Innovation Spotlight: Turning Every Day Lifting Challenges into Practical Solutions

The Challenge: Bunched Slings and Shackle Stress

When performing 4-point lifts with angled slings, multiple slings can bunch together in a single shackle. This crowding increases stress on the shackles and accelerates wear on the slings, creating a higher risk of damage and reducing the overall safety and efficiency of the lift.

The Solution: Modulift Clevis Drop Link & Delta Plate

The Clevis Drop Link and Delta Plate are designed to allow two bottom shackles to be used simultaneously on 4-point lifts. By changing the orientation of the shackles, sling bunching and crowding are eliminated, reducing wear and damage to both slings and shackles. The result is a safer, cleaner lift that protects your equipment and enhances operational efficiency.

The Challenge: Risk of Accidental Hook Opening & Damage to Hook

During lifting operations, standard hooks can accidentally open or unhook, particularly when using thinner lifting accessories or under off-axis loads. This creates a serious safety risk for personnel and increases the chance of dropped loads or equipment damage. Hooks can also be damaged when dragged along the ground, often leading to broken triggers.

The Solution: pewag Oversized Self-Locking Hook

The Oversized Self-Locking Hook reduces the risk of accidental opening and hook damage. The trigger sits flush with the hook rather than protruding, and the recessed trigger design makes it easier to operate even when wearing gloves. Reinforced profiles prevent unintended hook release, while the specially shaped tip minimises accidental unhooking, even when using thinner lifting accessories.

Integrated wear and deformation indicators provide a clear visual reference, allowing operators to identify when inspection or replacement is needed. The raised clevis profile also ensures the last link in the chain is less likely to wear prematurely, supporting safer and more reliable lifting operations.

The Challenge: Uneven Load Distribution and Difficult Sling Assessment

When using 2-leg or 4-leg slings, improper contact with the crane hook can lead to uneven load distribution. This increases stress on lifting equipment and makes it harder for operators to quickly and accurately assess sling angles, potentially compromising lift safety.

The Solution: pewag Oversized Master Link

Engineered for use with 2-leg and 4-leg slings, the oversized master link ensures improved contact with the crane hook, helping to distribute loads evenly. Manufactured to DIN 15401 standards, it delivers strength, durability, and reliability.

Its lower geometry allows operators to quickly assess sling angles, providing a clear visual guide to ensure lifts are safely and correctly configured.

The Challenge: Limited Working Load Limit Without Upsizing

When lifting with chain slings, the Working Load Limit (WLL) is often constrained by the chain size. This can limit the load that can be lifted safely, requiring larger, heavier chains to achieve higher capacities. Upsizing chains adds cost, weight, and complexity, making lifts less efficient and more cumbersome to manage.

The Solution: pewag Load Distributor

The Load Distributor safely increases the Working Load Limit of chain slings without upsizing the chain.

For example, a 3-leg Grade 12 chain sling at 0–45° has a WLL of 10.6 t without a Load Distributor. With one fitted, this rises to 14 t — a 32% increase. Simple to use, it delivers higher load capacity while maintaining full safety, making lifting operations more efficient and effective.

The Challenge: Sling Wear and Reduced Durability on Heavy Lifts

When lifting heavy loads from 12 Te upwards, standard round sling sleeves are prone to abrasion and wear. This can damage the inner sling, reduce the sling’s lifespan, and compromise reliability during demanding lifts, increasing maintenance costs and safety risks for operators.

The Solution: Aberdeen Web Tough Outer Sleeve

From 12 Te upwards, Aberdeen Web round slings can be fitted with a Tough Outer Sleeve, offering significantly increased abrasion resistance compared to standard sleeves.

This enhanced sleeve protects the inner layer from wear, extends the life of the sling, and ensures reliable performance on heavy lifts, giving operators confidence to work safer and stronger.

The Challenge: Uncertainty Around Load Balance and Centre of Gravity

When lifting complex or irregular loads, it can be difficult for operators and engineers to accurately determine the centre of gravity. Misjudging load balance can lead to uneven sling angles, unstable lifts, increased risk of accidents, and inefficient rigging, compromising both safety and operational efficiency.

The Solution: LMS Centre of Gravity (CoG) Software

The LMS CoG software allows operators and engineers to visualise the centre of gravity of complex loads with ease. By providing accurate, real-time data, it helps plan lifts safely by optimising sling angles, load distribution, and rigging configurations.

Integrated with LMS load monitoring devices, the CoG software reduces risk, helps prevent accidents, and ensures every lift is controlled, precise, and compliant with safety standards.

The Challenge: Unreliable or Undetected Pad Eye Wear

Pad eyes are critical lifting points, but wear, damage, or deformation can go unnoticed until it’s too late. Failing to identify compromised pad eyes increases the risk of lift failures, endangering personnel, damaging equipment, and causing costly downtime on site.

The Solution: LMS Digital Pad Eye Tester

The LMS Digital Pad Eye Tester provides quick and accurate checks of pad eye integrity, helping prevent failures before they happen.

Lightweight and easy to use, it delivers precise load readings, giving confidence that lifting points are safe. Commonly used in offshore applications, it verifies weld integrity and confirms the pad eye will not stretch, bend, or fail under load.

By identifying damaged pad eyes early, it reduces risk, improves on-site safety, and supports efficient, reliable lifting operations.

The Challenge: Controlling Heavy, Imbalanced Loads Safely and Efficiently

Managing heavy or unevenly balanced loads can be difficult and hazardous. Traditional lifting methods often require multiple operators and frequent repositioning, and can strain equipment. This increases the risk of accidents, downtime, and inefficient operations. Electric load control systems may also struggle to maintain performance under heavy or prolonged use.

The Solution: pewag Load Balancer & Compensator (Levo)

The Levo Load Balancer and Compensator deliver smooth, precise load control, outperforming electric equivalents with the strength and accuracy required to manage heavy imbalances. Powered by hydraulics, it reduces energy use while maintaining full performance even where electric motors falter.

The Levo enables multi-directional movement without stopping to reposition, keeps personnel out of danger through remote operation up to 100 m, and lowers labour costs by requiring fewer operators. Durable and low maintenance, it also features flexible load turning (5 t option with belt attachment), integrated floodlights for enhanced visibility, free-release functionality, and options for use with chain or synthetic slings.

For more information, please contact our UK sales team at [email protected].