Part 2 of the 2-part article.Click hereto read Part 1.
Risk Analysis: A Crucial Step for Integrated and Attachable Lifting Points
A comprehensive risk analysis is mandatory before conducting a lift, whether utilising integrated or attachable lifting points. This analysis should consider the following key aspects regarding lifting points:
The lifting point or lifting eye should not have any sharp edges.
The lift point must be suitable for the hooks/shackles/slings being used.
Wall thicknesses and edge distances must be assessed to ensure the load can be transferred appropriately into the structure.
The product-specific marking must be provided.
Lifting Point Selection Criteria
Choosing the appropriate lifting point is crucial for ensuring the safety and efficiency of any lifting operation. Here are some key factors to consider during the selection process:
Mass and Centre of Gravity: The payload's mass and centre of gravity are the primary determinants. Lifting points with a Working Load Limit (WLL) equal to or exceeding the load weight must be selected. Additionally, the centre of gravity will influence the number and placement of lifting points required for balanced lifting.
Number of Lifting Points and Lifting Configuration: The number of lifting points depends on the number of legs in the lifting sling and the desired lifting configuration (single-leg, multi-leg). The chosen configuration will impact the overall WLL of the lifting system.
Deduction Factors: External factors like tilt angle and temperature fluctuations can affect the WLL of a lifting point. Deduction factors specific to the anticipated lifting scenario should be considered during selection.
Lifting Point Type and WLL: Based on the load weight, lifting configuration, and deduction factors, a lifting point with an appropriate WLL and suitable type (boltable, weldable, rigid, swivel) must be chosen.
Verification and Documentation
The selected lifting point should possess a valid test certificate conforming to the relevant standards. This certification verifies that the manufacturer adheres to stringent testing protocols, including proof load application, destructive tensile tests, and crack detection procedures.
Design and Calculation Resources
Providing engineers access to 2D/3D CAD design documents and calculation programs can significantly enhance the lifting point selection process. These resources allow engineers to incorporate lifting points directly into technical drawings while considering factors impacting WLL calculations, such as:
The number of lifting strands/legs.
Potential angle variations during the lift.
The symmetry or asymmetry of the lifted object.
Simplified Lifting Point Inspection with RFID Technology
Regular inspection and maintenance of lifting points are essential for safe operation. RUD offers lifting points equipped with RFID transponders. These transponders contain unique identification numbers that a dedicated reader can scan to transmit data to cloud-based software. This technology simplifies inspection recordkeeping and allows for convenient access to vital lifting point information.
Click here to see the RUD ACP-TURNADO, the world’s first intelligent lifting point with RFID.
Lifting Point Purchasing Checklist
To streamline the selection process, consider this checklist when purchasing lifting points:
Is the lifting point type specified in the project plan?
How many lifting points are needed per component?
What is the required WLL for the lifting point?
Are there any specific design dimensions to consider?
What are the anticipated loading directions for the lifting point?
Are there any necessary approvals or certifications required for the lifting point?
By following these guidelines and utilising available resources, you can ensure the selection of the most suitable lifting points for your specific lifting applications, promoting a safe and efficient operation. RUD Australia has a team of experienced, CPEng-qualified engineers who can assist you in selecting the correct lifting points for your application.
Article copyright to RUD Group. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.
This is a 2 part article.
Lifting points are fundamental elements within any lifting system. They are the crucial connection between lifting equipment (cranes, hoists) and the load itself, facilitating lifting, rotating, and manoeuvring operations. Common lifting point examples include eyebolts, swivel load rings and pad eyes, which connect to lifting chains using hooks, shackles, or other dedicated connectors. Modern lifting points are engineered to ensure safe load handling and to prevent damage throughout the lifting and transportation process.
Integrating Lifting Points at the Design Stage
With over 140 years of experience, RUD recognises that lifting points are often overlooked during the initial design phase. This can lead to complications and potential safety hazards later in the project. Incorporating lifting points should be prioritised from the outset to prevent such issues. This includes considering lifting requirements throughout the product lifecycle, from production and internal transportation to delivery, installation, assembly, and even potential relocation or decommissioning. Implementing lifting points at each stage minimises risk and promotes smooth operation. During the design phase, collaboration between the engineering, production, logistics, and supply chain management teams ensures proper lifting point integration.
Evolution of Lifting Points: From Simple Eye Bolts to Modern Safety Standards
Over time, lifting point design has evolved to comply with changing regulations and safety requirements. Four decades ago, DIN 580 eyebolts were the most prevalent lifting point option. However, a series of accidents in German underground operations, attributed to eyebolt breakage, necessitated stricter standards. These types of incidents regarding the misuse of collared eyebolts led to the development of modern lifting points, offering significantly higher safety margins against breakage in all directions. As a result, collared eyebolts such as DIN 580 and AS 2317.1 eyebolts are no longer the preferred choice for lifting points.
The Role of Lifting Points in Conjunction with Lifting Equipment
Lifting points play a vital role when working with lifting equipment like cranes, crane trucks, and material-handling machinery. Lifting chains that connect the machine to the load rely on these critical components. In Australia, specific standards for lifting (e.g. AS 4991, AS 3775.2, AS 3776) set the requirements for various lifting gear, prioritising operator safety. This focus on safety emphasises the importance of selecting the most suitable lifting gear for each application.
Types of Lifting Points: Boltable vs. Weldable, Rigid vs. Swivel
Lifting points are generally categorised into two primary types: boltable and weldable. Boltable options are the most common due to their versatility, allowing for easy assembly and disassembly as needed. They are available for standard thread sizes, offering maximum flexibility. Conversely, weldable lifting points are permanently affixed to the load. Their primary advantage is eliminating accidental unscrewing or over-tightening during load rotation or turning. Beyond these classifications, lifting points can also be rigid or swivelling. Rigid variants, such as collared eyebolts or pad eyes, lack adjustability in the pulling direction. Swivel lifting points, on the other hand, offer greater flexibility. They are commonly employed in multi-strand lifting applications, as they can automatically align themselves with the lifting force during load handling.
Advantages of Lifting Points with Swivel and Rotation Capabilities
Lifting points specifically designed for rotating and turning applications offer additional benefits, translating into increased value. These points often integrate ball bearings, enabling a full Working Load Limit (WLL) under rotation. This makes them ideal for scenarios requiring load manipulation during lifting. The ball bearings significantly reduce sudden and unwanted movements during rotation, a crucial safety feature. Achieving smooth, impact-free rotation under load is only possible with these bearings.
WLL is a critical industry term indicating the working load a lifting point can be subject to. Selecting appropriate lifting points necessitates a thorough understanding of their WLLs. Several factors influence a lifting point's WLL, including its attachment method, positioning, load symmetry, and the number of lift points used.
To be continued ...
Article copyright to RUD Group. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.
Introduction:
Germany, with 34 million tons of cement production, is Europe's leading cement producer*. When TBA, a renowned concrete supplier needed assistance to lift the roof of a concrete silo used for an infrastructure project, they turned to RUD.
The Challenge:
The project required lifting and placing a roof on top of a silo located near Unterkochen.
The project presented several challenges for the lifting operation:
Logistics: The circular silo roof was 10 meters in diameter, 3 meters in height and weighed 16 tonnes. Lifting such an object requires careful planning.
Inclement Weather: The project location was known for inclement weather conditions from strong crosswinds and average temperatures of 2°C.
Limited Lifting Space: The lift was done using a crane with double hooks. This required precise planning of the lifting equipment to maintain safe load capacity within the permissible range while ensuring sufficient chain length.
The Solution:
Due to the heavy lift and the lifting configuration, RUD engineers proposed that a 13mm, 2 x 2-strand ICE 120 chain was ideal for the operation. To maintain the chain's working load limit (WLL) within safe parameters, it was calculated that a minimum length of 6.402 meters was required for low sling angles.
However, there were only 2 x 7-metre 2-strand chains and 2 x 4-metre chains in stock. Instead of postponing the project to another date, we decided to use IH (ICE-H) Connectors to extend the 4-metre chains.
The I-H Connectors are a fast, simple, and cost-effective solution for converting ICE chains into endless configurations. They are compact, easier to manage than conventional chain connectors, and flexible enough to fit the ICE chain.
Once the chains were extended to the necessary length, ICE Star Hooks were attached to the chain ends. Due to their innovative skeletal design, ICE Star Hooks can be used in temperatures from -60°C to 300°C and are up to 25% lighter than Grade 80 hooks of the same WLL.
This solution enabled a safe and secure lift of the silo roof. The roof was lifted to its final height of 35 meters above ground for the final assembly.
Products used in the project:
ICE 120 2-strand 13mm chains
ICE H-Connectors
ICE ISAK Masterlinks
ICE IMVK Shortening Claws
ICE Star Hooks
Conclusion:
This project demonstrates how RUD's innovative lifting solutions, such as the flexible ICE Chains, can solve complex lifting challenges. RUD is the innovator and sets standards for lifting technologies through expertise and flexible solutions to ensure safe and successful operation even in challenging conditions.
* The European Cement Association. Key Facts & Figures: Main World Producers in 2018; The European Cement Association: Brussels, Belgium, 2020
Article copyright to RUD Ketten and RUD Australia. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise. Some pictures are for illustration only.
Part 2 of the 2-part article.Click hereto read Part 1.
Lifting chain safety depends on selecting the correct chain grade, ensuring proper certification and conducting regular inspections. Grade identification markings, traceability systems and electromagnetic crack testing all play an important role in preventing lifting incidents. Choosing the right lifting chain requires consideration of load weight, attachment points, operating conditions and Working Load Limit (WLL) requirements to ensure safe and efficient lifting operations.
Identifying Chain Grades
Lifting chains are stamped with their grade for easy identification. Grade 80 and Grade 100 lifting chains use the “(H)” stamp followed by the corresponding number:
H8 for Grade 80
H10 for Grade 100
Grade 120 lifting chains use the “(D)” stamp. It is important to note that hoist chains cannot be used for lifting applications. Hoist chains are stamped with letters to prevent potentially dangerous mix-ups with lifting chains.
Safety Certifications and Testing
Safety is critical in lifting operations. Lifting chains should always be approved by relevant regulatory bodies, such as DGUV in Germany. Traceability is also important for lifting chain safety and compliance. Batch codes and RFID chip tracking, offered by RUD, assist with identification and inspection management. Regular inspections and electromagnetic crack testing are essential to maintaining lifting chain integrity and operational safety. Electromagnetic crack testing should be conducted every three years as part of ongoing inspection procedures.
Choosing the Right Lifting Chain
Selecting the correct lifting chain depends on several operational and environmental factors.
RUD assists customers in selecting the appropriate chain suspension for lifting applications based on:
Load type and weight
Attachment points
Presence of sharp edges or rough surfaces
Required Working Load Limit (WLL)
Load centre of gravity
Operating temperature range
Ease of operational safety checks
Choosing the correct lifting chain helps improve lifting safety, operational efficiency and compliance with lifting standards.
Conclusion
Understanding the types, grades and applications of lifting chains is essential for safe and efficient lifting operations.
Safety should always remain the priority by:
Following lifting regulations and standards
Conducting regular inspections and testing
Selecting the appropriate lifting chain for the application
Ensuring traceability and compliance
Proper lifting chain selection and maintenance help reduce operational risks and improve lifting performance across industrial applications.
Frequently Asked Questions
How can lifting chain grades be identified?
Lifting chain grades are identified through stamped markings on the chain. Grade 80 uses H8, Grade 100 uses H10 and Grade 120 uses a D stamp.
Can hoist chains be used for lifting?
No. Hoist chains are not designed for lifting applications and are marked differently to prevent unsafe use.
Why is lifting chain certification important?
Certification ensures the lifting chain complies with recognised safety and performance standards required for lifting operations.
What inspections are required for lifting chains?
Lifting chains require regular visual inspections and electromagnetic crack testing to identify wear, damage or fatigue.
What factors should be considered when selecting a lifting chain?
Factors include load weight, attachment points, sharp edges, Working Load Limit (WLL), centre of gravity, temperature range and inspection requirements.
What is electromagnetic crack testing?
Electromagnetic crack testing is a non-destructive inspection method used to detect cracks or defects within lifting chains to improve operational safety.
Click hereto download our Lifting Points and Lifting Means Catalogues.
Article copyright to RUD Australia. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise. Some pictures are for illustration only.
This is a 2 part article.
Lifting chains are critical components in material handling and heavy lifting applications. Grade 80, Grade 100 and Grade 120 lifting chains each offer different levels of strength, weight reduction and durability. Modern lifting chains provide superior adjustability, temperature resistance and sharp-edge performance compared to wire rope and synthetic slings, making them ideal for demanding industrial environments.
What are Lifting Chains?
The age-old proverb, "A chain is only as strong as its weakest link," first used in Thomas Reid’s “Essays on the Intellectual Powers of Man” in 1786, perfectly encapsulates the critical role of lifting chains in material handling. This article delves into the world of lifting chains, exploring their types, grades, uses, and essential safety considerations.
Lifting chains are crucial connectors between a load and a lifting hook. They are typically secured to a designated lifting point on the load, ensuring safe and secure lifting. Lifting chains form part of chain suspensions, which, along with the chains, include a master link, end components like hooks, connecting or shortening components and balancers if required.
Evolution of Lifting Chains
Modern lifting chains have significantly improved compared to their predecessors. While older chains suffered from lower material strength and cumbersome weight, today’s lifting chains offer high strength, durability and cost-effectiveness, making them the preferred choice for lifting and lashing applications. Modern lifting chains also weigh considerably less for the same Working Load Limit (WLL), which is beneficial when lifting heavy loads.
Types of Lifting Equipment
While wire rope and synthetic slings offer alternative lifting options, they have limitations, particularly in terms of adjustability, susceptibility to sharp edges and performance under extreme temperatures.
Lifting chains stand out because of their:
Adjustability - Length can be easily modified using additional components.
Sharp-edge resistance - Greater resilience against damage from sharp edges.
Temperature tolerance - Suitable for a wider range of operating temperatures.
Choosing the Right Chain Grade
Several lifting chain grades exist, including Grade 80, Grade 100 and Grade 120, each with its own Working Load Limit (WLL). Selecting the appropriate grade is critical for safety and efficiency.
Grade 80 Lifting Chain
Grade 80 lifting chain has been in existence since 1970 and remains popular in some parts of the world because it offers affordability. However, it has a lower breaking force and higher weight compared to newer grades. Tip: RUD was the first chain manufacturer approved for Grade 80 in 1972.
Grade 100 Lifting Chain
Grade 100 lifting chain has been in existence for more than 30 years and is widely used across lifting applications. It is a step up from Grade 80 and provides a balance between cost and performance. Tip: RUD launched Grade 100 as VIP (Verwechslungsfrei in Pink) in 2006, and it remains a popular solution for many lifting applications.
Grade 120 Lifting Chain
Grade 120 is the latest and strongest lifting chain grade, offering lighter weight and higher breaking force than Grade 80. It is exclusive to only a few manufacturers, including RUD.
Grade 120 lifting chains provide:
A 30% reduction in weight compared to Grade 80
A 60% higher breaking force than Grade 80
Excellent robustness and resistance to sharp and rough edges
This means that an ICE Grade 120 lifting or lashing chain, regardless of nominal thickness, can replace a Grade 80 chain of the next higher nominal thickness. Click here for more details on RUD ICE 120 Chains.
Frequently Asked Questions
What are lifting chains used for?
Lifting chains are used in material handling and lifting applications to connect loads to lifting equipment safely and securely.
What is the difference between Grade 80, Grade 100 and Grade 120 lifting chains?
Grade 80 is a traditional lifting chain grade offering affordability. Grade 100 provides improved strength and performance, while Grade 120 offers the highest strength, lower weight and increased durability.
Why are lifting chains preferred over synthetic slings?
Lifting chains provide better adjustability, improved resistance to sharp edges and better performance under extreme temperatures.
What does WLL mean in lifting chains?
WLL stands for Working Load Limit, which is the maximum load a lifting chain can safely lift under normal operating conditions.
What are the advantages of Grade 120 lifting chains?
Grade 120 lifting chains offer reduced weight, higher breaking force and greater resistance to harsh lifting environments compared to lower chain grades.
to be continued ...
Article copyright to RUD Australia. This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise. Some pictures are for illustration only.
