Grade 120 vs Grade 100 Chain: Weight and WLL Differences

Are you trying to decide between grade 120 vs grade 100 chains for your mining operation? Well, Grade 120 lifts 20% more but costs more, while Grade 100 offers great value for most jobs.

The thing is, Grade 100 chains work well for standard overhead lifting applications and represent the sweet spot for most operations. On the other hand, Grade 120 chains provide higher lifting capacity with less weight, which makes them perfect for remote operations where every kilogram counts. The choice comes down to your working load requirements and budget.

At RUD Chains, we manufacture both grades in our Brisbane facility and help Australian mining operations choose the right lifting equipment for their specific needs.

In this guide, we’ll cover the performance differences, weight savings, and cost analysis so you can pick the right chain grade for your operation.

Ready to learn more? Let’s get started.

What Makes Grade 120 Chains Different from Grade 100

Grade 120 chains pack 20% more lifting capacity than Grade 100 chains, but the real differences go far beyond basic strength numbers. If you’ve been using Grade 100 chains for your overhead lifting operations, you might wonder what makes Grade 120 worth the extra cost. The truth is, these chains come with completely different engineering from the ground up.

The following are the main differences you need to know:

• Square links vs rounded links: Grade 120 uses square links instead of the rounded links in Grade 100 chains. These square links create more bearing surface contact, which means the working load gets spread out better across different grades of chain.
• Better steel treatment: Both chain grades use high-strength alloy steel material, but Grade 120 goes through more precise heat treatment. This process gives you superior tensile strength while keeping the chain flexible. The result is higher minimum breaking load ratings than Grade 100.
• Stricter quality control: Grade 120 chains need tighter manufacturing tolerances and go through stricter testing. Each batch gets individual proof testing to check the breaking strength, which costs more but ensures reliable performance.

The manufacturing differences don’t stop there. When you’re working with RUD Chains, you’ll find that Grade 120 chains also get better surface treatments that help them last longer against wear and tear.

These upgrades give you better performance for rigging jobs where you can’t afford equipment failure. For industries like mining and construction, this extra reliability helps keep your workers safe and your operations running smoothly.

Grade 120 vs Grade 100 Working Load Limit Comparison

Grade 120 chains lift 20% more than Grade 100 chains of the same diameter. This gives you a higher lifting capacity without increasing chain size. The difference becomes important when you’re trying to determine the right chain grade for your lifting equipment.

You’ll also save weight while getting more capacity, which helps with manual handling and transportation costs.

Here’s what the numbers look like across common chain sizes:

• 8mm chains: Grade 100 handles a safe working load of 2.5 tonnes for direct lifting, while Grade 120 handles 3 tonnes. That’s a solid 0.5 tonne increase that could make the difference in your lifting capacity.
• 13mm chains: Grade 100 lifts 6.7 tonnes compared to Grade 120’s 8 tonnes. Now you’re looking at over a ton more lifting capacity with the same diameter chain.
• 16mm chains: Grade 100 manages 10 tonnes while Grade 120 handles 12 tonnes. This 2-tonne difference becomes significant when you’re planning heavy lifts.

Safety Factor and Load Calculations

The safety factor implications matter for your operations, too. Both grades maintain the standard 4:1 safety factors required by Australian standards, but Grade 120’s higher minimum breaking load gives you an additional safety margin.

If you’ve ever dealt with shock loading or unexpected force during crane operations, this extra safety margin becomes important. Grade 120’s strength advantage means you can either lift heavier loads or add an extra safety buffer for challenging jobs where conditions change quickly.

Multi-Leg Sling Performance

Load limits change when you’re using multi-leg chain slings with your gantry cranes. At 60-degree sling angles, both grades experience capacity reduction according to the working load limit WLL calculations. 

However, Grade 120 maintains proportionally higher limits throughout the angle range.

Instead of oversizing Grade 100 chains to get the working load you need, Grade 120 lets you use smaller components. You still get the same lifting performance but with less weight and bulk to handle.

Weight Savings and Cost Analysis: When Grade 120 Pays Off

The best part about Grade 120 chains is that you get more lifting capacity with less weight, but does the math work for your operation? Many Australian mining companies wonder if the higher upfront cost makes sense for their specific applications. The answer depends on how often you use the equipment and whether weight reduction creates measurable benefits for your job sites.

Weight Differences Between Chain Grades

Let’s look at a practical example. A Grade 100 chain sling rated for 10 tonnes requires 16mm chain, weighing approximately 2.5kg per metre. Compare that to an equivalent Grade 120 setup, which uses a 13mm chain at 1.7kg per metre. The result is 32% lighter while maintaining identical load limits.

The difference becomes obvious when you handle the equipment. A 20-metre Grade 120 sling weighs 34kg compared to 50kg for an equivalent Grade 100. This 16kg difference becomes significant when competent person operators handle multiple slings daily across various applications in light construction or heavy industrial work.

Transportation and Handling Benefits

Think about remote mine sites where every kilogram counts during equipment mobilisation (helicopter transport costs around $3,000 per hour). When you use lighter lifting equipment, you get more payload capacity for essential hardware transport. This means fewer trips and lower overall costs.

Manual handling becomes easier, too. Less weight means less physical strain on riggers, which reduces injury risk and improves productivity across your rigging applications.

Cost Analysis and Investment Returns

Cost analysis reveals Grade 120’s value proposition emerges in high-utilisation scenarios. While initial purchase costs from the manufacturer run 40-60% higher than grade 80 alternatives, you need to look at the bigger picture.

The reduced handling time alone saves money. When your riggers can move slings faster and with less physical strain, productivity goes up. You also cut transportation costs significantly (especially important for FIFO operations).

Based on our experience working with Australian mining companies, these efficiency gains create payback periods of 12-18 months for active operations.

When Grade 120 Makes Financial Sense

Choose Grade 120 when weight reduction provides clear operational benefits. This includes crane hook applications where capacity is important, rigging industry jobs with frequent sling changes, and remote locations where every kilogram costs money to transport.

On the other hand, grade 100 remains suitable for standard construction applications where cost sensitivity outweighs the weight and capacity advantages of Grade 120 chains.

Choosing the Right Chain Grade for Australian Mining Operations

Now that you know the performance differences, how do you determine which grade makes sense for your specific mining operation and rigging industry requirements?

The answer depends on three main factors: your compliance requirements, environmental conditions, and specific application needs.

Australian Standards and Compliance Requirements

• AS 3775 compliance: Australian Standard 3775 covers both Grade T(80) and Grade V(100) systems, with Grade 120 meeting or exceeding Grade V requirements.
• Documentation needed: You’ll need your supplier to provide Australian compliance documentation and proof testing certificates calculated based on local safety standards and health administration regulations.
• Individual certificates: Each chain batch comes with test certificates showing the minimum breaking load and working load limit WLL for your specific equipment (essential during safety inspections).

Environmental Factors in Australian Mining

• Harsh conditions: Extreme temperatures, corrosive environments, and abrasive materials in Australian mines favour Grade 120’s superior resistance to wear and tear.
• Durability advantage: The enhanced metallurgy withstands degradation better than Grade 100 in challenging conditions where ensuring safety is paramount.
• Cost consideration: Dust, moisture, and temperature swings can accelerate chain wear, making Grade 120’s durability worth the extra cost in tough environments.

Application-Specific Selection Criteria

Choose Grade 120 for:

• Critical lifts where failure isn’t an option
• Remote operations where reliability is essential
• High-frequency lifting applications
• Crane hook applications and gantry cranes handling heavy loads regularly
• When weight reduction provides clear operational benefits

Choose Grade 100 for:

• Standard construction applications where cost sensitivity outweighs performance advantages
• Light construction projects and less demanding rigging applications

Getting Expert Guidance

When you’re working with RUD Chains’ Brisbane facility, you’ll get local manufacturing, testing, and engineering support for both grades. Our mechanical engineers can assess your specific requirements and explain which solution will carry your loads safely while meeting all applicable regulations for your operation’s unique challenges.

What works best is matching the chain grade to your specific needs rather than choosing the highest grade available.

Making the Right Chain Grade Decision for Your Operation

Equipment failures in Australian mining operations can cost hundreds of thousands of dollars and put lives at risk. When you understand the differences between Grade 120 and Grade 100 chains, you can make the perfect decisions that improve safety and reduce costs.

Throughout this guide, we’ve shown you how Grade 120 chains deliver 20% more lifting capacity with 32% less weight, along with the cost analysis to determine when the investment makes sense. You’ve also learned about Australian compliance requirements and application-specific selection criteria for your operations.

Now, are you ready to upgrade your lifting operations with the right chain grade? Contact RUD Chains today for expert guidance on selecting the best solution for your needs. We provide custom lifting solutions and engineering support that keep Australian mining operations running safely and productively.