Safety isn’t just a suggestion when you’re working on or near the water—it’s a daily requirement. Whether you’re lifting a barge component, adjusting a mooring system, or coordinating a heavy haul, the condition of your rigging equipment can make or break your operation. At Paducah Rigging, our team has inspected countless marine rigging setups, and we’ve seen some patterns emerge. Here’s a closer look at the most common safety violations we encounter during inspections—and how you can steer clear of them.
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Damaged Wire Rope
One of the most frequently identified issues is damaged wire rope. Over time, heavy use, corrosion, improper reeving, and environmental exposure can all contribute to worn-out strands, bird-caging, flattening, or kinking. Even a single frayed area can severely compromise the strength of the entire line.
Relying on compromised rope to lift or support heavy loads isn’t just inefficient—it’s dangerous. Always inspect your wire rope before each use, paying particular attention to rope near wire rope sheaves, where tension and friction are highest. If damage is found, take that line out of service immediately.
Pro Tip: Use sheaves that match your rope size and construction. Mismatched sheaves can accelerate rope wear and reduce your rope’s safe working life.
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Damaged or Missing Rigging Hardware
From hooks and shackles to swivels and master links, rigging hardware plays a vital role in ensuring secure connections. Unfortunately, it’s all too common to find gear that’s bent, cracked, corroded, or even completely missing during inspections.
Missing cotter pins or bent shackles might seem like minor issues, but they can result in sudden failures under load. Be sure your team performs visual inspections daily—and thoroughly checks each connection point before lifting operations begin.
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Improperly Maintained Rigging Equipment
Even rugged, marine-grade rigging gear isn’t immune to wear and tear. Equipment like plate clamps—used to safely lift and position steel plates or other heavy materials—must be maintained to perform properly. We often find clamps with worn teeth, damaged springs, or seized components.
Don’t assume a piece of hardware is good to go just because it worked yesterday. Plate clamps and other gear should be cleaned, lubricated, and inspected regularly for signs of fatigue or malfunction. Keeping maintenance logs can also help you track when gear is due for repair or replacement.
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Lifting Without Knowing the Load Weight
You wouldn’t pick up a barbell at the gym without knowing the weight—so why risk your crew and equipment by lifting unknown loads in the field?
Improper load estimation is a common cause of overloaded rigging gear, snapped slings, and structural stress. Always verify the load weight before lifting and match it to your equipment’s rated capacity. That includes the lifting points, the sling angle, and environmental factors like water resistance or wind.
Remember: It’s not just about the load—it’s about the load path. Plan your lifts carefully, especially in marine environments where uneven surfaces and swaying platforms add complexity.
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Inadequate Training in Rigging Safety
Even the most advanced rigging setup won’t help if the crew doesn’t know how to use it safely. One of the most overlooked violations is insufficient training—or worse, no training at all.
All workers involved in lifting and rigging should receive thorough instruction in load calculations, hardware inspection, signaling, and safe lifting techniques. They should also understand how to properly use components like wire rope sheaves, blocks, and slings.
Paducah Rigging strongly encourages every marine crew to prioritize training—not just once, but on an ongoing basis. Refresher courses, toolbox talks, and hands-on practice can prevent accidents and empower your crew with confidence.
Stay Ahead of Safety Violations with Paducah Rigging
Paducah Rigging is committed to helping you prevent these common safety violations. All of our rigging equipment undergoes extensive testing and certification to ensure durability and compliance.
We also offer services that help you prevent violations before they happen, including:
- Load testing
- Non-destructive testing
- On-site inspections
- Custom rigging consultations
- Equipment maintenance scheduling
Don’t wait for a problem to arise – schedule rigging equipment maintenance with us today and keep your operations safe out there on the water.