02 Oct 2025
RIGGING FAILURES THAT COULD HAVE BEEN PREVENTED: LESSONS FROM THE FIELD
WHEN LIFTING GOES WRONG: WHAT REAL FAILURES TEACH US ABOUT RIGGING SAFETY
In high-risk environments like construction, offshore energy, and industrial logistics, rigging failures are rarely caused by major equipment defects. More often than not, they're the result of small oversights: using the wrong type of shcakle, skipping inspection steps, or assuming compliance without verification.
In this article, we break down real-world examples of rigging incidents that could have been avoided with smarter decisions, better processes, and strogner leadership. If you're responsible for operational safety, this is your guide to understanding not just what when wrong - but what to do differently in the future.
🡺 If you're new to rigging hardware, we advise reading our Complete Guide to Lifting Shackles & Their Industrial Applications first
THE SCALE OF THE PROBLEM: RIGGING-RELATED ACCIDENTS IN THE UK
According the the UK Health and Safety Executive (HSE), over 22% of fatal injuries in construction are due to falls caused by lifting gear or loads shifting unexpectedly. In the past five years:
- An average of 6 lifting-related fatalities per year were recorded across UK industries.
- Dozens of incidents involved incorrect or uncertified lifting accessories, including shackles.
- Insurance claims from lifting-related failures have exceeded £12 million annually.
These aren't just numbers – they represent preventable events.
FAILURE CASE 1: WRONG PIN TYPES IN A HIGH-VIBRATION OFFSHORE LIFT
WHAT HAPPENED:
An offshore contractor was tasked with lifting a motor housing onto a drilling platform. The job used screw pin bow shackles, assuming the temporary lift wouldn’t require long-term rigging.
However, sea swell and platform motion introduced significant vibration. Over time, the screw pin began backing out. Mid-lift, the pin sheared completely, dropping the load and damaging critical infrastructure. Thankfully, no one was injured—but the downtime cost the project over £150,000.
WHAT WENT WRONG:
- Screw pin shackles are unsuitable for vibration-heavy environments.
- No secondary pin check was in place.
- The shackle was not tagged for inspection.
WHAT COULD HAVE PREVENTED IT:
- Using bolt-type or safety pin shackles, which resist loosening in motion.
- Pre-lift risk analysis focused on environmental dynamics.
- Sourcing from certified offshore-rated brands like Green Pin or William Hackett.
🡺 Learn more about and shop our extensive range of Bow Shackles
FAILURE CASE 2: NO CERTIFICATION ON HIRED SHACKLES IN A WAREHOUSE LIFT
WHAT HAPPENED:
A third-party contractor was lifting steel beams using gear supplied by a local plant hire firm. One of the D shackles failed under load, causing the beam to shift and damage nearby racking.
On investigation, the shackle had no visible WLL marking, no batch traceability, and no certification paperwork.
WHAT WENT WRONG:
- Equipment was accepted without a pre-use compliance check.
- Procurement had no policy on lifting accessory verification.
- The site team assumed all hired gear was compliant by default.
WHAT COULD HAVE PREVENTED IT:
- A formal inspection and verification process for all lifting shackles.
- Partnering only with suppliers offering batch-traced, CE-marked equipment.
- Training the site team to spot unmarked or mismatched shackle components.
🡺 Browse our fully certified Dee Shackles for safe, traceable lifting hardware
FAILURE CASE 3: MISJUDGED LOAD ANGLE IN A CONFINED SITE LIFT
WHAT HAPPENED:
On a city-centre commercial build, a contractor was using galvanised bow shackles in a multi-leg sling configuration to lift HVAC units into a rooftop enclosure. The load angle was tighter than expected due to spatial constraints.
The lift proceeded, but one shackle deformed under stress, forcing an emergency stop. Post-lift analysis showed that the shackle was rated for a straight pull, but not for the side-loading angle imposed by the sling configuration.
WHAT WENT WRONG:
- The lifting plan did not calculate the angle reduction in WLL.
- The wrong type of shackle was selected for a multi-leg sling.
- No competent person signed off on the revised lift geometry.
WHAT COULD HAVE PREVENTED IT:
- Using specialist shackles designed for angular loads or low-clearance rigs.
- Pre-lift planning with 3D lift modelling or virtual rigging software.
- Applying manufacturer WLL derating factors for angled loads.
🡺 Read our article on How to Choose the Right Shackle for Lifting Operations for sling-specific advice
🡺 View our collection of specialist lifting shackles, including high-load and confined space solutions
THE COMMON THREADS ACROSS FAILURES
Despite occurring in different industries, these rigging failures share common root causes:
| Common Mistake | Preventative Measure |
|---|---|
| Wrong shackle or pin type selected | Use load-specific and motion-rated equipment |
| Lack of traceability or paperwork | Require CE markings, batch codes, and certs |
| No inspection or verification | Embed daily pre-use checklists and visual cues |
| Misunderstood load angles | Train teams to calculate WLL reduction at angles |
| Procurement gaps | Source from certified suppliers like LES |
🡺 Explore our certified collections of Bow Shackles, D Shackles, & Specialist Shackles
BUILDING A PREVENTATIVE CULTURE AROUND LIFTING
True rigging excellence is not just about reacting to failures, but embedding preventative thinking at every level of your lifting operation:
- Procurement: Only purchase traceable, certified shackles from trusted brands.
- Operations: Match hardware to application conditions – environment, movement, angle.
- Supervision: Verify certification and WLL markings on every shackle before lift.
- Leadership: Model proactive safety practices and invest in advanced training.
🡺 Keep your eyes peeled for our upcoming article Building a Culture of Rigging Excellence: What Leaders Need to Know to learn how to create this mindset from the top down
FINAL WORD: THE FAILURES YOU DON'T SEE
For every high-profile rigging failure, there are dozens of near misses. The wrong pin type that almost came loose. The unmarked shackle that just held. The lift that succeeded, but shouldn’t have.
Rigging safety isn’t just about the catastrophic failures—it’s about tightening the margin for error until incidents become nearly impossible.
At LES - Lifting Equipment Store, we’re here to help you raise those standards. From guidance and training to certified lifting shackles, our team is always ready to support your journey toward safer, smarter lifting.
🡺 Browse our full Lifting Shackles collection today and make every lift a confident one
📥 Want to audit your lifting gear or simply discuss your shackle options? Contact our expert team for free advice
