Lifting gear is built to work under pressure, but without proper care, it can deteriorate faster than expected and become unsafe to use.

Chains, slings, shackles, hooks and lifting attachments are all exposed to load stress, impact, corrosion and general wear. Over time, that wear can reduce performance and increase safety risks.

Routine maintenance helps to prevent failed inspections and equipment being taken out of service unexpectedly. It keeps lifting gear in safe working condition between thorough examinations, reduces downtime, and makes LOLER compliance far easier to manage.

Why Lifting Gear Maintenance Matters

LOLER inspections confirm whether lifting gear is safe at the point it’s examined.

Maintenance is what keeps it safe the rest of the time.

Without consistent checks and proper handling, lifting gear can deteriorate quickly, especially in environments where equipment is:

• used daily
• stored outdoors
• exposed to moisture, dust or chemicals
• moved frequently between teams
• used across multiple sites

In practice, most inspection failures aren’t caused by a single dramatic fault. They’re caused by gradual wear that wasn’t spotted early enough.

A basic maintenance routine reduces:

• unexpected equipment failure
• emergency repairs
• failed inspections
• premature replacement costs
• safety risk on site

Lifting Gear Maintenance vs LOLER Thorough Examination

A LOLER thorough examination is a formal inspection carried out by a competent person, with certification and a written report. It is required at set intervals.

Maintenance includes the day-to-day and scheduled actions that keep equipment in good condition, such as:

• visual checks
• cleaning
• lubrication (where relevant)
• storage and handling controls
• removal of damaged gear
• planned repairs and servicing

Both are necessary. Maintenance supports compliance, but it does not replace statutory inspections.

The Most Common Causes of Wear and Failure

Lifting gear tends to fail for predictable reasons. The most common issues include:

Corrosion and pitting

Often caused by wet storage, outdoor use, or poor cleaning after use.

Deformation

Bending, twisting, or elongation caused by overloading, impact, or incorrect use.

Wear on load-bearing points

Especially on hooks, shackles, chain links and lifting attachments.

Missing markings and traceability

Even if the gear is physically sound, missing ID or SWL markings can result in it being removed from service.

The key point is this: most of these issues develop gradually. They can be identified early if routine checks are in place.

Pre-Use Checks: The First Line of Safety

Pre-use checks should be carried out before lifting gear is used, particularly for accessories such as:

• slings
• chains
• shackles
• hooks
• lifting clamps

The check should be quick, but it should be taken seriously.

Operators should look for:

• cracks or fractures
• bent or distorted components
• excessive corrosion
• worn safety latches
• damaged stitching or fibres (for textile slings)
• missing tags, markings or SWL information

If there is any doubt about condition, the gear should be removed from service and assessed.

Storage and Handling: The Most Overlooked Maintenance Issue

Storage is one of the biggest factors in how long lifting gear lasts.

Poor storage leads to corrosion, impact damage and general deterioration, often long before the gear reaches the end of its working life.

Good storage should include:

• dry, clean conditions
• slings stored hanging rather than on the floor
• separation of different gear types to prevent contact damage
• clear identification and traceability
• removal of damaged gear so it cannot be reused

Improving storage is one of the quickest ways to reduce inspection failures and extend lifespan.

Scheduled Maintenance: What Should Be Done Between Inspections?

A sensible maintenance routine includes scheduled checks that go beyond pre-use inspections.

Depending on how often the gear is used, many businesses implement:

• weekly checks on high-use accessories
• monthly reviews of lifting registers and inspection dates
• periodic cleaning and condition assessments
• planned replacement of worn items

This is especially important where lifting gear is shared between teams, moved between sites, or stored in mixed environments.

When to Arrange Professional Servicing or Repair

Some issues can be identified on site, but repairs and servicing should be carried out properly, and in line with compliance requirements.

Professional servicing is recommended when:

• lifting gear is used heavily or daily
• equipment is exposed to harsh conditions
• gear has failed an inspection
• markings or traceability are unclear
• damage suggests possible overload
• you need repairs, replacements or re-certification

How Maintenance Helps With LOLER Compliance

Regular maintenance doesn’t just improve safety, it improves compliance outcomes.

Well-maintained lifting gear is more likely to:

• pass thorough examinations
• stay within safe wear tolerances
• remain properly marked and traceable
• reduce the number of items removed from service unexpectedly

It also reduces disruption. Instead of dealing with urgent repairs when inspections are due, issues can be identified and resolved earlier.

If you want a clearer understanding of inspection schedules and statutory requirements, our guide to lifting gear inspections and LOLER compliance explains what’s typically required under LOLER and PUWER.

Lifting Gear Maintenance as Part of a Safer System

Maintenance works best when it’s part of a wider system, including:

• correct equipment selection
• operator training
• inspection scheduling
• clear record keeping
• safe storage and handling
• planned servicing and replacement

It doesn’t need to be complicated, but it does need to be consistent.

Support With Lifting Gear Inspections, Servicing and Repairs

If you need help maintaining lifting gear across your site, whether that’s routine servicing, repairs, or inspection scheduling, our team at Merica can support you.

FAQs

How often should lifting gear be maintained?

Maintenance frequency depends on use and environment, but pre-use checks should be carried out before lifting gear is used, and scheduled checks should be carried out regularly between LOLER examinations.

Does maintenance replace LOLER inspections?

No. Maintenance supports safety and reduces wear, but thorough examinations are still required under LOLER.

What should we do if lifting gear is damaged?

Remove it from service immediately and have it assessed. Continued use of damaged gear increases risk and may breach compliance requirements.

Can lifting gear be repaired?

In some cases, yes, but repairs should be carried out properly and may require re-testing and re-certification depending on the equipment type.