From jobsite safety to workforce evolution, below-the-hook lifting tools are reshaping how the industry thinks, plans, and performs.
BY: Michael Chalmers
Whether fabricated to order or pulled from stock, below-the-hook (BTH) lifting devices remain among the most essential—and misunderstood—tools on today’s jobsite. From design loads and service classifications to markings, certifications, and real-world field use, a BTH device carries far more than its rated capacity.
That was the premise behind “From Hook to High-Tech,” a session delivered at the 2025 SC&RA Crane & Rigging Workshop in Indianapolis by Jon Alberson, Chief Engineer at Means & Methods Engineering LLC, and Brooks Nunley, VP of Sales at Kennedy Wire Rope & Sling and President and Founder of Innovative Lifting LLC. Far from a product overview or safety seminar, the presentation traced the full lifecycle of a BTH device—from concept and contract to procurement, fabrication, field use, and eventual retirement.
Along the way, the speakers challenged attendees to consider the broader design standards, engineering assumptions, and technological advancements shaping this critical segment of the lifting industry.
“Most people are familiar with traditional structural shapes for below-the-hook lifting devices,” Alberson explained. “Spreader bars, beam clamps, lifting lugs—what you’d call first-generation tools. But we’re now working on equipment that’s far more sophisticated.”
That sophistication includes devices with expanded operational functions, including remote control capabilities and the ability to dynamically adjust the center of gravity below the hook. Alberson noted that such innovations are more than just conveniences—they’re tools that reduce manual strain and increase both safety and efficiency on the jobsite.
“I asked the crowd: who’s ever been stuck on the wrong end of a twenty-ton chain hoist because someone missed the center of gravity?” he said. “It’s not fun. It makes for a long day.”
And as Alberson pointed out, technology isn’t just making jobs easier—it’s helping the industry attract a new generation of workers. “It’s not brute force anymore,” he said. “Rigging and below-the-hook lifting require smart thinking and the right tools. You want young people in this business? Show them they’ll be operating equipment with the same kind of tech they’ve grown up with—not throwing a wrench on a massive bolt and hoping they don’t get crushed.”
At the heart of Alberson’s message was the importance of standards—specifically, ASME BTH-1 and ASME B30.20. “BTH-1 is the design standard we use in the U.S.—and outside the U.S.—for below-the-hook lifting devices,” he said. “It’s technical, but critical. Engineers rely on it for everything from load formulas to capacity calculations. Even if you’re not the engineer—if you’re a purchaser, end-user, or safety lead—you need to understand that this is what people are working from.”
ASME B30.20, he added, functions as the safety counterpart to BTH-1. Both are meant to be used in tandem—regardless of whether someone is designing a bespoke lifting solution or performing a standard field lift. “If you’re in the field, you’re going to use the safety standard more often,” Alberson said. “But it doesn’t matter what your role is—everyone should be familiar with both.”
Still, gaps remain. According to Alberson, many professionals either don’t know the standards exist or don’t fully apply them. “We get a lot of questions about what qualifies as a BTH device and what doesn’t,” he said. “And just because something doesn’t fall under the standard doesn’t mean you can’t still use BTH-1 as a resource. Engineering judgment plays a big role. If it applies to your situation, there’s good information in there.”
For Alberson, elevating industry practices begins with recognizing the value of standards—and using them not just for compliance, but for continuous improvement. “It’s about working smarter,” he said. “Whether you’re lifting five tons or fifty, these tools, these standards, and this mindset—this is what’s going to move the industry forward.”
Shift in Expectations
For Nunley, the first stumbling block when it comes to BTH equipment is a familiar one: reluctance to change.
“As an industry, we’re very slow to adopt change,” he said. “And the first instinct—understandably—is to look at what standard, off-the-shelf items might solve the issue.”
While those options—shackles, master links, basic rigging assemblies—can sometimes get the job done, Nunley noted that they’re often not the most effective. “There are maneuvers like pitch, roll, and other directional changes that can only be executed safely with a dynamic lifting tool,” he explained. “Without them, your only alternative is using multiple cranes.”
The implications go well beyond convenience. According to Nunley, dynamic BTH tools reduce the number of cranes required, remove human exposure, eliminate manual labor with chain or lever hoists, and create a safer, more controlled lift environment overall.
“And with the next generation of labor being a real concern, technology is becoming essential,” he added. “Younger workers are drawn to industries that feel modern. Electrical and mechanical lifting tools—integrated with the kind of tech other industries already use—are a natural progression for ours.”
That shift in expectations has already reshaped his work. “I’ve leaned fully into that,” Nunley said. “I rarely get called for standard BTH devices anymore. I get called when people need dynamic adjustment and high-tech lifting components.”
By dynamic, Nunley means more than just adjustability. “These are wirelessly controlled, battery-powered tools with automation, logic, and programming that essentially create a smart lifting device,” he said.
The origin of these tools, he noted, was rooted in practical necessity. “You can solve almost anything using standard, off-the-shelf components—we’ve been doing that for decades. The Egyptians built the pyramids that way. But now we have technology that allows us to be more efficient. We’re taking proven technologies from other industries and deploying them into the crane and rigging BTH space.”
That evolution is especially crucial when considering rigging handling at scale. “At higher loads, something as simple as the pin of a shackle can weigh two hundred pounds,” Nunley explained. “A human being can safely handle forty pounds or less.”
The takeaway, he emphasized, is that safety begins with asking better questions. “When you need a piece of equipment just to assemble or disassemble your rigging, that’s when you should start thinking more creatively,” he said. “How do we work safer? How do we remove hands from dangerous positions? How do we eliminate brute force operations?”
Emerging Trends
Alberson emphasized that dynamic lifting devices represent a natural evolution—especially when the right application calls for something beyond the basics. “The point of the presentation was to show the evolution of where we’re headed,” he explained. “These tools take you to the next level.”
But designing for both safety and versatility requires clear priorities from the start. “As you move through the design process, you start zoning in on what you want. You have to make decisions—do I want this, or that? You can’t have everything. You give up one thing to gain another.”
Two of the biggest technical challenges, he noted, are structural weight and hook height. “To make a beam or device stronger, it usually has to get heavier. And many of these tools take up space between the hook and the load. Add in the rigging required to hold them, and suddenly you’re looking at real overhead limitations.”
Choosing the right lifting geometry—bar vs. single-point pick—can help reclaim critical hook height, especially in low-overhead situations. “Stability might suffer with a single-point pick, but you gain clearance,” he said. “It’s all about trade-offs, and those discussions need to happen on the front end. You don’t want to get eighty percent through design and then realize you’re boxed in.”
He pointed back to the BTH standard as the foundation for every decision. “You’ve got to stay within those parameters, but even within that, you have room to make smart choices.”
For Nunley, one of the most persistent misconceptions around modern BTH devices isn’t cost—it’s timing. “Honestly, I’ve never seen budget be the real issue—the issue is planning,” he said. “Smart BTH devices require time. They can’t be a last-minute add-on to a lift plan.”
He pointed out that while slings, shackles, and other rigging hardware are widely understood as off-the-shelf tools, advanced lifting devices (2.0) don’t belong in that same category. “When you’re considering technology-driven tools, you need the right internal teams—engineering, safety, operations—to evaluate what fits the lift, the safety goals, and the manpower requirement. With proper planning, the total cost of ownership makes sense. Increased safety, reduced manpower, better control—it all pays for itself. Cost isn’t the hindrance. Time is.”
He pushed back on the notion that urgency should dictate equipment strategy. “People claim emergencies drive everything, but that’s the exception. Most of the time, a job gets bid, it moves into a project plan, and it gets executed. We just need the conversations to happen before execution—not after.”
Asked about trends in documentation and compliance, Nunley referenced a broader shift toward traceability. “The term ‘asset management’ really applies,” he said. “A lot of companies are requiring rigging to be traceable now. These slings aren’t just for one use—they go back into the inventory fleet. You’ve got to know the manufacture date, track usage, and follow ASME guidelines for recertification.”
He added that while some companies still rely on spreadsheets—or have no system at all—more sophisticated platforms are now entering the fold. “We’re seeing more customers require us to input data directly into their own asset-management systems. So yeah, there’s a lot of improvement happening there.”
Artificial intelligence, Nunley noted, will only accelerate that trend. “If you’re not using some form of AI in today’s world—for reporting, for planning, for thinking—then you’re already behind.”
Freedom to Improve
Off-the-shelf BTH tools still serve a purpose, Alberson said—but custom jobs remain prevalent because every project is different. “Look around, and you’ll see air conditioners, generators, prefab electrical buildings—all kinds of components with off-center centers of gravity. They don’t always fit what’s available on the shelf.”
That’s where purpose-built solutions come into play, he expressed. “These other industries are driving the need for what I call bespoke below-the-hook lifting devices. Sure, traditional steel erection methods still use standard gear. But in power plants, chemical plants, even manufacturing, the lifting needs are often unique.”
His biggest takeaway? “At the end of the day, we’re trying to build safe, high-quality projects. If something simple gets the job done, use it. But don’t rule out a next-gen tool just because it seems like overkill.”
Sometimes, he added, innovation pays off in hindsight. “You use it once or twice and think, ‘Why didn’t I come up with that two years ago?’ Don’t limit yourself. The right tool can change everything.”
As for practical guidance, Nunley offered a two-pronged approach. “First, identify the markings required by the BTH standard. Know the rated capacity, but also the design category and service class. That tells you what the device has been built and tested for, and whether it’s safe for your use.”
And second, he said, be willing to challenge the status quo. “A lot of jobs get executed by doing what worked last time. That’s fine—but what if there’s a better way? Not just lessons learned, but lessons borrowed—from other industries, from competitors, from new technologies. That’s where growth happens.”
He stressed the urgency of letting the next generation play an active role in that growth. “If we don’t allow them to use the technology they’ve grown up with, we’re going to have a severe problem. You see it already—an aging workforce, and a younger one that’s not being handed the tools to evolve.”
The best path forward, Nunley believes, is through collaboration. “There are guys out there who’ve forgotten more about lifting and lowering than most people will ever know. We need to preserve that knowledge while also giving new people the freedom to improve on it. That combination is what will build the future.”
This story originally appeared in the January/February 2026 issue of Wire Rope Exchange.