Rigging Gear Inspection Checklist: When to Replace Lifting Gear

A piece of rigging equipment doesn't fail all at once. It fails over time, through load cycles, abrasion, heat exposure, and chemical contact, until one day it's well past the point of retirement. The problem is that gear rarely announces when it crosses that line.

That's what regular inspection is for. OSHA section 1926.251 requires that rigging equipment be inspected before each use and periodically by a qualified person. ASME B30.9 and B30.26 set the criteria for what unsafe actually looks like. This guide puts both into plain language - what to look for, how to identify it, and when to pull gear from service. 

Jump to a Section:

• Nylon Slings
• Polyester Round Slings
• Wire Rope
• Chain Slings
• Rigging Hardware
• Quick Reference Retirement Table

Nylon Web Sling Inspection

The softness and flexibility of nylon lifting slings make them great for lifting fragile or expensive cargo. But just because they're lifting delicately doesn't mean that they can't become worn out and dangerous to use. Synthetic webbing is more vulnerable to UV cuts, chemical abrasion, and UV degradation than metal alternatives.

How to Inspect: Lay the sling on a flat surface in good lighting. Flex the webbing back and forth along its length. This will open up surface cuts and worn areas that aren't visible at first glance. Give particular attention to the eye ends where the slings take the most stress. 

Discontinue use and cut the sling into 3' to 4' lengths (and cut the eye) if you notice any of the following:

• Snags, tears, or cuts - any cut that penetrates the webbing surface regardless of size.
• Melting or charring of any surface area - indicates heat exposure that has damaged fiber integrity.
• Acid or caustic burns - shows up as discoloration, stiffness, or powdery surface texture. Often occurs in industrial or cleaning environments.
• Broken or worn stitching - stitching at the eyes carries load; broken stitches reduce the rated capacity of the sling.
• Elongation beyond manufacturer's specification - Measure against the original tagged length.
• Distorted fittings - Any hardware that is bent, twisted, or cracked.

Polyester Round Sling Inspection

Polyester round slings consist of a continuous loop of polyester yarn inside and a durable polyester fabric on the outside, usually color-coded by lifting capacity. The cover's job is to protect the load-bearing yarn core and to signal when the core has been compromised. Any breach of the cover - no matter how small - means the yarn inside is exposed and the sling must be pulled from service. 

How to Inspect: Run the entire length of the sling through your hands, feeling and looking for surface damage. Flex it in different directions - cuts that aren't obvious will open up. Check the entire circumference at any point that contacts hardware, edges, or high-temperature surfaces.

If you notice these issues during inspection, cut the sling in half to retire it from service:

• Exposure of the yarn core - A visible window into the inner yarn, regardless of size, is an immediate discard.
• Broken, damaged, or knotted yarn - If you can see or feel any inconsistencies in the yarn core, retire the sling.
• Heat damage - Glazed, melted, or stiff areas on the cover
• Discolored, brittle, or stiff areas often indicate chemical contact or UV degradation.
• Acid or caustic burns - show up as discoloration, stiffness, or powdery surface texture. Often occurs in industrial or cleaning environments.

Wire Rope Inspection

Wire rope is often combined with wire rope clips and thimbles, and also used in wire rope slings that are great for a variety of lifts. It's also commonly used on specialty vehicles, like tow trucks, as a winch line. Between load stress, environmental conditions, and abrasion, many factors can shorten the life of wire rope.

How to Inspect: Lay the rope out straight if possible. Run a gloved hand along the entire length, feeling for kinks, flat spots, or broken wires that catch. Pay close attention to the ends - this is where fatigue concentrates. 

Regularly inspect your wire rope and discard it if any of the following is evident:

• Broken wires - Per ASME B30.9, 10 or more broken wires in one rope lay, or 5 or more in one strand in one rope lay, is cause for removal.
• Distortion or kinking - Any kink, bird-caging, or crushing that has altered the rope's structure
• Severe corrosion - surface rust is a warning sign; pitting or corrosion that has penetrated between strands warrants immediate removal.
• Shiny, worn outer wires - indicate abrasion and show the rope is losing cross-sectional area.
• A one-third reduction in the outer wire diameter - measure with callipers compared to the original spec.
• Damaged or displaced end fittings - inspect  hooks, links, and rings for deformation, cracks, or elongation at the termination point.

Chain Sling Inspection

Even the strongest chain slings, like a mighty grade 120 chain sling, can become overly stressed and eventually unsafe to continue using. Heat, chemicals, and heavy loads all take a toll on a chain sling's longevity.

How to Inspect: Lay the sling out flat. Inspect each link individually. Look at the inner radius of the link, where wear concentrates, and at the weld area. Check master links and end fittings with the same attention you give the body of the chain. Use a calliper to check link diameter in wear zones if elongation is suspected.

If you notice any of the following on your chain slings, cut them up into 3' to 4' lengths (to prevent salvaging) and then recycle them:

• Stretched or overly elongated links - Per ASME B30.9, chain showing 3% or more permanent elongation from original length must be retired. 
• Kinks or binding - Links that won't move freely indicate damage to the link geometry.
• Nicks or gouges - sharp notches in chain links create stress concentration points; any nick deep enough to catch a fingernail is cause for concern.
• Heat discoloration - Blue or straw-colored links indicate heat exposure that may have compromised strength.
• Illegible or missing load ratings - if you can't confirm grade or capacity, don't use it.

Rigging Hardware Inspection

Common pieces of rigging hardware used for lifts include: shackles, turnbuckles, hooks, links and swivels, rings, wire rope clips, and thimbles. The integrity of these smaller items is vital to rigging safety.

How to Inspect: Inspect each piece individually before assembling. Look at load-bearing cross sections, not just surfaces. For hooks, check the throat opening to ensure it has not opened beyond its original dimension. Verify any latch, locking pin, or cotter pin is present and fully functional.

Before using rigging hardware, visually inspect each piece and discontinue use if you notice the following:

• Excessive nicks, gouges, or corrosion - surface damage that has reduced cross-sectional area
• Bent, twisted, elongated, or cracked load-bearing components - Any deformation from original geometry
• Reduction in original dimension by 10% or more - Measurable with callipers at the wear point
• Indication of heat damage - discoloration, blue/straw tones on steel, or any sign of flame contact.
• Missing or illegible load rating information - if you can't confirm the rated capacity, don't use it.

Quick Reference Rigging Gear Retirement Table

Ready to Replace? Shop Lifting Gear at USCC

If any of the above signs are evident during your routine inspection, it's time to take your gear out of service before the next lift. Explore replacements by category:

• Nylon Lifting Slings
• Polyester Round Slings
• Wire Rope & Wire Rope Slings
• Chain Slings
• Rigging Hardware
• Sling Protection

Related Articles

• Polyester Round Sling Strength Test
• Calculating Sling Angles
• 5 Types of Synthetic Slings
• Calculating Bearing Stress for Anchor Shackles & Roundslings

Questions about the equipment you need? Our team of lifting and rigging experts is available to help. Call them at 866-444-9990, or email customerservice@uscargocontrol.com