What Most People Get Wrong About Lifting Slings (And How to Fix It)

When it comes to industrial lifting, there’s one tool that plays a critical role in safety, efficiency, and load control—lifting slings. Despite being a staple in construction yards, shipyards, warehouses, and manufacturing facilities, lifting slings are frequently misunderstood or misused. This misunderstanding can lead to equipment damage, worker injuries, and even catastrophic failures. Knowing the right way to use and maintain lifting slings isn’t just a best practice—it’s essential. This article explores the common misconceptions about lifting slings and offers clear, practical solutions to help ensure their proper use.

Misidentifying the Right Sling for the Job

One of the most common errors is assuming all lifting slings are the same. In reality, lifting slings come in different materials—chain, wire rope, synthetic web, and round slings—each designed for specific tasks. A synthetic sling, for example, is excellent for lifting delicate or polished items because it won’t scratch the surface. However, that same sling can be destroyed in environments with sharp edges or high heat. Choosing the wrong sling can compromise the safety of the load and the people around it. The fix here is straightforward: always assess the environment, the weight of the load, and the material compatibility before choosing your sling.

Overlooking Load Capacity Ratings

Many users either ignore or misunderstand working load limits (WLL). Every sling has a designated capacity that must never be exceeded, and it varies depending on the sling angle, hitch type, and load configuration. When these limits are exceeded, the risk of sling failure increases significantly. Worse yet, using slings without knowing their ratings, especially old or untagged ones, can be like gambling with safety. The best way to avoid this mistake is to read and understand the manufacturer’s load rating tag and consult the relevant lifting charts. The sling should be immediately removed from service if the tag is missing or illegible.

Ignoring Sling Angle and Hitch Configuration

Another critical mistake is not noticing how the sling angle impacts load tension. As the angle decreases, the tension on each leg of the sling increases. A seemingly light load can become dangerously heavy at the sling attachment points if the angle is too tight. Similarly, improper hitching—like using a choker hitch on a load that’s not balanced or secure—can cause slippage and tilting, which puts both the load and personnel at risk. Proper training and real-world demonstrations of how angle and hitch types affect lifting are essential for avoiding this common misjudgment.

Misunderstanding Wear and Tear

Too many operators rely on visual inspection alone without knowing what signs indicate wear or damage. Small cuts, frays, burns, or corrosion may not seem like a big deal, but they can significantly compromise sling integrity. One common myth is that synthetic slings can still be used if only one layer is damaged. The reality is that even minor surface damage can compromise the entire structure. Wire ropes with broken strands or chain slings with stretched links also need immediate retirement. Establishing a rigorous inspection routine, both pre-use and scheduled, is critical. Keeping a log and using checklists ensures that nothing gets missed.

Storing Slings Improperly

Lifting slings are often tossed aside after use, hung on hooks, or dropped on the floor. This carelessness leads to premature degradation, especially for synthetic slings sensitive to UV rays, moisture, and chemicals. If exposed to corrosive substances or extreme temperatures, chain and wire rope slings can also suffer. Proper storage matters more than most operators realize. Slings should be kept in dry, cool, and clean environments, ideally hung properly or stored in protective containers away from sunlight and hazardous substances.

Neglecting Manufacturer Guidelines

There’s a tendency in many workplaces to rely on habit and experience rather than manufacturer-provided information. While experience counts, it should never replace documented guidelines. Each sling is built to specific tolerances, and ignoring instructions such as temperature limits, load angle adjustments, and repair rules can create dangerous conditions. Always refer back to the technical documentation, and ensure all team members are familiar with the equipment specifications.

Relying on Old or Uncertified Slings

Old slings that have been “getting the job done for years” may seem trustworthy. Still, their actual condition is unknown without recertification or inspection history. Using uncertified or homemade slings is also a serious liability. If a failure occurs and it’s traced back to non-compliant equipment, it could result in serious injury, lawsuits, and OSHA penalties. To correct this issue, companies must enforce strict equipment certification policies, ensure slings are sourced from trusted suppliers, and replace slings once they reach the end of their rated service life.

Skipping Training and Education

Training often focuses on rigging, hoisting, and signaling, but specific sling training is frequently overlooked. Workers may know how to connect a sling but lack understanding about angle factors, load balancing, or proper hitch selection. Without training, misuse becomes inevitable. Investing in proper certification programs, in-house refresher courses, and on-site demonstrations ensures everyone understands sling use and safety from a theoretical and practical perspective.

Misjudging Environmental Effects

Lifting slings don’t exist in a vacuum. Chemical exposure, extreme heat, freezing temperatures, and UV degradation affect sling performance. For example, using a polyester sling in a chemical-heavy environment can cause it to deteriorate much faster than anticipated. Similarly, high temperatures can reduce the tensile strength of chain slings. Users often don’t adjust sling selection based on environmental changes, leading to unexpected failures. The solution is to match the sling material to the specific environmental conditions and regularly reevaluate if the work environment changes.

Failing to Communicate During Lifts

A commonly overlooked issue is the lack of coordinated communication among riggers, crane operators, and spotters. Even with the right sling and perfect hitch, a miscommunication during the lift can result in disaster. In high-noise or fast-paced environments, losing track of who’s doing what is easy. Every lift should involve a clear communication plan, use of hand signals or radios, and assigned roles for each team member. This not only improves efficiency but drastically enhances safety.

Understanding the correct use and maintenance of Lifting Slings is essential for ensuring safety, preventing equipment failure, and maintaining efficient operations in any industrial setting. Most common mistakes stem from overlooked details or outdated habits that can be easily corrected through proper training, adherence to manufacturer guidelines, and regular inspection routines. By committing to these best practices, businesses not only protect their workforce but also extend the life of their equipment and reduce costly downtime. The key is staying proactive, informed, and consistently focused on safe lifting practices.