In the lifting and rigging industry, the choice of chain grade can significantly influence safety, efficiency, and operational performance. For decades, Grade 80,T(G80) alloy steel chain has been the industry standard for lifting applications. However, advances in metallurgy and manufacturing have led to the development of Grade 100 (G100) and Grade 120 (G120) chains, which offer increased strength and enhanced performance for demanding operations.
For businesses looking to boost lifting capacity, reduce equipment weight, and improve durability, upgrading to a higher-grade chain can be a smart investment. This guide explores the advantages of Grade 100 and Grade 120 chains, the key considerations before upgrading, and how Bunzl Safety and Lifting’s range of Grade 80 and Grade 100 chain slings can meet your operational needs.
Understanding Chain Grades
The grade of chain refers to its tensile strength, determined by the material composition and manufacturing process. This grading is standardised, ensuring that chains meet specific mechanical properties and safety factors.
Grade 80 (G80): Manufactured from high-strength alloy steel, G80 is suitable for most lifting applications and remains the industry benchmark for safety and reliability.
Grade 100 (G100): Offers around 25% greater strength than G80 for the same chain size, allowing for higher Working Load Limits (WLL) without increasing weight.
Grade 120 (G120): Currently the highest commercially available grade in many markets, providing up to 50% greater strength than G80, along with superior fatigue resistance and wear performance.
Advantages of Upgrading to G100 or G120
The most immediate benefit of upgrading is the increase in WLL. This means that, for a given chain size, you can lift heavier loads without upsizing the chain. For example, a 10 mm G100 chain will have a higher WLL than a 10 mm G80 chain, enabling greater capacity without additional weight or bulk.
This advantage can translate into fewer lifting legs or lighter assemblies needed for the same job, improving handling and reducing strain on operators.
Alternatively, if your load requirements remain constant, you can achieve the same WLL with a smaller-diameter G100 or G120 chain compared to G80. This results in a lighter overall lifting assembly, which is easier to handle, transport, and store. Lighter gear reduces operator fatigue, speeds up rigging, and can contribute to improved workplace safety.
Higher-grade chains, particularly G120, are designed with improved resistance to fatigue and wear. This is especially valuable for operations involving frequent lifting cycles, as it extends service life and reduces the frequency of replacement—providing long-term cost efficiency.
Some G100 and G120 chains feature special surface finishes or coatings that increase corrosion resistance and reduce surface wear. These enhancements make higher-grade chains better suited to harsh environments, such as offshore, mining, or heavy construction sites, where equipment is regularly exposed to dirt, moisture, or chemicals.
Using higher-grade chains can help future-proof your lifting operations. As industries demand higher safety margins, greater efficiency, and reduced downtime, the capability to handle heavier loads with lighter gear positions your operation ahead of evolving requirements.
Considerations Before Upgrading
While the benefits are compelling, there are important factors to consider before switching to G100 or G120.
- Cost vs. Return on Investment: Higher-grade chains generally have a higher upfront cost. The long-term benefits in productivity, reduced wear, and fewer replacements should be weighed against the initial investment.
- Compatibility with Existing Components: Ensure that hooks, master links, and other fittings are rated for the same grade as the chain. Mixing grades can compromise safety and compliance.
- Training Requirements: Operators should be trained on the differences in handling, inspection, and safe use of higher-grade chains.
- Environmental Conditions: While higher grades offer better fatigue resistance, the specific environment (temperature, corrosion risk, etc.) should still guide material choice and coating selection.
At Bunzl Safety & Lifting, we supply and assemble Grade 80 and Grade 100 chain slings to meet a wide range of lifting applications.
- Grade 80 Chain Slings: A trusted choice for general lifting, offering robust performance and excellent value. Suitable for most industrial and construction environments.
- Grade 100 Chain Slings: For operations requiring increased WLL, reduced weight, and higher fatigue resistance. Ideal for demanding sectors such as heavy manufacturing, transport, and resource industries.
Our chain slings are:
- Manufactured from high-strength, heat treated alloy steel
- Tested and certified to Australian Standards AS3775.1 and supplied with NATA test certificates
- Available in 1,2,3 & 4 leg configurations
- Customisable with shortening clutches, grab hooks, and other fittings to suit your application
- Supplied with WLL tag fitted
We don’t just supply the chain. We provide expert guidance, inspection, and compliance support. Our services include:
- LEEA-trained inspectors for on-site or in-house inspections
- NATA-accredited testing for peace of mind and full compliance
- Nationwide distribution for fast delivery
- Tailored chain sling configurations built for your operational needs
Upgrading from Grade 80 to Grade 100 or Grade 120 can deliver substantial operational and safety benefits. However, the upgrade must be implemented with careful consideration of your load requirements, existing equipment, budget, and compliance obligations.
At Bunzl Safety & Lifting, we’ll work with you to determine whether a higher-grade chain is the right choice for your operation, ensuring your investment translates into measurable gains in efficiency and safety.
Explore our range of lifting chain solutions and speak to our experts today at bunzlsafety to see how an upgrade could transform your lifting capabilities.