When it comes to lifting operations, every rigger understands that the load must move safely from point A to point B. But what often gets overlooked in the day-to-day hustle of a job site is the critical importance of using the correct lifting sling.
The consequences of using the wrong one aren’t just about delayed timelines—they can include catastrophic injuries, damaged goods, legal liabilities, and financial setbacks. Selecting the right sling isn’t just a best practice—it’s a lifeline.
In this article, we’re breaking down what every rigger absolutely must know to avoid dangerous mistakes and lift smarter every time.
The Different Types of Slings Explained
Before you can make the right choice, you need to understand what’s available. The three most common categories of lifting slings are wire rope slings, chain slings, and synthetic slings. Each type has its advantages, disadvantages, and specific use cases.
Wire rope slings are known for their durability and are often used in environments with sharp edges. Chain slings offer exceptional strength and flexibility, making them ideal for rugged industrial applications. Synthetic slings, including nylon and polyester varieties, are lightweight and excellent for lifting delicate or finished goods, but can fail easily if misused.
Load Weight Isn’t the Only Factor
Most riggers check the load weight first, and while that’s an important step, it’s far from the only one. You also have to consider load shape, center of gravity, lifting points, angle of lift, and environmental conditions. A sling that works perfectly in one setting may fail under different conditions, even if the load weight remains constant.
For example, using a nylon sling in a high-temperature environment could compromise its integrity, while chain slings exposed to harsh chemicals may corrode over time.
The Hidden Dangers of Sling Angle Miscalculations
One of the most misunderstood and overlooked variables in rigging is the angle of the sling during a lift. As the angle between the sling and the horizontal decreases, the force exerted on the sling increases dramatically. This phenomenon often catches inexperienced riggers off guard.
If you’re using a sling with a safe working load of 2,000 pounds, and your sling angle drops to 30 degrees, the effective load on each leg can rise to over 3,800 pounds. Without proper calculations, you’re setting the stage for a catastrophic sling failure, even if the load itself is under capacity.
Understanding Sling Tags and Their Critical Role
Sling tags are not optional—OSHA and other safety standards require them. These tags provide all the necessary information about the sling’s material, capacity, length, and certifications. If the tag is missing or illegible, that sling is considered unusable and unsafe.
Never assume or guess what a sling can handle. Always refer to the tag and the manufacturer’s specifications before using it. Riggers who skip this step are putting their crew’s safety at risk.
Common Signs a Sling Should Be Retired
Even if you’re using the right type of sling, all slings have a lifespan, and it’s your job to know when they’ve reached the end of theirs. For synthetic slings, signs of wear include fraying, melted fibers, discoloration, and cuts. Wire rope slings show their age through broken wires, kinks, rust, or crushed sections.
Chain slings may stretch, crack, or exhibit excessive wear on links. Ignoring these indicators doesn’t just increase risk—it puts lives at stake. A single overlooked defect can lead to the total failure of a sling during a lift.
Environmental Factors You Can’t Ignore
The environment in which you’re lifting plays a major role in determining the right sling. Exposure to UV rays, extreme temperatures, moisture, chemicals, and abrasion all affect sling performance. A polyester sling might perform well on a clean indoor floor but fail quickly in a hot and corrosive outdoor setting.
That’s why riggers must evaluate not only the load, but also the context, because even the best sling on paper may be completely inappropriate in the field.
Proper Storage Makes a Big Difference
Many riggers do everything right on the job, only to ruin their equipment with improper storage. Slings should be stored in a clean, dry, and well-ventilated area away from direct sunlight and chemicals.
Tossing a sling in the back of a truck bed or leaving it exposed to the elements reduces its lifespan and increases the likelihood of failure. Treat your lifting gear like the high-stakes tool it is, not a throwaway accessory.
Training Isn’t Optional—It’s Essential
Using the correct lifting sling requires knowledge that goes beyond a toolbox talk. Ongoing training for riggers, supervisors, and safety teams is essential. New technologies, changing regulations, and updated best practices mean yesterday’s knowledge can be dangerously outdated.
Investing in hands-on training, certification courses, and regular safety reviews ensures your team remains prepared and your job sites remain compliant.
Why Cutting Corners Always Costs More
There’s often pressure to meet tight deadlines and minimize costs, but taking shortcuts with your rigging equipment will always cost more in the long run. Using a damaged sling to save five minutes can result in destroyed equipment, workplace injuries, or even fatalities.
When you make smart, informed choices about your lifting slings, you don’t just protect your people—you protect your bottom line, your reputation, and your future projects.
Metal lifting slings have earned their reputation as a trusted solution for demanding lifting tasks across various industries. Their unmatched durability, strength, and resistance to extreme conditions make them a clear choice for professionals who prioritize safety and performance.
Unlike other options, metal slings deliver consistent results, even under the most demanding loads and in the most extreme environments. If you’re looking to equip your team with reliable lifting gear that won’t let you down, check out SlingSmarter for expertly designed metal slings built for the job.
Article and permission to publish here provided as Contributed Content. Originally written for Supply Chain Game Changer and published on July 10, 2025.
Cover image provided by pexels.com.