7 Common Mistakes When Using a Manual Chain Hoist (Over 90% of lifting accidents are caused by improper use)

Manual chain hoists are widely used in construction, manufacturing, warehousing, and maintenance work.
However, field experience shows that more than 90% of manual chain hoist accidents are not caused by product defects, but by incorrect operation.

Below are 7 common and quantifiable mistakes that significantly increase the risk of failure and accidents.

Mistake 1: Overloading the Hoist (≈35% of serious accidents)

Typical behavior:

Using a 3-ton manual chain hoist to lift 4–5 tons
Ignoring dynamic load during lifting

Quantified impact:

Brake system load increases by 25–50%
Chain fatigue life reduced by over 60%
High risk of brake slipping or hook deformation

Even with G80 lifting chain (4:1 safety factor), overloading is strictly prohibited.

Mistake 2: Side Pulling or Non-Vertical Lifting (≈20%)

Typical behavior:

Hoist not positioned directly above the load
Pulling the hand chain at an angle

Quantified impact:

Chain and load wheel wear increases 2–3 times
Higher risk of chain jamming and uneven stress

Manual chain hoists are designed for vertical lifting only.

Mistake 3: Insufficient Suspension Point Strength (≈15%)

Typical behavior:

Hanging the hoist on scaffolding or thin beams
Not checking the WLL of the anchor point

Quantified impact:

Anchor point failure risk increases 3–5 times
Failures are often sudden and without warning

👉 The suspension point must be at least as strong as the hoist itself.

Mistake 4: Twisted or Misaligned Load Chain (≈10%)

Typical behavior:

Load chain twisted 180°
Chain not properly seated in the load wheel

Quantified impact:

Local stress on chain links increases by over 40%
Increased risk of jamming and abnormal wear

Mistake 5: Jerking the Hand Chain (≈8%)

Typical behavior:

Pulling the hand chain violently to lift faster
Applying sudden force repeatedly

Quantified impact:

Impact load on gears increases 1.5–2 times
Accelerated wear of braking components

Mistake 6: Using a Manual Chain Hoist for Continuous Lifting (≈7%)

Typical behavior:

Long, uninterrupted lifting operations
Replacing an electric hoist with a manual hoist

Quantified impact:

Brake overheating
Significant reduction in service life

Manual chain hoists are designed for intermittent lifting, not continuous operation.

Mistake 7: Lack of Inspection and Maintenance (≈5%)

Typical behavior:

Using rusty or dry chains
Ignoring worn hooks or safety latches

Quantified impact:

Increased risk of chain jamming
Reduced braking reliability

How to Use a Palan manuel à chaîne Safely

✔ Never exceed the rated load
✔ Lift vertically at all times
✔ Inspect hooks and chains before use
✔ Lubricate the load chain regularly

Why VD Manual Chain Hoists Are Built for Safety

1.25× dynamic load tested
1500-cycle life tested
Dual pawl braking system
G80 lifting chain with 4:1 safety factor
Heat-treated internal gears for durability

Conclusion

Even the best manual chain hoist cannot compensate for incorrect operation.
Understanding and avoiding these common mistakes is the key to safe and reliable lifting.