Rigging and Lifting Job Safety Analysis
Published:
Rigging and lifting operations carry some of the highest-consequence risks in construction and industrial settings. A dropped load, failed sling, or improper rigging configuration can kill instantly. OSHA reports that struck-by injuries from crane and rigging operations are among the leading causes of death in construction, and nearly every rigging fatality traces back to a preventable error in planning, equipment selection, or execution.
This JSA covers the critical steps in a typical rigging and lifting operation using slings, shackles, and overhead cranes or mobile cranes. The sequence applies whether you are rigging structural steel, mechanical equipment, piping assemblies, or any other load requiring engineered lifting. Each step identifies the specific hazards that create the most serious injury potential.
OSHA regulates rigging under 29 CFR 1926 Subpart H (cranes and derricks in construction) and 29 CFR 1910.179-184 (overhead cranes, slings, and rigging in general industry). A qualified rigger is required by OSHA for any lift where the load is not readily visible to the crane operator or where the rigging requires engineering judgment.
Disclaimer
This content is provided for general informational and educational purposes only. It is not a substitute for a site-specific Job Safety Analysis conducted by a qualified safety professional familiar with your workplace conditions, equipment, and personnel. OSHA citations, BLS statistics, and hazard controls referenced here may not reflect the most current standards or apply to your specific situation. Always consult current OSHA regulations, manufacturer guidelines, and a competent person before beginning work. Health & Safety Systems LLC assumes no liability for actions taken based on this content.
Build This JSA in Minutes
Use JSABuilder to create, manage, and share professional JSA worksheets with your team.
Start Free TrialStep-by-Step JSA Breakdown
Step 1: Plan the lift and calculate load weight
Hazards
- Overloading the crane or rigging hardware by underestimating load weight
- Center of gravity miscalculation causing load tipping or rotation
- Inadequate clearance from structures, power lines, or personnel
Controls
- Determine load weight from manufacturer data, shipping documents, or engineering calculation — never estimate
- Identify center of gravity and plan rigging attachment points to keep load level
- Develop a lift plan specifying crane position, boom configuration, load radius, and rigging hardware
- For critical lifts (over 75% of crane capacity or unusual configurations), require an engineered lift plan
Step 2: Select and inspect rigging hardware
Hazards
- Sling failure from damage, overloading, or incorrect type for the load
- Shackle failure from improper pin engagement or load rating exceeded
- Hardware degradation from corrosion, heat damage, or fatigue
Controls
- Select slings and hardware rated for the load weight plus a safety factor
- Account for sling angle factor — slings at less than 60° from horizontal significantly reduce rated capacity
- Inspect all slings before each use: check for cuts, abrasion, broken wires (wire rope), heat damage, and chemical degradation
- Remove from service any hardware that fails inspection; tag and isolate for disposal
Step 3: Establish exclusion zone and communicate the lift plan
Hazards
- Personnel in the fall zone struck by the load or rigging if released
- Miscommunication between rigger and crane operator causing uncoordinated movements
Controls
- Barricade or rope off the area beneath and around the lift path
- Conduct a pre-lift briefing with all involved personnel: operator, signal person, rigger, and ground crew
- Establish hand signals or radio communication protocol between signal person and operator
- Designate a single signal person — operator responds only to that person (or any stop signal)
Step 4: Attach rigging to the load
Hazards
- Pinch points between rigging hardware and the load during attachment
- Unstable load shifting during rigging attachment
- Sharp edges cutting slings during tension
Controls
- Use proper rigging connections: shackle pins fully engaged, hooks latched, slings properly seated
- Protect slings from sharp edges with softeners, pads, or edge protectors
- Ensure the load is stable and will not shift when rigging tension is applied
- Keep hands and body clear of pinch points between slings, shackles, and the load
Step 5: Perform a test lift
Hazards
- Rigging failure under load that was not apparent during visual inspection
- Load instability (tilting, spinning) indicating incorrect center of gravity or rigging geometry
Controls
- Lift the load just enough to clear the surface (6-12 inches) and hold
- Check that the load is level and stable — if it tilts, lower and re-rig
- Verify all rigging is properly seated and not slipping
- Confirm crane is stable (outriggers loaded, no settling) before proceeding to full lift
Step 6: Execute the lift and move the load
Hazards
- Load swing or pendulum action striking structures or personnel
- Two-blocking (hook block contacts boom tip) causing rigging failure or boom damage
- Crane overload from exceeding load chart radius during swing
Controls
- Use tag lines to control load rotation and swing — never use hands to guide a suspended load
- Move slowly and smoothly; avoid sudden starts, stops, or direction changes
- Monitor load chart — capacity decreases as radius increases; never swing a load over rated radius
- Never walk or position personnel under a suspended load
Step 7: Set the load and remove rigging
Hazards
- Crushing or pinch-point injuries when lowering load onto supports
- Load instability after rigging removal (load tips or rolls)
- Sling recoil when tension is released
Controls
- Lower the load slowly onto prepared supports, blocking, or dunnage
- Keep hands and feet clear while load is being landed
- Verify the load is stable on its supports before slackening rigging
- Remove rigging only after confirming the load is secure and will not move
Required Personal Protective Equipment
Applicable OSHA Standards
29 CFR 1926.251
Rigging Equipment for Material Handling (Construction)
Specifies requirements for slings, shackles, hooks, and other rigging hardware. Requires daily inspection, rated capacity tags, and removal of defective equipment. Covers wire rope, synthetic, chain, and metal mesh slings.
29 CFR 1926.1400-1442
Cranes and Derricks in Construction
Comprehensive crane safety standard requiring qualified operators, qualified riggers, signal persons, assembly/disassembly directors, ground conditions assessment, and power line safety provisions.
29 CFR 1910.179
Overhead and Gantry Cranes (General Industry)
Covers overhead crane operation, inspection, and maintenance in manufacturing and warehouse environments. Requires regular inspections, operator training, and specific operational practices.
29 CFR 1910.184
Slings (General Industry)
Specifies sling requirements for general industry: rated capacity, inspection criteria for each sling type, removal from service criteria, and safe use practices including temperature limitations and chemical exposure restrictions.
Injury and Fatality Statistics
Crane and rigging-related struck-by incidents cause approximately 250 fatalities across all industries every 5 years, making rigging operations one of the highest-consequence work activities.
The primary causes of rigging fatalities are contact with the load or rigging hardware (struck-by), crane overload and tip-over, and contact with overhead power lines during crane operations.
Source: Bureau of Labor Statistics, 2022
Frequently Asked Questions
What is a qualified rigger?
OSHA defines a qualified rigger as a person who can demonstrate the ability to properly rig loads for safe lifting based on their knowledge and experience. There is no specific OSHA certification requirement, but the rigger must understand load weight calculation, sling capacity, sling angle factors, hitch types, inspection criteria, and safe rigging practices. Many employers require third-party rigging certification through programs like NCCCO or equivalent.
How does sling angle affect capacity?
As the sling angle decreases from vertical (90°), the tension in each sling leg increases. At 60° from horizontal, each sling leg carries the full rated load. At 45°, each leg carries 1.41x the load share. At 30°, each leg carries 2x the load share. This means a sling rated at 10,000 lbs in a vertical hitch can only safely lift 5,000 lbs at a 30° angle. Never rig at angles below 30° from horizontal.
When is a critical lift plan required?
A critical lift (also called an engineered lift) requires a written lift plan reviewed by a qualified engineer or lift director. OSHA does not define "critical lift," but industry standard practice requires engineered lift plans when: the load exceeds 75% of the crane's rated capacity at the operating radius, the lift involves multiple cranes, the load is lifted over occupied areas, the load is of unusual shape or cannot be easily balanced, or when the consequences of failure include serious injury or significant property damage.
How often should slings be inspected?
OSHA requires slings to be inspected before each use by the person using them. In addition, a thorough periodic inspection by a competent person is required — ASME B30.9 recommends annual documented inspections for slings in regular service, and more frequently for slings used in severe conditions. Remove wire rope slings with broken wires, kinking, crushing, or bird-caging. Remove synthetic slings with cuts, burns, melting, acid damage, or missing identification tags.
What is a tag line and when is it required?
A tag line is a rope attached to a load to control its rotation, swing, and position during lifting without requiring workers to touch the load directly. Tag lines are required whenever the load could swing and contact workers, structures, or other equipment. They are essential for loads that tend to rotate (asymmetric loads), lifts in windy conditions, and any lift where ground workers would otherwise need to guide the load by hand. Never wrap a tag line around your hand or body.