Chain come alongs—commonly known as lever hoists—are among the most versatile lifting and pulling tools used across construction, maintenance, industrial, and mechanical projects. Their compact design, precise load control, and ability to perform horizontal, vertical, or angled pulls make them an essential component of many lift plans.
However, improper use of a lever hoist can lead to equipment damage, reduced service life, or serious jobsite safety risks. Below are some of the most common chain come along misuses and practical steps to prevent them.
When a lever hoist is used in a straight vertical or horizontal pull, the rated capacity of the hoist applies directly. But when the pull shifts to an angled or diagonal position, additional forces increase the actual tension placed on the hoist and rigging hardware.
For example, a load requiring a 5-ton lift at a 45-degree angle may generate forces that exceed the rated capacity of a 6-ton lever hoist once sling tension and angle factors are considered. Failure to account for these forces can result in equipment overload, load instability, or component failure.
Best practice: Always calculate sling tension and load angles as part of your lift plan and select equipment rated appropriately for the true applied load.
Adding a cheater bar to extend the lever handle is one of the most dangerous lever hoist practices. While a longer handle may reduce the physical effort required to move the load, it also bypasses the designed operating limits of the hoist and can easily overload internal components.
In many cases, this results in bent handles, damaged gearing, or sudden mechanical failure, creating significant safety hazards for operators and nearby personnel.
Best practice: Never modify the handle length. If additional pulling force is required, use a hoist with a higher rated capacity instead of attempting to increase leverage manually.
The load chain of a lever hoist is designed strictly for lifting and pulling in-line loads. Using the chain in a choker configuration or as a tie-down/binding device can bend hooks, twist links, and permanently damage the hoist. Once a hook or chain is deformed, the hoist must be removed from service for inspection, testing, and recertification.
Best practice: Always use properly rated slings, shackles, or tie-down equipment for choking or securing loads. Lever hoists should never be used for load binding.
Proper rigging practices can significantly extend the service life of a lever hoist. Using accessories such as shackles, beam clamps, and properly rated suspension hardware helps protect hoist hooks from excessive wear and ensures loads are applied correctly to the lifting system.
Small rigging adjustments—such as connecting the hoist hook to a shackle rather than directly to a lifting lug—can reduce stress on equipment, minimize maintenance costs, and improve overall lifting safety.
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