Can a condemned chain sling or wire rope sling be repaired?

No. Chain slings and wire rope slings that meet the condemn criteria must be destroyed, not repaired. AS 3775.2 explicitly states that condemned chain slings must be permanently removed from service. Wire rope slings with broken wires, kinking or birdcaging cannot be safely repaired. The only option is physical destruction by cutting into short lengths.

What is the 10% rule for chain sling links?

The 10% rule is the primary condemn threshold for chain sling wear under AS 3775.2. If any individual link has worn to 90% or less of its original nominal diameter at any point, the entire sling must be condemned. This is measured using callipers at the most worn point of each link. Even if only one link meets this threshold, the complete sling assembly must be destroyed.

Who qualifies as a competent person to inspect lifting gear?

A competent person must have adequate knowledge of AS 4991, AS 3775 and the other relevant standards, practical experience with the types of gear being inspected, and the ability to identify defects and apply discard criteria. This is typically a rigging supervisor, qualified rigger or dedicated lifting equipment inspector with authority to remove defective items from service.

Free lifting gear inspection register (as 4991)

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Free lifting gear inspection register per AS 4991 and AS 3775. Chain slings, wire rope slings, synthetic slings and shackles with discard criteria.

Jarrod Milford

Commercial Director

Updated 5 May 2026

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What is a lifting gear inspection register (as 4991)?

A lifting gear inspection register is a consolidated record used to document the periodic inspection of all lifting accessories at a workplace, including chain slings, wire rope slings, synthetic webbing slings, round slings and shackles. Unlike equipment-specific checklists that assess one item in depth, a register format allows a competent inspector to work through multiple items in a single session, recording the condition and pass/fail/condemn status of each piece of lifting gear on one form.

This register aligns with AS 4991 (Lifting equipment) and AS 3775 (Chain slings), which require that all lifting gear be inspected at defined intervals by a competent person, with defective items immediately removed from service. The template includes quick-reference discard criteria for each gear type, enabling the inspector to make condemn decisions on the spot without referring to separate standard documents. Any item marked C (condemn) must be quarantined and physically destroyed to prevent accidental re-use.

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Benefits of using this lifting gear inspection register (as 4991)

Multi-item efficiency: inspect and record an entire site inventory of lifting gear on a single form rather than completing a separate checklist for every sling and shackle.
Clear condemn authority: the integrated discard criteria boxes give the inspector objective, standards-referenced thresholds for condemnation decisions, reducing uncertainty.
Regulatory compliance: satisfies AS 4991 and AS 3775 requirements for documented periodic inspection by a competent person with traceable records.
Prevents fatal incidents: lifting gear failure during a crane lift can cause dropped loads resulting in fatalities. Systematic periodic inspection is the primary control.
Inventory visibility: the register format provides a snapshot of every lifting accessory on site, its WLL, type and current condition.
Destruction accountability: items marked condemn must be destroyed and recorded, creating an audit trail showing condemned gear was identified and removed.

Benefits of digitising forms in MapTrack

When you move your checklists from paper to MapTrack, you get:

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Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
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Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
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Set recurring audit schedules with automatic reminders and escalation.
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What to include in a lifting gear inspection register (as 4991)

This lifting gear inspection register (as 4991) covers 10 key areas:

Unique identification tag or number for each item.
Lifting gear type (chain sling, wire rope sling, synthetic webbing sling, round sling, shackle).
Working Load Limit (WLL) in kg or tonnes.
Visual inspection result for each item.
Wear assessment against type-specific discard criteria.
Damage assessment (cracks, cuts, deformation, corrosion).
Label and tag legibility check.
Overall result with P (pass), F (fail) or C (condemn) classification.
Chain sling discard criteria: 10% diameter reduction, elongation, cracks, heat exposure above 400C.
Wire rope sling discard criteria: broken wire counts per lay, kinking, birdcaging, damaged ferrules.

How to use this lifting gear inspection register (as 4991)

Gather all lifting gear from designated storage areas and cross-reference against the site register.: Collect all chain slings, wire rope slings, synthetic slings and shackles from storage racks and tool boxes. Cross-reference against the site lifting gear register to confirm all items are accounted for. Any item that cannot be located must be reported and investigated before the inspection can be completed.
Inspect each item systematically, starting with visual examination for obvious defects.: For chain slings, check each link for cracks, gouges, bending and corrosion. For wire rope slings, inspect the full length including terminations. For synthetic slings, examine both faces and all edges for cuts, abrasion and UV damage. For shackles, check the body and pin for deformation, wear and corrosion.
Assess wear against the specific discard criteria for each gear type.: Measure chain link diameter if wear is suspected and condemn at 10% or greater reduction. Count broken wires in wire rope per lay length. Measure cut depth in synthetic slings and condemn cuts over 1mm. Check shackle pin hole elongation. Use the reference boxes on the form to confirm condemn thresholds.
Verify all identification tags, WLL markings and colour codes are legible.: Missing or illegible identification is grounds for condemning the item, as the Working Load Limit can no longer be confirmed. Check that colour-coded inspection tags match the current inspection period. Verify manufacturer markings and compliance stamps are intact.
Record results and quarantine condemned items immediately.: Record P (pass), F (fail, requires repair, generally only applicable to shackles) or C (condemn, quarantine and destroy) for each item. Tag condemned items with a red defective tag and move to a quarantine area immediately. Physically destroy condemned slings by cutting into short lengths to prevent re-use. Complete the sign-off with the site supervisor or lifting supervisor.

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How often should you complete this checklist?

AS 3775.2 recommends periodic inspection at intervals not exceeding 3 months for lifting gear in normal service. The interval must be reduced for severe service conditions including chemical exposure, high temperatures or frequent use. Pre-use visual checks must occur before every lifting operation. In MapTrack, automated 3-monthly inspection cycles cover your entire lifting gear inventory, with notifications when inspections are due and flagging of condemned items so they cannot be assigned to future lifts.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 4991 Lifting equipment
AS 3775.1 Chain slings - Grade T (80) and Grade V (100)
AS 3775.2 Chain slings - Care and use
AS 1666.1 Wire rope slings - Product specification
AS 1353 Flat synthetic webbing slings
AS 4497 Round slings - Synthetic fibre
AS 2741 Shackles
WHS Regulations 2011, Part 5.1 (plant)

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