Common Mistakes to Avoid When Using Cargo Nets in Helicopters

Helicopter cargo transport is one of the most effective ways to move goods and equipment in remote, rugged, or inaccessible locations. Whether supporting military operations, construction projects, offshore platforms, or disaster relief, cargo nets allow for safe, efficient lifting and delivery of loads. 

However, the success of these operations depends heavily on the proper selection, preparation, and handling of helicopter cargo nets. Even small errors in setup or execution can compromise safety, damage valuable cargo, or result in costly delays. By understanding and avoiding common mistakes, operators and ground crews can ensure smooth and secure external load operations. 

This guide covers the most frequent errors made when using helicopter cargo nets, along with tips for preventing them. 

1. Using the Wrong Type of Cargo Nets 

Not all cargo nets are created equal. The first and most fundamental mistake is selecting a net that is not designed for helicopter operations. While some ground-transport nets may look similar to aerial nets, they lack the design features and certifications needed for safe flight. 

Helicopter-specific cargo nets are built to meet strict load-bearing and safety requirements. They often have reinforced perimeters, heavy-duty mesh, and certified attachment points that can withstand the dynamic forces encountered during flight. 

Tip: Always verify that your net is rated and certified for helicopter use. When in doubt, consult the manufacturer or supplier to confirm its specifications. 

2. Overloading the Cargo Nets 

Every cargo net has a maximum load capacity. Exceeding this limit is one of the most dangerous mistakes in helicopter lifting operations. Overloading can cause the net to fail mid-flight, leading to cargo loss, damage, or injury. 

This issue often arises when operators assume the net can handle “just a bit more” weight. But in aerial lifts, weight isn’t the only factor — the distribution of that weight and the effects of flight dynamics also play a major role. 

Tip: Always weigh cargo before loading and compare it to the net’s safe working load (SWL). Remember to factor in the weight of slings, hooks, and any secondary securing equipment. 

3. Poor Weight Distribution 

Even when the total load is within the safe limit, uneven weight distribution can cause instability during flight. If heavy items shift to one side, the net may tilt or deform, creating aerodynamic drag and increasing the risk of losing the load. 

This problem is particularly common when lifting irregularly shaped items or multiple loose objects together. 

Tip: Arrange cargo evenly in the net, placing heavier items at the center and lighter items toward the edges. Use tie-down straps to secure loose components before lifting. 

4. Failing to Inspect the Net Before Use 

Regular inspection of helicopter cargo nets is essential. Small tears, frayed edges, or damaged attachment points can quickly become major hazards under the stress of flight. Unfortunately, crews under time pressure sometimes skip a thorough inspection. 

Tip: Before every operation, check the net for: 

• Worn or frayed mesh 

• Damaged stitching 

• Rusted or bent hardware 

• Missing or damaged identification tags 

If any damage is found, take the net out of service immediately and replace it with a certified, undamaged one. 

5. Using Incompatible Attachment Hardware 

The hardware used to attach the net to the helicopter — such as hooks, rings, and shackles — must be compatible with the net’s design and rated for aerial lifting. Using mismatched or substandard hardware can compromise the connection and increase the risk of load loss. 

Tip: Always use hardware recommended by the net manufacturer or certified for helicopter external load operations. 

6. Neglecting Weather and Wind Conditions 

Helicopters are vulnerable to wind and weather, and using cargo nets can further intensify these challenges. Strong winds can cause the load to swing, rotate, or lift unpredictably, making it harder for the pilot to control. 

This is particularly dangerous when operating near obstacles like towers, ships, or buildings. 

Tip: Monitor weather reports before flight. Avoid using cargo nets in high-wind conditions unless absolutely necessary and only if your crew is trained for such scenarios. 

7. Failing to Secure Loose Cargo 

Loose or improperly secured items within the cargo net may shift during flight, potentially destabilizing the load or even falling out completely. This is not only a safety risk but can also violate aviation regulations. 

Tip: Use straps, shrink wrap, or secondary containment bags to secure small or irregularly shaped items within the net. 

8. Loading Cargo on Uneven Ground 

When loading a cargo net on sloped or uneven ground, gravity can pull items to one side before the lift begins. This can make maintaining load stability challenging once the helicopter is in the air. 

Tip: Whenever possible, load the net on level ground. If that’s not possible, adjust the placement of items to counteract the slope and secure them tightly. 

9. Not Communicating Properly with the Pilot 

Helicopter lifts demand precise coordination between the pilot and ground crew, and inadequate communication can lead to mistimed hoists, uneven loads, or sudden, unplanned movements. 

Tip: Assign a single crew member to communicate with the pilot during the lift. Use clear hand signals or radio communication to confirm readiness and guide the helicopter into position. 

10. Ignoring Regulatory and Certification Requirements 

Aerial lifting with cargo nets is subject to strict aviation regulations in most jurisdictions. Using uncertified nets or ignoring operational guidelines can lead to fines, penalties, or worse — accidents. 

Tip: Ensure your equipment meets all relevant aviation and safety certifications, such as FAA, EASA, or military standards. Keep documentation readily available for inspection. 

11. Overlooking Post-Flight Maintenance 

After each use, helicopter cargo nets should be inspected, cleaned, and stored properly. Leaving them exposed to moisture, UV light, or abrasive surfaces can shorten their lifespan and compromise safety. 

Tip: Rinse off dirt and debris, allow the net to dry completely, and store it in a clean, dry location. Keep it away from chemicals or sharp objects that could cause damage over time. 

12. Using Improvised or Damaged Nets in Emergencies 

In emergency situations, crews may be tempted to use whatever net is available. However, using damaged or makeshift nets significantly increases risk — even in urgent scenarios. 

Tip: Always keep a backup supply of certified cargo nets ready for use. This ensures you have a safe option available even during high-pressure situations. 

13. Not Accounting for Load Aerodynamics 

Some loads may cause drag or turbulence during flight, especially if they’re large and flat. This can create instability and make the helicopter harder to control. 

Tip: Whenever possible, streamline the load within the cargo net. Secure tarps or covers tightly to minimize drag. 

14. Forgetting About Sling Length and Load Clearance 

The length of the sling or line used with the cargo net can affect both stability and clearance from the helicopter’s rotors and fuselage. Too short, and the load may cause dangerous rotor wash interference; too long, and it may swing excessively. 

Tip: Follow manufacturer recommendations for sling length and adjust according to load size and operational environment. 

Conclusion 

Helicopter cargo nets are invaluable tools for lifting and transporting goods in challenging environments, but their safe use requires attention to detail, strict adherence to guidelines, and a commitment to ongoing maintenance. Avoiding the mistakes outlined above will help ensure your cargo arrives safely and your operations run smoothly. 

For operators who want the highest standards of performance and safety, working with a trusted helicopter safety manufacturing company like Gem Air-Sea Systems ensures that every piece of lifting equipment is designed, tested, and certified to meet the demanding conditions of aerial operations. The right equipment, combined with proper training and procedures, makes all the difference in keeping both crews and cargo secure.