Lever blocks, also known as lever hoists, are indispensable tools in industries such as construction, mining, and manufacturing, offering a reliable means to lift, lower, and position heavy loads with precision. Their compact design and manual operation make them especially valuable in environments where space is limited or where power sources are unavailable. This guide provides a comprehensive overview of lever blocks, their applications, and a step-by-step approach to their safe and effective use.

What is a Lever Block?

A lever block is a manual device equipped with a lever handle and internal gear mechanism, designed to lift or pull heavy loads. By cranking the handle, the operator engages the gear system, which incrementally moves the load chain over a load sheave, facilitating controlled lifting or lowering of the load. Unlike chain blocks that operate vertically, lever blocks can function both vertically and horizontally, offering versatility in various lifting and pulling applications.

Key Components of a Lever Block

• Lever Handle: The arm used to operate the hoist manually.
• Load Chain: A high-strength chain that bears the load during lifting or pulling.
• Load Hook: The hook that attaches to the load, often equipped with a safety latch to prevent disengagement.
• Top Hook: The hook used to anchor the hoist to a secure point.
• Brake System: Ensures the load remains in position when the lever is not in motion.

Advantages of Using Lever Blocks

• Portability: Their compact and lightweight design allows for easy transport and use in confined spaces.
• Versatility: Capable of lifting, pulling, and positioning loads in both vertical and horizontal orientations.
• Precision: Offers fine control over load movement, essential for delicate operations.
• Independence from Power Sources: Ideal for remote locations or areas without access to electricity.

Step-by-Step Guide to Using a Lever Block

1. Pre-Operation Inspection:

Before you begin any lifting operation, always inspect your equipment thoroughly.

• Inspect the Lever Block Body: Check the housing for any visible signs of damage such as cracks, warping, rust, or excessive wear. If the lever handle is bent or the mechanism feels sticky or jammed, the device should not be used.
• Check the Load Chain: Unravel the load chain fully and look for twists, kinks, corrosion, or stretching. Each chain link should be free-moving and not deformed. Make sure the chain is properly lubricated and clean.
• Examine the Hooks: Both the load and suspension hooks should rotate freely and be free from cracks or bending. Ensure that the safety latches are functioning properly and will close fully to prevent slippage.
• Verify the Brake System: The internal brake must engage and release smoothly. Conduct a light tension test with a small load or apply a bit of resistance manually to confirm functionality.

2. Secure the Top Hook:

Proper anchoring is essential for a safe lift.

• Select a Suitable Anchor Point: Choose a beam, bracket, or fixed structure capable of supporting at least 150% of your intended load. Use appropriate rigging gear such as a beam clamp or anchor sling rated to match the working load limit (WLL) of the lever block.
• Attach the Top Hook: Engage the top hook of the lever block onto the anchor point. Ensure the hook's safety latch is securely closed. The hook should align with the direction of the lift to avoid side loading, which can weaken the system and cause failure.

3. Attach the Load:

Connecting the load correctly helps maintain balance and control.

• Wrap or Attach the Load Securely: Use rated lifting slings, chains, or other appropriate rigging equipment to cradle the load.
• Centre the Hook: The load should be positioned directly beneath the hook. An off-centre connection can cause swinging, tipping, or overload one side of the mechanism.
• Engage the Safety Latch: Once the load hook is in place, double-check that the safety latch is closed and secure.