly shaped loads?

A6: Lifting irregularly shaped loads requires careful planning:

• Accurately determine the center of gravity before attempting the lift

• Select multiple attachment points to stabilize the load

• Consider using spreader beams or lifting frames for better load distribution

• Use padding at contact points to prevent damage to both the load and slings

• Apply sling protection where slings contact sharp edges

• Consider the potential for load shifting during the lift

• Use tag lines for additional control

• Lift initially just off the ground to verify stability before proceeding with the full lift

TOP LIFT can assist in designing custom rigging solutions for challenging or irregular loads, ensuring both safety and efficiency in these complex lifting operations.

Q7: What documentation should I maintain for my rigging equipment?

A7: Proper documentation for rigging equipment should include:

• Original manufacturer's certificates with unique identification numbers

• Periodic inspection records with dates, results, and inspector identification

• Any repair or alteration documentation

• Load test certificates where applicable

• Employee training records for equipment usage

• Equipment rejection and removal from service records

• Maintenance logs

• Proof of compliance with relevant regulations and standards

Good documentation practices not only ensure regulatory compliance but also help track equipment history and predict replacement needs. TOP LIFT provides comprehensive documentation with all of their rigging products, including certificates of conformity, test reports, and user manuals.

Conclusion

Selecting and using the right rigging devices for moving loads is a critical process that directly impacts workplace safety and operational efficiency. By understanding the various types of rigging equipment available, their proper applications, and the safety considerations that govern their use, organizations can develop effective load-handling protocols that minimize risks while maximizing productivity.

Remember that rigging is both a science and an art—it requires technical knowledge of equipment capabilities and limitations combined with practical experience in applying these tools to real-world situations. Investing in quality rigging equipment from reputable manufacturers like TOP LIFT, providing proper training for personnel, and maintaining rigorous inspection and maintenance protocols are essential components of a successful rigging program.

As rigging technology continues to evolve, staying informed about new innovations and best practices will help ensure that your load-moving operations remain at the forefront of safety and efficiency. By making safety the primary consideration in all rigging operations, you protect not only your personnel but also your equipment, facilities, and the valuable loads being moved.