Lifting equipment failures cause some of the most serious injuries on worksites. A snapped sling, a worn shackle or a hook with an opened throat can result in a dropped load, crushing injuries or fatalities. Regular inspection of all lifting equipment, before every use and at formal intervals, is both a legal requirement and a critical safety control.
This guide covers the inspection of common lifting accessories: chain slings, wire rope slings, synthetic webbing and round slings, shackles, hooks, eyebolts and lifting beams. It explains the difference between a user pre-use check, a periodic inspection and a formal thorough examination, with references to Australian, UK and US standards.
Before you start
Gather the lifting equipment inspection checklist, the lifting equipment register, a vernier calliper or go/no-go gauge for measuring chain link and rope diameters, a torch and appropriate PPE. You will also need access to the manufacturer discard criteria for each item. If you do not have an up-to-date register, start by recording every lifting accessory with its unique ID, safe working load (SWL), certification date and last inspection date.
Only a competent person should carry out formal periodic inspections. In the UK, the competent person must have sufficient practical and theoretical knowledge and experience of the type of lifting equipment being examined. In Australia, competence is defined under the WHS Act as having the knowledge, experience and training to perform the task safely.
Step-by-step inspection
1. Verify identification and certification
Every lifting accessory must have a unique identification number, a legible SWL marking and a current test certificate or thorough examination report. Cross-reference each item against the lifting equipment register. Any item without identification, without a legible SWL marking or with an expired certificate must be withdrawn from service until it has been re-examined and re-certified.
2. Inspect chain slings
Examine every link in the chain for stretching, wear, nicks, gouging, corrosion and twisting. Measure the link diameter at the most worn point using a vernier calliper. Reject the chain if wear exceeds the manufacturer discard criteria, which is typically a 10% reduction in the original diameter. Check master links, coupling links and hooks for deformation, corrosion and correct operation.
3. Inspect wire rope slings
Examine the full length of the rope for broken wires, corrosion, kinking, crushing, bird-caging, flattening and any reduction in rope diameter. Count the number of visible broken wires per rope lay length and compare against the rejection criteria in the relevant standard (AS 3775 in Australia, BS EN 13414 in the UK). Check ferrules, thimbles and end terminations for deformation, cracking or slippage.
4. Inspect synthetic webbing and round slings
Look for cuts, abrasion, chemical damage, UV degradation, stiffening, knots and any exposed core yarns. Check load labels for legibility, as a sling with an illegible label cannot be verified as suitable for the lift. Any webbing sling with cut or frayed load-bearing fibres must be immediately withdrawn from service and destroyed to prevent reuse.
5. Check shackles, hooks and eyebolts
Inspect shackle bodies and pins for wear, distortion, thread damage and corrosion. The pin must thread smoothly without cross-threading. Check hooks for throat opening beyond the manufacturer tolerance (typically 5% of the original dimension), tip wear, deformation and latch operation. Verify eyebolts are not bent, cracked, corroded or showing thread damage.
6. Inspect lifting beams and spreader bars
Check structural members for cracks, corrosion, dents and deformation. Verify that adjustment pins and locking mechanisms operate correctly. Check attachment points, lugs and welds for cracking or fatigue. If the beam is adjustable, confirm that all positions are clearly marked with the corresponding SWL.
7. Record and tag
Complete the inspection record for each item with the date, inspector name, findings and pass/fail result. Apply a colour-coded inspection tag showing the inspection date and next due date. Immediately quarantine and tag any item that fails inspection. Update the lifting equipment register with the inspection results.
Common defects to watch for
| Equipment type | Common defect | Action |
|---|---|---|
| Chain sling | Link diameter reduced by more than 10% | Reject and destroy |
| Wire rope sling | Broken wires exceeding discard criteria | Reject and destroy |
| Webbing sling | Cut load-bearing fibres or exposed core | Reject and destroy |
| Shackle | Pin thread damage or body distortion | Reject and return to supplier |
| Hook | Throat opening exceeds 5% | Reject, do not attempt to re-close |
| Eyebolt | Bent shank or cracked eye | Reject and replace |
| Lifting beam | Cracked weld on attachment lug | Reject, engage engineer for assessment |
Inspection vs thorough examination
There are three levels of checking for lifting equipment. Understanding the difference is essential for compliance.
| Level | Who | Frequency | Scope |
|---|---|---|---|
| Pre-use check | User (trained worker) | Before every use | Quick visual check for obvious defects |
| Periodic inspection | Competent person | Monthly or quarterly | Documented visual and dimensional checks |
| Thorough examination | Certified examiner | 6 or 12 months (varies by equipment and jurisdiction) | Detailed examination per LOLER, AS 4991 or relevant standard, with formal report |
In the UK, LOLER 1998 requires a thorough examination of lifting accessories at least every 6 months. In Australia, WHS Regulations require regular inspection of plant used for lifting, and AS 4991 provides the framework for thorough examination of lifting equipment.
Standards and regulations
In Australia, the WHS Regulations Part 4.5 covers registration and inspection of certain plant, including cranes and hoists. AS 4991 (Lifting equipment) sets the requirements for design, manufacture, testing and examination of lifting equipment. AS 3775 covers chain slings, and AS 1353 covers wire rope slings. Competent persons must have relevant knowledge and experience to carry out inspections.
In the UK, the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) requires employers to ensure that lifting equipment is strong and stable enough for use, inspected before first use and subject to thorough examination at prescribed intervals. PUWER 1998 covers general equipment safety. BS EN 818 (chain slings) and BS EN 13414 (wire rope slings) provide detailed inspection criteria.
In the US, OSHA 29 CFR 1910.184 covers slings, and ASME B30.9 (slings) and B30.10 (hooks) set the inspection and rejection criteria. OSHA requires that slings be removed from service if damage is observed and that only qualified persons inspect rigging equipment. Annual documented inspections are standard practice.
Going digital with MapTrack
Keeping track of inspection dates, certificates and discard criteria for dozens or hundreds of lifting accessories is difficult with paper registers. MapTrack gives you a digital lifting equipment register where every sling, shackle and beam has a unique record with its SWL, certification date, inspection history and next due date.
Use digital inspection checklists tailored to each equipment type. Inspectors scan the item's QR code with their phone, complete the checklist with mandatory photo capture, and the result is logged against the asset record automatically. When a thorough examination is due, MapTrack sends automated alerts to the responsible person so nothing is overlooked.
For a related guide on inspecting another type of lifting plant, see how to inspect a crane. To maintain a complete compliance trail, link your lifting equipment inspections to the relevant work permits and project records.
