Lifting Gear Inspection Checklist (Free Template)
KALIRA Research Team March 18, 2026 7 min read
Why a lifting gear inspection checklist matters
Lifting gear failures kill people. A parted chain sling, a cracked hook, a synthetic sling used past its service life: these are not hypothetical risks. They are the reason SOLAS, LOLER, and Depnaker K3 impose mandatory inspection requirements on all lifting equipment.
A checklist is not a substitute for competence. An inspector must understand why each item matters, what failure looks like, and when to withdraw equipment from service. But a systematic checklist ensures consistency: the same items are checked every time, by every inspector, regardless of production pressure or familiarity with a particular piece of equipment.
This checklist covers pre-use inspection requirements applicable to the most common categories of lifting gear: chain slings, wire rope slings, synthetic fiber slings, shackles, hooks, and lifting beams. Reference standards include MSC.1/Circ.1663 (maritime), LOLER 1998 (UK), and BS EN 818/1677 series.
Before the inspection: documentation check
Before physically inspecting any lifting gear, verify the documentation status:
| Check | Pass Criteria | Action if Fail |
|---|---|---|
| Certificate on file | Current test certificate exists for this item | Do not use. Source certificate or re-test. |
| Certificate not expired | Expiry date has not passed | Do not use. Schedule examination. |
| Color code current | Paint mark or tag matches current inspection period | Verify inspection record. Recolor if examined and current. |
| SWL marked | Safe Working Load visible on the item | Do not use if SWL cannot be determined. |
| Item in register | Lifting gear appears in the asset register | Add to register if missing. |
Chain slings
Pre-use visual inspection
| Item | Check | Pass Criteria | Fail: Withdraw if: |
|---|---|---|---|
| Links | Examine every link | No cracks, no deformation | Any crack, gouge, or nick > 10% of link cross-section |
| Elongation | Measure overall length against original | Within 5% of original length | Elongation exceeds 5% |
| Wear | Check link cross-section at contact points | <10% reduction in cross-section diameter | Wear exceeds 10% |
| Twist | Inspect for twist in chain body | Chain hangs straight, no twist | Any permanent twist visible |
| Opening | Check hook or ring opening | Within manufacturer's tolerance | Opening exceeds 5% above nominal |
| Corrosion | Check for rust or pitting | Surface rust acceptable if no pitting | Deep pitting reducing section by >10% |
| Identification | Verify item number / serial visible | Legible tag or stamping | No identification: do not use |
| Connecting components | Inspect rings, master links, hooks | No deformation, cracks, or excessive wear | Any deficiency on master link or hooks |
Grade identification (chain slings)
Verify the grade of chain: Grade 8 (80) and Grade 10 (100) are current production standards. Grade 30 and Grade 43 proof coil chains must not be used as lifting slings. Grade is stamped on the master link or identified by the test certificate.
Wire rope slings
Wire rope slings deteriorate through broken wires, kinking, corrosion, and reduction in diameter. The discard criteria below follow BS EN ISO 4309 and common industry practice.
Pre-use visual inspection
| Item | Check | Pass Criteria | Fail: Withdraw if: |
|---|---|---|---|
| Broken wires | Count broken wires in any 30d or 6d length | Zero broken wires in thimble/ferrule areas | ≥2 broken wires in 6d; ≥4 in 30d; any at attachment |
| Diameter reduction | Measure at several points | Less than 3% reduction from nominal | ≥3% diameter reduction anywhere |
| Kinking | Inspect for kinks in the rope body | No permanent kink | Any permanent kink: immediate withdrawal |
| Corrosion | Check surface and visible strand gaps | Surface discoloration acceptable | Pitting, corrosion in strand valleys |
| Core damage | Inspect end terminations for core protrusion | Core flush with outer strands | Any core protrusion |
| Ferrule/swage | Inspect pressed or swaged terminations | No cracking, no movement of ferrule | Any crack or movement |
| Label and SWL | Verify identification tag | Legible, securely attached | Missing or illegible: do not use |
Synthetic core warning
Wire rope with fibre cores (FC or IWRC fibre) must not be used where the sling could be subjected to crushing forces (e.g. between a load and a crane block) or high temperatures. Wire rope slings are rated for temperatures up to approximately 100°C continuous. Lubrication should be applied if the sling is stored dry for extended periods.
Synthetic fiber slings (webbing and round slings)
Synthetic slings are the most time-sensitive category. They degrade invisibly: UV exposure, chemical exposure, and cyclic loading cause internal fiber damage that is not visible on the surface. The date of manufacture tag is a critical safety document.
Pre-use visual inspection
| Item | Check | Pass Criteria | Fail: Withdraw if: |
|---|---|---|---|
| Date of manufacture | Check label date | Within manufacturer's stated service life (typically 5–10 years depending on manufacturer and operating conditions) | Exceeds manufacturer's stated service life from manufacture date |
| Cuts and tears | Inspect webbing surface and edges | No cuts, nicks, or tears in load-bearing material | Any cut or tear in load-bearing fibers |
| Abrasion | Check high-wear areas (eyes, body) | Minor surface fuzz acceptable | Fraying exposing load-bearing fibers |
| Chemical exposure | Check for discoloration or brittleness | Even color, supple material | Discoloration, stiffness, brittle texture |
| UV damage | Inspect surface for chalking, bleaching | Minor surface fading acceptable | Widespread chalking, surface degradation |
| Heat damage | Check for glazing, melting, or discoloration | No evidence of heat exposure | Any glazing or melting |
| Load indicator | If fitted, check status indicator | Green (if red or brown, sling is overloaded) | Red or brown indicator |
| Label | Verify label is legible and attached | All data legible: SWL, material, date | Missing or damaged label: do not use |
Round slings
Round slings (ratchet slings or endless round slings) require inspection of the outer protective jacket as well as internal core condition where visible at the ends. If the core is visible through the jacket, the sling must be withdrawn regardless of apparent fiber condition.
Shackles
| Item | Check | Pass Criteria | Fail: Withdraw if: |
|---|---|---|---|
| Body | Visual inspection of bow and crown | No cracks, no deformation | Any crack or deformation visible |
| Pin | Inspect pin condition | Pin straight, threads clean | Bent pin, stripped threads, pin not secured |
| Pin security | Verify moused or screwed secure | Screw pin fully engaged, safety moused if required | Screw pin not fully engaged |
| Wear | Check pin hole and saddle bearing | <10% wear on bearing surfaces | Wear exceeds 10% of original diameter |
| SWL marking | Verify SWL legible | Stamped SWL readable | SWL not readable: do not use |
| Compatibility | Verify pin is original to shackle body | Pin matches body stamping/size | Mixed components: do not use |
Hooks
| Item | Check | Pass Criteria | Fail: Withdraw if: |
|---|---|---|---|
| Opening | Measure throat opening | Within 5% of original specification | Opening exceeds 5% above specification |
| Twist | Check shank for twist | No permanent twist | Any permanent twist |
| Safety latch | Inspect spring latch | Latch closes fully and spring loaded | Latch missing, bent, or not spring-loaded |
| Surface | Inspect for cracks, notches, gouges | No cracks visible | Any crack: immediate withdrawal |
| Wear | Check at tip and throat | <10% reduction in cross-section | Wear exceeds 10% |
Lifting beams and spreader beams
| Item | Check | Pass Criteria | Fail: Withdraw if: |
|---|---|---|---|
| Main body | Visual inspection for cracks and deformation | No cracks, no visible bending | Any crack or permanent deformation |
| Attachment points | Inspect all lugs, shackle holes, pin points | No cracks at welds, no elongation of holes | Any crack or hole elongation |
| Dimensions | Check for bending of beam body | Visually straight | Any permanent bow or twist |
| Identification | Verify SWL, span markings, and beam ID | All markings legible | Missing identification: do not use |
| Adjustable stops | For adjustable spreader beams, check locking mechanism | Locks positively at each position | Any slippage or loose locking |
What to document after each inspection
Every pre-use inspection must be recorded. The record should capture:
- Asset identifier (serial number or NFC/QR tag reference)
- Date and time of inspection
- Inspector name and qualification level
- Result for each checked item (pass / marginal / fail)
- Overall status: cleared for use / withdrawn
- If withdrawn: specific deficiency noted and action taken (quarantined, tagged out, sent for examination)
- Photographic evidence for any deficiency found
Paper records satisfy the recording requirement but create the problems described in our guide on tracking assets without spreadsheets: records that cannot be retrieved quickly under inspection, cannot be verified as unaltered, and cannot provide fleet-level visibility.
Digital inspection records captured at the point of inspection (with GPS, timestamp, and attached photos) satisfy both the legal requirement and the practical need for auditable, retrievable records.
When to withdraw and what to do
Equipment must be withdrawn from service immediately when:
- Any discard criterion above is met
- The inspector is uncertain whether a criterion is met (uncertainty = withdraw)
- The identification tag, SWL marking, or test certificate cannot be located or read
- The color code does not match the current inspection period and records cannot confirm current examination
Withdrawn equipment must be physically tagged out, not just mentally noted. A "WITHDRAWN: DO NOT USE" tag attached to the equipment prevents it being returned to service by someone who was not present for the inspection.
Withdrawn equipment must either be:
- Repaired or reconditioned by a competent workshop, then re-tested and re-certified before return to service
- Permanently retired and physically destroyed (cut, deformed, or marked) so it cannot be inadvertently returned to service
For SOLAS compliance: see our detailed guide on SOLAS lifting gear inspection requirements.
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