Chain Sling Grades Explained: 80 vs 100 vs 120

Choosing the right chain sling involves more than just selecting the correct length or fittings. The grade of the alloy-steel chain determines its safe working load capacity, mechanical performance, and elongation characteristics. Historically, the first lifting chains featuring a minimum elongation of 20% became the standard for overhead lifting in the 1980s. As load requirements increased, advancements in steel metallurgy led to the development of higher grades such as Grade 100 and Grade 120, which gained popularity for their greater working load limits (WLL), enhanced durability, and reduced weight.

This article explores the differences among chain grades in terms of design, capacity, application, and compliance standards.

Disclaimer : This article is intended for informational purposes only. Always verify capacities and configurations with the manufacturer's load charts and follow the relevant OSHA/ASME standards. Never carry out a lift based solely on this information.

Grade 80 - The Industrial Chain

Grade 80 chain is a heat-treated alloy steel chain frequently used in overhead lifting slings. It is known for its strength, toughness, and cost-effectiveness in a wide range of rigging applications. Beyond meeting the minimum 20% elongation requirement, Grade 80 often exceeds this threshold, making it the most ductile and deformable among the commonly used lifting chain grades, a property that provides an additional margin of safety under extreme loading conditions. Usually finished in black (though colors may vary by manufacturer), these chains are designed with a 4:1 safety factor in accordance with ASME B30.9 Section 9-1.4.1.

Best suited for : For general lifts that are not extremely high-stakes or weight-sensitive, Grade 80 offers a reliable balance of performance and economy. Like most alloy chains used in lifting applications, it maintains its strength and structural integrity even when exposed to elevated temperatures, a common requirement in foundries, steel mills, and heavy-maintenance environments. Grade 80 chains retain a higher proportion of their working load limit under these demanding conditions compared to Grade 100 or Grade 120, which are somewhat more sensitive to heat exposure.

Grade 100 - The Workhorse Upgrade

Grade 100 chain is manufactured from a high-performance alloy steel and undergoes a specialized heat-treatment process that enhances both its strength and toughness. While maintaining an elongation of over 20%, a key safety characteristic that distinguishes chains from wire rope or synthetic slings, it provides roughly 25% higher working load limit (WLL) than a Grade 80 chain of the same diameter and weight. This improvement allows for the use of smaller, lighter chains to handle equivalent loads, resulting in easier handling and more efficient rigging operations.

For example, a ½-inch Grade 80 chain sling may have a capacity of approximately 12,000 lb, whereas a ½-inch Grade 100 chain can reach around 15,000 lb, though actual ratings should always be confirmed using the manufacturer’s load charts. In addition to higher strength, Grade 100 chains typically offer better abrasion resistance, making them a reliable choice for demanding industrial, construction, and general lifting applications where both durability and performance are required.

Grade 120 - The Premium Chain

Grade 120 chain represents a major advancement in lifting chain technology. It is produced from one of the most advanced alloy steels available and retains an elongation of over 20%, maintaining the critical ductility expected from high-quality lifting chains. A defining feature of Grade 120 is its profile-link geometry, which departs from the traditional round-link design. Each link forms four contact points with the adjacent link, distributing the load evenly rather than concentrating stress on a single point as in round-link chains. This innovation significantly **reduces internal wear between links, by as much as a factor of four, **resulting in a much longer service life and improved durability under repeated loading cycles.

Beyond its re-engineered shape, the enhanced alloy composition and precision heat treatment elevate its mechanical performance to the Grade 120 level, allowing for up to 50% higher Working Load Limit (WLL) compared with an equivalent Grade 80 chain, while remaining lighter per foot.

The square-profile design also improves link alignment, minimizing twisting or tangling during lifting operations. With superior abrasion resistance and outstanding strength-to-weight characteristics, Grade 120 chains are ideal for demanding lifting applications where the weight of the rigging equipment plays a critical role, such as in heavy fabrication, energy, and aerospace industries, where every pound saved can make a significant difference.

Comparison Summary

Note : These are typical ranges. Always confirm values from certified load charts.

Example (Sample)

A ½-inch single-leg sling rated at 12,000 lb (WLL) in grade 80 might need only a ⅜-inch grade 120 chain to support the same load, reducing sling weight by nearly 20%. This weight reduction is significant when using multiple slings or handling lengthy chains. Always check manufacturer charts and avoid relying solely on rule-of-thumb estimates.

Inspection & Safety

Frequent Inspection (Before Each Use)

Per OSHA 1910.184(d) and ASME B30.9 Section 9-4.1.1, slings must be visually inspected by a competent person before each shift and after any event that might damage the chain (shock loading, chemicals, etc.).

Periodic Inspection (Scheduled)

A qualified inspector should perform documented inspections at intervals based on service severity, frequency, and environmental impact.

Removal Criteria :

• Missing or illegible identification tag.
• Links stretched over 5 %.
• Cracks, gouges, nicks, or distortion.
• Excessive wear that reduces link thickness.
• Heat damage or non-manufacturer weld repairs.
• Corrosion or loss of the original surface finish.

Maintaining detailed inspection records is also required for ASME compliance.

Compliance and Standards for Chain Slings

All overhead lifting slings used in the United States must comply with the regulations set forth by the Occupational Safety and Health Administration (OSHA) and the design/performance standards from the American Society of Mechanical Engineers (ASME).

• OSHA 1910.184 - Slings : This is the federal law that governs the use, inspection, and removal criteria for all types of lifting slings in general industry.
  • Reference : OSHA 1910.184 Official Standard
• ASME B30.9 - Slings : This is the detailed industry consensus standard that provides specific guidance on the fabrication, marking, and testing of slings, including the specific properties of different chain grades.
  • Reference : ASME B30 Safety Standards Page
• Manufacturer’s Load Charts - Must always be referenced for precise WLL, chain combinations, and angles

Following these standards is not optional; it is a fundamental requirement for providing a safe and compliant lifting environment.

How to Choose the Right Chain Grade

Selecting the right chain grade directly affects both lifting performance and workplace efficiency. Although Grades 80, 100, and 120 are all approved for overhead lifting, each is suited to different operational needs.

• Grade 80 : A practical choice for general lifting where cost control is important and sling weight is not a major concern.
• Grade 100 : The current industry preference for most lifting operations. It provides higher lifting capacity with a lighter sling compared to Grade 80, offering an efficient balance of strength and handling.
• Grade 120 : Designed for specialized lifts where maximum strength, reduced sling weight, best abrasion resistance are critical factors for optimizing load handling.

Common Mistakes & Misuse

1. Using hoist load chain interchangeably with lifting chain

Alloy lifting chain is not precision-calibrated for use as hoist load chain. Using it in a hoist or winch is non-compliant with safety standards and can lead to equipment failure or serious injury.

2. Overuse without inspection / improper care

Leaving chain on the ground, dragging, or exposing to chemicals accelerates wear and damage.

3. Using Grade 70 or lower for overhead lifts

Grade 70 chain, made from carbon steel, is not approved for overhead lifting. It lacks the ductility, toughness, and mechanical performance required of alloy lifting chains. Using Grade 70, or mixing it with lifting-grade chains, can lead to serious safety incidents, as many field accidents have resulted from incorrectly combining different chain grades.

4. Mismatched components

Always match the chain grade with the corresponding fittings, hooks, master links, and couplers. Using a weaker or mismatched component immediately invalidates the rated capacity and compromises safety. In a properly designed lifting chain sling, the chain is intended to elongate under overload, providing a visible warning before failure. This ductile behavior is a key safety advantage of alloy lifting chains, and it only works as intended when all components are rated for the same chain grade.

5. Price & Material Considerations

Higher chain grades require more advanced alloys, heat treatments and manufacturing precision, which increases cost. The biggest price jump is when you move from carbon to alloy chain. But often, the performance benefits of grade 100 or 120 outweigh the extra cost, especially for heavy or frequent lifting.

FAQs

Q. Can all three grades be used for overhead lifting?

A. Yes, grade 80, 100, and 120 alloy chain slings are acceptable if manufactured and proof-tested per ASME B30.9 and marked properly.

Q. What’s the difference in strength between grades?

A. Grade 100 is ~25 % stronger than grade 80 (same diameter), and grade 120 is 50 % stronger (always refer to manufacturer charts).

Q. Are color codes standardized?

A. No. Color helps identify products visually, but capacity must be confirmed via stamped markings, not color alone.

Q. Do higher grades require matching fittings?

A. Absolutely. Hooks, master links, and couplers must be rated and certified for the same chain grade to preserve system capacity.

Q. How frequent should chain slings be inspected?

A. Before each use by a competent person, and periodically by a qualified inspector (per ASME B30.9 guidelines).

Q. When should a chain sling be removed from service?

A. Remove the chain sling from service if any link is stretched more than 5%, cracked, heat-damaged, or corroded, or if wear has reduced the link diameter by 10% or more. It must also be removed if the identification tag is missing, as required by OSHA and ASME standards.

Q. Are Grade 120 chains compatible with Grade 100 components?

A. Absolutely not. Always use components that are rated for the same grade as the chain. Mixing different grades can cause unexpected failure of the fittings or accessories. Remember, in a proper lifting sling, only the chain is designed to elongate under overload, providing a visible warning before failure. This critical safety feature works only when all components are matched to the same chain grade.

Know More

Understanding how chain sling grades impact strength, weight, and inspection requirements is vital for safe, efficient lifts. As projects grow heavier, the right grade, be it grade 80 chain, grade 100 chain, or grade 120 chain, which can offer both safety and performance benefits. Whenever in doubt, reference manufacturer charts, confirm ASME/OSHA compliance, and involve rigging professionals for final validation.