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Rigging Risk Assessment

Rigging Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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  • • Includes 2 Years of Free Compliance Updates

Rigging Risk Assessment

Product Overview

Identify and control organisational risks associated with Rigging operations using this management-level Rigging Risk Assessment, focused on planning, governance, systems and equipment across your business. This document supports executive Due Diligence, strengthens WHS Risk Management processes, and helps demonstrate compliance with the WHS Act to minimise operational and legal exposure.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance & WHS Duties: Assessment of PCBU obligations, officer due diligence, safety leadership, and oversight of all rigging activities across projects and sites.
  • Competency, Licensing & Supervision: Management of high-risk work licences, verification of competency, refresher training, and supervision requirements for riggers and doggers.
  • Rigging Design & Lift Engineering: Evaluation of lift studies, engineered lift plans, load calculations, and approval processes for complex and critical rigging operations.
  • Procurement & Equipment Selection: Controls for purchasing, pre-qualification, and certification of rigging gear including slings, shackles, spreader bars, lifting devices and associated hardware.
  • Inspection, Maintenance & Asset Management: Systems for periodic inspection, tagging, defect reporting, quarantine, and lifecycle management of all rigging equipment.
  • Operational Planning for Rigging Activities: Planning and control of routine and non-routine rigging operations, including onshore construction, offshore facilities, shutdowns and confined or congested work areas.
  • Communication, Coordination & Dogging Systems: Protocols for signalling, radio communications, spotters, dogging arrangements, and coordination between crane crews, riggers and other work groups.
  • Exclusion Zones & Load Path Management: Management of no-go areas, suspended loads, public interface, traffic separation, and segregation of non-essential personnel from rigging operations.
  • Work at Height & Fall Protection in Rigging: Assessment of harness use, anchor points, temporary work platforms, rescue planning, and integration of fall protection into rigging tasks.
  • Offshore & Remote Rigging Work: Controls for marine environments, vessel and platform interfaces, weather and sea-state considerations, logistics, and emergency response in remote locations.
  • Documentation & Information Management: Systems for managing lift plans, permits, certificates, inspection records, training files, and version control of rigging procedures.
  • Incident Management & Continuous Improvement: Processes for reporting, investigating and analysing rigging-related incidents, near misses and equipment failures, and implementing corrective and preventive actions.

Who is this for?

This Risk Assessment is designed for Business Owners, PCBU representatives, Construction and Operations Managers, and Safety Professionals responsible for planning, approving and overseeing Rigging activities across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and PCBU Oversight for Rigging Activities
  • • Lack of clear assignment of WHS duties for rigging under WHS Act 2011 leading to gaps in accountability between PCBUs, principal contractors and subcontract rigging companies
  • • Inadequate WHS governance framework for high risk construction work including basic, intermediate, advanced and offshore rigging
  • • Failure to identify and manage overlapping duties where multiple PCBUs share a workplace (e.g. builders, crane companies, offshore operators, façade installers)
  • • Insufficient consultation, cooperation and coordination arrangements between duty holders for complex lifts, offshore rigging and high-load tension line work
  • • Inadequate WHS policy coverage for specialised rigging activities such as wire rope reeving, safe use of synthetic slings, tensioning cable guides and large awning installation
  • • Absence of documented risk appetite and criteria for high-risk rigging operations (e.g. hoisting heavy components over public areas or occupied buildings)
  • • Failure to ensure health and safety duties are met for remote and offshore rigging work including fatigue, isolation and emergency response
  • • Inadequate verification that officers are exercising due diligence in relation to rigging risk (e.g. no structured WHS reporting, no rigging performance indicators)
2. Rigging Competency, Licensing, Training and Supervision
  • • Use of riggers or doggers without appropriate high risk work licences (basic, intermediate, advanced rigging) for the complexity of the task being undertaken
  • • Inadequate verification of competency for specialised activities such as offshore rigging, tensioning rigging gear, safe use of high-load tension lines and synthetic sling usage
  • • Insufficient training in current Australian Standards and manufacturer instructions for wire rope handling, wire rope reeving, shackles, slings and harness systems
  • • Poor understanding of load dynamics when hoisting large-scale awnings or installing heavy granite or façade components resulting in unsafe rigging configurations
  • • Supervisors lacking rigging-specific knowledge to effectively monitor and challenge unsafe systems of work
  • • No structured refresher training program leading to skill fade in complex rigging calculations, tensioning systems and safe dogging communication
  • • Contract and labour-hire riggers entering site without site-specific induction covering rigging and de-rigging operations, offshore conditions or unique lifting configurations
  • • Inadequate training for emergency lowering, rescue, and failure scenarios of high-load tension lines and elevated harness-based rigging work
3. Rigging Design, Engineering and Lift Planning
  • • Absence of formal engineering review for complex lifts such as hoisting large-scale awnings, heavy granite components or modular sections using multiple lifting points
  • • Reliance on informal or generic rigging arrangements not suited to site-specific constraints, offshore conditions or unusual geometries
  • • Inadequate design of tensioning systems for cable guides, rigging gear and high-load tension lines causing overloading of components or anchors
  • • Failure to consider dynamic effects, wind load, vessel or structure movement during offshore rigging work in the lift planning process
  • • No documented lift plans or critical lift procedures for lifts over live plant, public areas, occupied buildings or critical infrastructure
  • • Incorrect selection of rigging gear due to lack of engineering input on load paths, centre of gravity and sling angles
  • • Inadequate assessment of supporting structures (e.g. awning fixings, building frames, anchor points) before applying rigging loads
  • • Insufficient integration of rigging design with crane or hoist configuration leading to incompatible systems, restricted headroom or side loading
4. Procurement, Selection and Certification of Rigging Equipment
  • • Procurement of rigging gear (slings, shackles, chains, synthetic slings, wire ropes, tensioners) that is non-compliant with Australian Standards or unsuitable for high-load applications
  • • Lack of system for ensuring traceability, certification and working load limit (WLL) markings on rigging components
  • • Use of incompatible equipment combinations (e.g. mixing different grade chains, using unsuitable shackles with synthetic slings or high-load tension systems)
  • • Inadequate control of offshore-rated equipment requirements such as corrosion resistance, protective coatings and specific certification
  • • No centralised specification or approved products list, resulting in ad-hoc purchasing of low-quality or unverified rigging gear
  • • Failure to procure manufacturer documentation and instructions necessary for safe use, inspection and tensioning procedures
  • • Inconsistent quality of harnesses and fall-arrest equipment used in conjunction with rigging tasks at height
  • • Inadequate consideration of storage and transport requirements for synthetic slings, wire ropes and high-tension equipment during procurement
5. Inspection, Maintenance and Asset Management of Rigging Gear
  • • Lack of systematic inspection program for slings, shackles, chains, wire ropes, tensioning devices and harnesses leading to use of damaged or degraded equipment
  • • No documented process for tagging, tracking and removing from service defective rigging components
  • • Inadequate inspection competencies for personnel assessing complex items such as wire rope reeving systems, high-load tension lines and cable guides
  • • Poor maintenance of offshore rigging gear exposed to saltwater, corrosion and high UV environments
  • • Inconsistent or missing inspection records, making it difficult to demonstrate compliance or identify recurrent issues
  • • Uncontrolled storage conditions causing deterioration of synthetic slings and wire ropes (e.g. UV exposure, chemical contamination, crushing)
  • • Lack of scheduled testing and re-certification for lifting and rigging equipment used in critical operations
  • • Failure to maintain and inspect personal fall protection and harness-based rigging equipment in line with manufacturer and Australian Standards
6. Planning and Control of Rigging Operations (Onshore and Offshore)
  • • Inadequate pre-planning of rigging and de-rigging operations leading to improvised systems of work
  • • Lack of documented procedures for common rigging activities such as assembling rigging, loading rigging gear, attaching cords, chains and ropes, and tensioning cable guides
  • • Insufficient consideration of access, egress, drop zones and interface with other trades during planning of heavy component installation or awning hoisting
  • • No formal process for assessing environmental conditions (wind, swell, tides) before offshore rigging activities
  • • Absence of a permit-to-work or authorisation system for high-risk rigging work (e.g. heavy lifts over public areas, high-load tensioning, offshore work)
  • • Inadequate coordination of simultaneous operations, creating potential for rigging activities to interact with crane operations, traffic movement or work at height
  • • Poor change management when rigging plans are altered on site in response to constraints or equipment availability
  • • Lack of standard operating procedures for tensioning rigging gear and high-load tension lines, leading to over-tensioning and sudden release hazards
7. Communication, Coordination and Dogging Systems
  • • Lack of clear communication protocols between riggers, doggers, crane operators and supervisors during lifting operations
  • • Inconsistent understanding of standard dogging signals and radio procedures across different crews and subcontractors
  • • Inadequate planning for communication in noisy, confined, offshore or line-of-sight restricted environments
  • • Multiple persons attempting to direct lifting operations without a single designated dogger or lift controller
  • • Language barriers or literacy issues affecting understanding of rigging procedures, exclusion zones and emergency instructions
  • • Poor coordination between rigging crews and other trades working adjacent to or below hoisting activities
  • • No formal process for communicating changes to rigging plans, tensioning sequences or lifting configurations
  • • Failure to communicate risks associated with high-load tension lines, including potential for snap-back zones and sudden release
8. Exclusion Zones, Load Path Management and Public Interface
  • • No systematic approach to establishing and maintaining exclusion zones beneath or adjacent to rigged loads, particularly for large-scale awnings and heavy components
  • • Uncontrolled access by other workers or public into rigging and lifting areas, especially in live facilities or city streets
  • • Inadequate planning of load paths resulting in loads travelling over public areas, occupied buildings or critical plant where alternatives exist
  • • Poor signage and physical barriers around tensioned rigging systems and high-load tension lines, exposing people to snap-back or failure zones
  • • Insufficient control of pedestrian and vehicle movements near offshore and quayside rigging operations
  • • Failure to coordinate exclusion zones across multiple PCBUs working on the same site or structure
  • • No defined policy restricting work under suspended loads or within potential collapse zones of large awnings or rigging frames
  • • Lack of monitoring or enforcement of exclusion zones once established
9. Work at Height, Harness Systems and Fall Protection in Rigging
  • • Inadequate system-level controls for rigging work at height when installing heavy components, awnings or cable guides
  • • Use of harness and rigging equipment without appropriate selection, inspection and rescue planning
  • • Insufficient engineering controls (e.g. edge protection, work platforms) leading to over-reliance on personal fall-arrest systems
  • • No documented rescue plans for workers suspended in harnesses during rigging or de-rigging activities
  • • Improper integration of rigging anchor points with structural capacity and fall-arrest requirements
  • • Inconsistent training in safe use of fall protection systems during rigging tasks, including connection methods and swing-fall hazards
  • • Lack of coordination between rigging systems and temporary works (e.g. scaffolds, mast climbers) used for access
  • • Poor management of dropped object risks associated with tools and rigging hardware used at height
10. Offshore and Remote Rigging Work Management
  • • Inadequate consideration of offshore-specific risks such as vessel movement, limited access, remoteness and severe weather when managing rigging systems
  • • Poor integration of offshore operator safety management systems with contractor rigging procedures leading to gaps or conflicts
  • • Fatigue and extended rosters for rigging crews working offshore or in remote locations impacting decision-making and communication
  • • Constraints on emergency response, rescue and medical support for rigging incidents offshore
  • • Insufficient corrosion control, inspection frequency and replacement planning for offshore rigging gear
  • • Inadequate logistics planning for availability of certified rigging equipment and critical spares in remote or offshore locations
  • • Limited supervision and auditing of rigging practices due to access and scheduling constraints
  • • Challenges in maintaining training currency and competency assessments for riggers deployed offshore
11. Documentation, Record Keeping and Information Management
  • • Incomplete or inconsistent documentation of rigging risk assessments, lift plans, permits and inspections
  • • Difficulty demonstrating compliance with WHS Act 2011 due to poor record keeping and version control of rigging procedures
  • • Critical rigging information (e.g. WLL charts, engineered configurations, tensioning instructions) not readily accessible to workers and supervisors
  • • Loss of traceability for rigging components, certifications and maintenance histories
  • • Reliance on verbal instructions and undocumented changes to rigging plans increasing the risk of miscommunication
  • • Insufficient retention and analysis of incident, near-miss and inspection data related to rigging operations
  • • Unclear document ownership leading to out-of-date rigging procedures remaining in circulation
  • • Lack of integration between contractor and principal contractor document systems on joint worksites
12. Incident Management, Investigation and Continuous Improvement for Rigging
  • • Under-reporting of rigging-related near misses, minor incidents and equipment failures, reducing learning opportunities
  • • Superficial or delayed investigations into rigging events such as dropped loads, sling failures or tensioning incidents
  • • Lack of root cause analysis focusing on system and management factors rather than individual blame
  • • No formal process for implementing and tracking corrective actions arising from rigging incidents and audits
  • • Limited sharing of lessons learned across projects, crews and subcontractors performing rigging work
  • • Failure to review and update rigging procedures, training and engineering standards following significant incidents
  • • Inadequate consideration of psychological harm, stress and fatigue impacts after serious rigging incidents
  • • Absence of metrics and key performance indicators specific to rigging safety performance

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – Construction Work: Guidance on managing WHS risks associated with construction and rigging activities.
  • Model Code of Practice – Managing the Risk of Falls at Workplaces: Requirements for fall prevention and protection relevant to rigging at height.
  • Model Code of Practice – Managing Risks of Plant in the Workplace: Risk management for cranes, lifting equipment and associated rigging plant.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 2550 series: Cranes, hoists and winches – Safe use, including inspection, maintenance and operational requirements.
  • AS 1418 series: Cranes, hoists and winches – Design, construction and testing requirements relevant to lifting and rigging operations.
  • AS 1891 series: Industrial fall-arrest systems and devices used for work at height during rigging activities.
  • AS 4991: Lifting devices – Selection, use and maintenance of lifting equipment and attachments.
  • AS/NZS 1892 & AS/NZS 1576 series: Portable ladders and scaffolding used in conjunction with rigging work at height.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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