Lifting equipment such as trolley jacks, floor jacks, and pneumatic air jacks play a critical role in workshops, garages, and industrial environments. These tools are engineered to raise heavy loads reliably, yet misuse remains one of the most common sources of workplace injury and equipment failure. While there are many errors that can occur in the process of lifting, the number one mistake when using jacks is the assumption that the jack alone can safely support a load for extended periods . This fundamental misunderstanding leads to improper use that compromises safety, reduces equipment life, and increases the likelihood of accidents.

Why Relying on the Jack Alone Is a Mistake

Jacks are engineered to lift a load, but not to hold it steadily over time. Regardless of type—hydraulic, mechanical, or pneumatic—the internal mechanisms in a jack (whether fluid seals, compressed air bladders, or gear systems) are not designed for static load support. When a jack is used as the sole support beneath a vehicle or machine:

Pressure loss may occur due to minor leaks in seals or hoses, causing gradual descent.

Mechanical creep under load can lead to load loss without obvious signs before failure.

Pneumatic components may lose air over time, reducing the jack’s ability to maintain lift height.

These behaviors are intrinsic to lifting systems that use dynamic pressure or mechanical advantage rather than rigid static locking. As such, a lifting device must never be relied upon as a permanent or long-term support mechanism .

Common Scenarios Where the Mistake Occurs

This mistake is observed across various contexts—from automotive repair to industrial maintenance. Instances include:

A vehicle lifted for an undercarriage inspection is left on a jack without additional support.

Heavy machinery is elevated during alignment or repositioning and remains supported only by the jack.

A jack is used to lift equipment awaiting adjustment or welding, with operators assuming the elevated position is stable.

None of these scenarios account for the inherent limitations of a jack as a support device, especially under variable loads.

Safety Protocols That Prevent the Mistake

Reducing risk begins with recognizing the appropriate role of a jack within a lifting operation. The following protocols should be established in any workshop:

Use Secondary Support Structures

Once the load reaches the desired height, it should be transferred to devices explicitly designed for static support, such as:

Jack stands

Blocking or cribbing systems

Shoring frames

These supports are engineered to maintain load placement without reliance on hydraulic pressure or pneumatic systems. They also reduce stress on the lifting device itself.

Ensure Stable Surface Conditions

Jacks and stand supports should be placed on flat, hard surfaces. Soft ground, uneven flooring, or sloped areas compromise stability and greatly increase risk. Level, solid surfaces ensure that the load remains balanced and fully supported by engineered support systems.

Verify Load Ratings

Each lifting device has a specific capacity rating. Using a jack near its maximum rating, without a margin of safety, increases the potential for failure. The rated capacity should exceed the load’s weight to account for dynamic forces and variability.

Conduct Routine Inspections

Regular inspections can identify early signs of wear, leaks, or mechanical degradation. For hydraulic or pneumatic jacks, checking seals and pressure control components is essential. Mechanical wear should be monitored through visual and functional testing.

When Advanced Tools Like Air Jacks Are Appropriate

Among lifting tools, air jacks (pneumatic jacks) represent a specialized option that addresses certain limitations of manual or purely hydraulic systems. These devices leverage compressed air to generate lift rapidly and with minimal manual effort. Key considerations regarding air jacks include:

Faster lifting time compared to manual systems.

Reduced operator fatigue due to pneumatic actuation.

Capability to lift a wide range of load types , making them suitable for frequent use.

Large wheels and handles  that facilitate movement in busy workshop environments.

Air jacks can be particularly useful where lifting tasks are frequent and time is a consideration. They are engineered with capacities that span typical workshop requirements, making them versatile for both cars and larger equipment with higher mass handling needs.

Despite these advantages, the same principle applies: even with pneumatic jacks, secondary support must be deployed after lifting . The pneumatic system should not replace rigid supports such as stands or blocking structures once the load is elevated.

Differences Between Jack Types and Support Roles

While all jacks serve the purpose of lifting, their suitability depends on the application:

The common thread across all types is that a jack’s role ends once the load reaches the desired height . Static support should then take over.

The number one mistake in jack usage is assuming that the jack can safely hold a load over time. This misconception leads to unsafe working conditions and an elevated risk of load drop, injury, or equipment damage. Understanding that a jack is a lifting device—not a support device—is fundamental to safe operation. 

Implementing best practices—such as using appropriate secondary supports, verifying surface stability, respecting capacity limits, and incorporating efficient tools like pneumatic air jacks for rapid lifting—ensures both operational efficiency and safety. A workshop that applies these principles consistently minimizes risk and enhances the longevity of its lifting equipment.