21 Jan 2026

SHACKLE SAFETY: AVOID COMMON MISTAKES IN LIFTING OPERATIONS

Shackles may be one of the smallest components in a lifting setup, but their impact on safety and performance is huge. Whether you’re hoisting beams on a construction site, transferring loads offshore, or rigging in a warehouse, the humble shackle is the critical link between your load and lifting equipment.

And yet, they’re often overlooked - misused, mismatched, or uninspected.

In this article, we’ll cover the most common mistakes people make when using shackles in lifting operations, how to avoid them, and what to look out for during inspections. Our goal is to help you build safer, more reliable lifting procedures and reduce avoidable risk.

🡺 If you're still new to shackle types, check out our article on Types of Shackles & Their Industrial Application s.
🡺 Need help selecting the right one? See our guide on How to Choose the Right Shackle for Lifting Operations.
🡺 Browse fully certified lifting shackles on our Shackles Collection Page.

1. Using the Wrong Type of Shackle

One of the most frequent errors is choosing the wrong shackle type for the job. Each shackle is designed for a specific use case, and misapplication can lead to instability or even failure.

Common examples:

Using D shackles (also known as dee shackles) where a bow shackle is required for multi-leg slings
Selecting a shackle that isn’t rated for side or angular loading
Using specialist shackles in the wrong environment (e.g. marine-grade in dry industrial spaces)

How to avoid it:

Understand the purpose of bow shackles, D shackles, and specialist shackles
Match the shackle shape and size to your sling configuration and load direction
Always refer to manufacturer load charts and application notes

🡺 Shop our certified Bow Shackles, D Shackles, and Specialist Shackles for every lifting need.

2. Mixing Components from Different Shackles

It might seem harmless to use a pin from one shackle and the body from another - especially if the thread fits - but this is a major safety risk.

Why it’s dangerous:

Pins and bodies are tested together and rated as a matched pair
Mixing brands or sizes can change the Working Load Limit (WLL) or cause thread misalignment
It voids any certification or compliance the original parts had

What to do instead:

Always use shackles as complete, matched units
Replace whole shackles—not just damaged pins
Store shackles in sets to prevent unintentional mix-ups

3. Ignoring Working Load Limits (WLL)

Every shackle is marked with a Working Load Limit, which indicates the maximum load it can safely handle. Exceeding this limit is one of the most serious mistakes in lifting.

Common causes:

Assuming a larger shackle = higher capacity without checking the marking
Using older or worn shackles without verifying load rating
Not considering load angle effects, which reduce actual capacity

How to fix it:

Read the WLL stamped on the shackle body before every use
Apply appropriate safety factors and derating for angled lifts
Train your team on how load angle affects lifting capacity

4. Using the Wrong Pin Type for the Application

Pin type matters. A screw pin, bolt pin, or safety pin can drastically change the safety of your setup.

Common mistakes:

Using screw pin shackles in vibrating environments where the pin can loosen
Choosing bolt-type pins for lifts that require frequent assembly/disassembly
Not securing cotter pins or split pins in long-term installations

The right approach:

Use screw pins for short-term or temporary lifts only
Use bolt-type or safety pins for long-term or vibration-prone environments
Inspect pins for thread wear, proper fit, and full engagement

🡺 Find the right configuration in our Bow Shackles and Specialist Shackles ranges.

5. Skipping Pre-Lift Inspections

Even with the correct shackle type, size, and pin, damage or wear can make it unsafe. Pre-lift inspections are essential - but often rushed or skipped.

Things to check:

Bent or deformed body
Damaged threads
Corrosion, pitting, or rust
Illegible markings
Loose pins or improper seating

Tip:

Build a daily or pre-lift shackle inspection checklist into your team’s routine. Encourage reporting of minor damage before it leads to failure.

🡺 Need a checklist? Download our free Shackle Safety Quick-Check.

6. Assuming All Shackles Are Compliant

Not all shackles on the market meet UK and international safety standards. Unmarked or counterfeit shackles are more common than many believe.

Key compliance features:

CE marking
Manufacturer logo
Working Load Limit (WLL) stamped clearly
Batch or traceability code

If your shackle has none of the above, it should not be used in any lifting operation.

7. Not Considering the Operating Environment

Shackles operate in all kinds of environments: offshore, indoors, high-humidity, chemical exposure - you name it. Material selection matters.

Mistakes to avoid:

Using standard galvanised shackles in corrosive or marine environments
Using stainless shackles in dry, low-risk settings where it adds unnecessary cost
Storing shackles outdoors without protective coatings

The better way:

Use stainless steel shackles in marine, chemical, or food-safe applications
Choose galvanised shackles for general construction and dry use
Match shackle material to site conditions for longer life and better performance

🡺 Explore our Specialist Shackles for marine, offshore, and corrosive environments.

Final Thoughts: Getting the Details Right

Shackles may be simple tools, but they carry heavy responsibility. Small mistakes - from mismatched pins to unmarked gear - can lead to major failures.

By understanding the most common errors and how to avoid them, you can improve lifting safety, reduce downtime, and protect your team.

Lifting Equipment Store is proud to support rigging professionals with quality products and practical advice. If you have any questions about shackle selection, safety, or certification -our team is here to help.