In lifting and materials handling, the chain is often the unsung hero of the operation. Whether you are hoisting heavy machinery, securing loads for transport, or carrying out complex rigging work, the chain is the vital link that holds everything together. Choosing the correct lifting or load chain is not simply about finding something that fits; it’s about selecting a product that delivers safety, strength, and reliability in the specific conditions you work in.
At Bunzl Safety & Lifting, we understand that the wrong choice can result in downtime, compliance issues, or even accidents. This guide will explain the key factors including chain grade, breaking load, environment, and application so you can make an informed decision every time.
Before diving into the selection process, it’s important to clarify the distinction between lifting chains and load chains.
Lifting chains are specifically designed and tested to support and move loads vertically. They are manufactured to meet strict standards, such as Australian Standard AS 2321, and have defined working load limits (WLLs) for safe lifting.
Load chains (often referred to in securing applications) are used to restrain or anchor loads during transport or storage. While strong, they are not always rated for overhead lifting unless manufactured to the correct specification.
Using the correct chain type is essential and load chains must never be used in place of lifting chains, unless explicitly certified for the task.
Selecting the Right Chain Grade
The grade of chain refers to its material composition and manufacturing standard, which in turn dictates its strength and performance.
Grade 80 (G80): The industry standard for most lifting applications. G80 (T) Lifting chains are made from high-strength heat treated alloy steel, offering an excellent balance of strength, durability, and affordability. They are ideal for heavy duty lifting applications.
Grade 100 (G100): Around 25% stronger than G80 chains, G100 chains allow you to lift the same load with a lighter chain or lift heavier loads with the same chain size. They are ideal for high-intensity industrial lifting operations where efficiency and reduced weight matter.
Grade 120 (G120): The highest grade available in some markets, offering even higher strength-to-weight ratios. These chains are often used in the most demanding environments, such as offshore lifting or extreme heavy industry.
Choosing the correct grade will depend on load weight, frequency of use, and the need for weight reduction in your lifting gear. Bunzl Safety & Lifting offers a range of chain grades to suit everything from standard workshop lifting to high-performance industrial tasks.
Considering Breaking Load and WLL
When selecting any lifting or load chain, understanding the difference between breaking load and WLL is vital.
Breaking load is the maximum force the chain can withstand before it physically fails. This is a test value and should never be approached in operational use.
WLL is the maximum safe load the chain is designed to carry during normal operations. This is typically a fraction of the breaking load, incorporating a safety factor (often 4:1) for lifting equipment.
To determine the WLL you need, you must calculate the maximum weight of your loads, factoring in the configuration of the lift (e.g. sling angles, multiple-leg assemblies) and potential dynamic forces.
Matching the Chain to your Environment
The environment in which your chain will operate can significantly impact its performance and lifespan.
Factors to consider include:
- Corrosive Environments: Chains used in marine, offshore, or chemical environments should be made from stainless steel or feature protective coatings such as galvanising or epoxy finishes. These protect against rust, corrosion, and chemical damage.
- High-Temperature Environments: Standard lifting chains are rated up to certain temperatures, beyond which their load capacity decreases. If working near furnaces, welding areas, or other high-heat zones, you must select chains designed for elevated temperature tolerance.
- Abrasive Conditions: Construction sites, mining, and quarries expose chains to constant abrasion. In these cases, chains with hardened surfaces or specialised wear-resistant coatings will maintain performance for longer.
- Outdoor Use: Exposure to UV light, moisture, and dirt can accelerate wear. Chains for outdoor use should have weather-resistant finishes and be subject to more frequent inspection schedules.
At Bunzl Safety & Lifting, we supply chains specifically engineered for challenging environments, ensuring maximum service life and reliability under tough conditions.
Choosing the Right Chain for the Application
Different tasks require different chain designs and configurations.
- Single-Leg Chain Slings: Ideal for vertical lifting of balanced loads.
- Multi-Leg Chain Slings: Used for lifting irregular loads, with two, three, or four legs connected to a master link for stability.
- Shortening Clutches: Allow adjustment of chain length for versatile lifting configurations.
- Transport Chains: Designed to restrain loads securely in transit; often paired with load binders.
- Hand Chain for Hoists: Specifically designed for use in manual or electric chain hoists; precision-manufactured for smooth operation.
The wrong chain configuration can cause instability, uneven load distribution, and dangerous working conditions. Consulting with trained experts ensures your chain selection matches the geometry and balance of your lift.
Inspection and Maintenance
Selecting the right chain is only the first step. Regular inspection, maintenance, and certification are essential to ensuring ongoing safety and compliance.
Chains should be inspected before each use for signs of wear, corrosion, elongation, or deformation. Any chain showing damage must be removed from service immediately. Lifting chains should also undergo periodic inspections by a competent person, as required by Australian Standards.
The right lifting or load chain can improve safety, efficiency, and compliance, while the wrong choice can put your people, equipment, and business at risk. By considering grade, breaking load, WLL, environment, and application, you can ensure every lift is performed with confidence.
At Bunzl Safety and Lifting, we don’t just supply chains—we provide complete lifting and rigging solutions tailored to your operation. Our range includes high-quality, load-rated chains across all grades, along with compatible fittings, slings, and accessories. We back our products with:
- Expert consultation from LEEA-trained inspectors
- On-site and in-house testing and certification
- Chains designed to meet Australian Standards for lifting and load restraint
- Nationwide distribution for fast, reliable supply
Explore our full range of lifting & load chains here or contact our team for expert advice and tailored solutions to keep your operation moving safely.