Top 5 Mistakes Companies Make When Installing Lifting Points

Lifting point failures can sLifting point failures can stop a project in its tracks. Often, it’s not the equipment that’s to blame but the way it was installed. At RUD Australia, we’ve seen how small setup errors with bolt-on lifting lugs or misaligned systems create major safety risks.

These mistakes aren’t always apparent at first. A missing spec here, an incorrect torque there. Suddenly, your lifting setup becomes unstable, and the whole operation is at risk.

In this guide, we’ll go over the five most common installation mistakes that can affect your lifting equipment. You’ll learn how to spot them, fix them, and avoid them altogether. We’ve also included further information and simple ways to prevent these issues before they start.

Let’s jump in and take a closer look at what you need to watch out for.

Using Incorrect or Poorly Installed Bolt-On Lifting Lugs

Most lifting point failures are traced back to incorrect use of bolt-on lifting lugs. When lugs are misaligned or not torqued properly, they create uneven stress across connected components. That stress builds over time and leads to equipment failure, sometimes without warning.

Even when the load seems manageable, a poorly mounted lug shifts pressure into places it shouldn’t go. That can weaken the structure, create instability, or crack nearby joints.

These are the areas where most mistakes happen:

Load rating match

Always check that the bolt-on lug you’re using exceeds the load capacity required for the equipment. You’ll find this info in the manufacturer’s spec sheet. Choosing an underrated lug puts excess force on the connection point, which increases your risk of deformation or shearing.

Thread and torque specifications

Follow the exact torque values recommended by the supplier. Use the torque chart as a reference. Under-tightening can cause the bolt to shift during lifts, while over-tightening stretches the threads, weakening their grip.

You don’t need complex technology to get this right. A calibrated torque wrench, alignment gauge, and a moment to double-check the specs are enough. Proper installation prevents breakdowns and keeps your systems working safely and smoothly.

Now, let’s see what happens when your tyres aren’t getting the protection they need.

Ignoring Tyre Protection Chains in Tough Environments

Running heavy equipment on rough ground without tyre protection chains is like sending someone into a scrap yard barefoot. Sooner or later, something’s going to give, and it won’t be the rocks.

Why tyre chains matter:

• They help tyres last longer: Chains stop sharp rocks and debris from slicing into your treads or sidewalls. That means fewer blowouts and more time on the job. Chains take most of the hits, so your tires stay safe.
• They keep loads steady: On bumpy surfaces, tyres slip. Slipping moves the load, and that can cause wobbling, tipping, or worse. Chains add grip and help keep your gear balanced.
• They cut downtime and costs: Fewer tyre issues mean your crew stays on schedule and jobs get finished without unexpected interruptions. You won’t have to stop everything just to deal with a flat. That keeps your timelines and costs in check.

Skipping chains might not seem like a big deal until your site is at a standstill and the job’s behind schedule. And if your tyres are taking hits, just imagine what’s going on inside the gear that’s driving them forward.

Disregarding Drive Technology Specs and Sync

If your drive system and lifting gear aren’t speaking the same language, expect problems. A mismatch between these parts slows things down. Plus, it increases wear, throws off the load, and raises your risk of a breakdown.

Here’s what to watch for:

• Torque and speed must match: The drive system needs the right strength and pace to control the lift. Too much torque or too little speed can strain components and throw off timing. That can cause jerky starts, sudden stops, or even failure.
• Check load compatibility: You need to be sure your machinery can handle the full load safely during regular lifting, inclines, or when starting under pressure. These are the moments when weak points show up and things go wrong.
• Maintain it like you mean it: This is the part that often gets skipped, but it matters. Keep things greased. Tighten anything that’s come loose. Give the system a proper once-over regularly. Catching small issues early can prevent major failures later.

Use the SINTEF PDS Handbook for guidance on failure patterns and reliability data. This solid resource will help you better understand.

Letting drive issues slide wears out your gear. Also, it can compromise the whole operation. When your gear starts to lag, inspections become even more important.

Skipping Routine Inspections and RUD Gear Lifecycle Checks

Not keeping track of inspections can get expensive fast. You might miss early signs of wear, which leads to breakdowns, stalled jobs, emergency repairs, or even damaged equipment. All of that costs time, money, and trust. Regular checks help you stay ahead of issues.

Why Records and Scheduling Matter

Keeping a log of inspection dates, usage cycles, and repairs shows how your systems age. It helps your team catch patterns and schedule replacements before things go wrong. A shared spreadsheet or tag system does the job.

What a Solid Check-In Includes

Inspections should follow a simple, repeatable process that works for your operation. You can follow this checklist: .

• Check for visible wear, corrosion, or cracks
• Rotate moving parts to check for stiffness
• Make sure mounting points sit flush with no gaps
• Compare the condition to lifecycle recommendations
• Record inspection results and note what’s due next

Pro Tip: Take photos during inspections to track wear and support clear handovers.

Staying on top of checks protects your people, your gear, and your workplace.

Overlooking External Expertise and Updated Guidance

It’s easy to keep doing things the way they’ve always been done. If the gear works and no one’s raised a flag, why change it? But relying only on internal knowledge can leave you behind.

Safety legislation evolves. So do lifting tools and setup standards. If your team isn’t checking in with specialists, there’s a good chance you’re missing out on better ways to work.

Our research indicates that small process changes, like using a newer part or following an updated spec, can prevent major issues later. What seemed fine last year might now fall short of compliance or safety best practices.

Solutions don’t always come from within your team. Sometimes, the best next step is reaching out to those who build, test, and improve the gear every day.

And if you ever need help, guidance, or a second opinion, we’re here for you.