When a foundry in Italy found itself in a hot problem, they turned to RUD.

Foundries are notoriously harsh environments. They get hot, insanely hot. Red-hot loads demand equipment that can withstand extreme temperatures while ensuring safe and efficient operation.

A foundry in Italy needed to move scorching hot steel bars that were long and weighed thousands of kilos. They were also square-shaped with a unique profile that required a unique lifting solution.

The Situation

The project had several challenges:

• Extreme Temperatures: The bars reached a staggering 300°C, requiring a heat-resistant lifting mechanism to protect operators and equipment.
• Weight and Size: Each bar measured 12 meters long and weighed a hefty 2,400 kg, requiring a robust lifting solution with a high working load limit (WLL).
• Square Geometry: The square profile of the bars (14x14 cm and 16x16 cm) demanded a unique clamping mechanism for secure grip and transport stability.

A Unique Solution

RUD has been in the lifting business for years and knows steel like the back of our hand. So, we took our knowledge of high-quality clamps and chains and devised a custom system to handle this hot situation.

• Built to Last: We customised a robust system that weighed 150 kg with a working load limit (WLL) of 2,500 kg. This was a rock-solid solution that provided stability and safety. The system's core component was a RUD VIP-2-strand sling, which hooked into the crane for a secure connection.
• Versatile Clamping: The clamping mechanism was versatile and could adjust to slight size differences (14x14 cm and 16x16 cm) without a problem. This ensured a secure grip regardless of minor size discrepancies, preventing potential slippage during transport - the last thing you need when dealing with red-hot metal!
• Safety First Followed by Efficiency: Safety is paramount in a foundry for both the employees and the equipment. Our safety-friendly design ticked all the boxes. We made it semi-automatic with a lever system for hooking and unhooking the bars. This kept the operators far away from the intense heat. The lever also controlled the rotation and locking of the clamps, ensuring the bars stayed put throughout the entire process. The clamps themselves were attached to super-strong 8mm RUD VIP Grade 100 sling chains - chosen specifically for their exceptional heat resistance and strength.

Game Change for the Client

This custom system has been a game-changer for the foundry, improving operations on the floor. It moves the steel bars with ease, keeping things efficient while prioritising operator safety. This project is a perfect example of how RUD combines high-quality lifting components with custom-designed solutions. This tailored approach sets RUD apart from the competition. We don't just sell products; we deliver solutions for even the most challenging high-temperature lifting situations.

This project shows our commitment to exceeding customer expectations. By combining our expertise in lifting with a dedication to custom design, we ensure safety, efficiency, and happy customers, no matter how hot the job gets.

If you want more details of our lifting and lashing solutions, email us or call us on 07 3809 1300.

Article copyright to RUD Group 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 shown for illustration only.

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 here to read Part 1.

Identifying Chain Grades:

Chains are stamped with their grade for easy identification. Grades 80 and 100 use the "(H)" stamp followed by the number (e.g., H8 for Grade 80, H10 for Grade 100). However, Grade 120 employs the "(D)" stamp. It is important to point out here that unlike lifting chains, hoist chains cannot be used for lifting and are stamped with letters to prevent potentially dangerous mix-ups.

Safety Certifications and Testing:

Safety is paramount. Always opt for chains approved by relevant regulatory bodies (e.g., DGUV in Germany). Traceability through batch codes and RFID chips (offered by RUD) is also recommended. Regular inspections and electromagnetic crack tests (every three years) are essential for safety assurance.

Choosing the Right Lifting Chain:

Selecting the right chain hinges on several factors.

RUD will help you with the best chain suspension for lifting based on the following:

• Load type and weight
• Attachment points
• The presence of sharp edges or rough surfaces
• Required WLL
• Load's centre of gravity
• Operating temperature range
• Ease of operational safety checks

 

Conclusion:

By understanding the types, grades, and applications of lifting chains, you can ensure safe and efficient lifting operations. Remember to prioritise safety by adhering to regulations, conducting proper inspections, and selecting the most suitable chain for your specific needs.

Click here to 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.

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.

What are Lifting Chains?

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 past chains suffered from low material strength and cumbersome weight, today's chains offer high strength, durability, and cost-effectiveness, making them the preferred choice for lifting and lashing applications. They also weigh considerably less for the same WLL (Working Load Limit), 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 with their:

• Adjustability: Length can be easily modified using additional components.
• Sharp-edge resistance: They exhibit greater resilience against damage from sharp edges.
• Temperature tolerance: They perform well across a wider range of temperatures.

Choosing the Right Chain Grade:

Several chain grades (Grade 80, 100, 120) exist, each with its own WLL (Working Load Limit). Selecting the appropriate grade is crucial for safety and efficiency.

Grade 80: This has been in existence since 1970. It is very popular in some parts of the world because it offers affordability. However, it has a lower breaking force and weight limitation.

Tip: RUD was the first chain manufacturer, approved for Grade 80 in 1972

Grade 100: It has been in existence for the last 30 years and is popularly used by many operators. It is a step up over Grade 80 and provides a balance between cost and performance.

Tip: RUD launched Grade 100 as VIP (Verwechslungsfrei in Pink) in 2006, and it is still a popular product used in many lifting applications. Click here for more details on the RUD VIP Grade 100.

Grade 120: Grade 120 is the latest and strongest grade, offering lighter weight and higher breaking force than Grade 80. Exclusive to a few manufacturers (including RUD).

Tip: Grade 120 offers a 30% reduction in weight than Grade 80 because it uses less material. It also possesses a 60% higher breaking force than a Grade 80 chain, and it is extremely robust, tough, and resilient to sharp and rough edges.

What this means is that an ICE Grade 120 Lifting or Lashing Chain - no matter the nominal thickness - can replace a Grade 80 chain of a next-higher nominal thickness.

Click here for more details on RUD ICE 120 Chains.

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.