Benefits of Lightweight Chain Technology for Mobile Plant

Ever notice how some mobile cranes seem to burn through diesel faster than others, even when doing the same work? We noticed it too. The difference often comes down to chain weight.

Many operators stick with traditional chains that keep burning extra fuel and need more repairs. Then they wonder why their competitors are running leaner operations with better margins.

For over 140 years, we’ve been manufacturing chains for Australian operators, and we see this all the time. However, the teams that switch to Grade 100 or Grade 120 chains see immediate savings.

And RUD Chains can help you save thousands annually with an upgrade that pays for itself.

In this article, we’ll walk you through:

• Lightweight chains vs traditional systems
• Real fuel savings from reduced weight
• Grade 100 vs Grade 120 performance comparison

Stick with us. We’ll show you how to cut operating costs with the right chain technology.

What is Lightweight Chain Technology?

Lightweight chains use advanced alloy steel that delivers the same strength at 25-30% less weight than traditional Grade 80 systems. The technology focuses on reducing weight without compromising lifting capacity.

Material Composition and Grade 80 Comparison

Modern Grade 100 and 120 chains achieve superior strength through heat-treated alloy steel instead of standard carbon steel. So these chains can handle extreme loads while weighing significantly less. Then again, older Grade 80 chains weigh 25-30% more than modern lightweight alternatives. 

Basically, the weight difference comes down to the metal treatment process and material quality. Alloy steel goes through heat treatment that boosts tensile strength without adding bulk, while carbon steel needs thicker links to achieve the same load ratings.

In our experience, Australian construction sites now prefer these modern Grade 100 or 120 chains for mobile equipment because the weight savings add up fast across large crane systems.

Weight Reduction Specifications

A typical mobile crane system saves between 800-1000kg by switching from Grade 80 to Grade 120 chain. That’s nearly a ton of weight you can redirect to the actual payload.

Here’s how the numbers break down: Standard Grade 120 chain weighs 3.2kg per metre versus 4.1kg for Grade 80. And over a typical 280-metre system, weight savings reach 900kg. 

When you consider transport regulations and payload limits, that extra capacity means more equipment per trip or staying within legal limits without costly modifications.

The best part is lightweight chain in Australia meets AS 1418 compliance standards. So you’re not sacrificing safety for weight reduction.

Now that we’ve covered the technical specifications, let’s look at how this weight reduction affects your bottom line through fuel savings.

How Do Lightweight Chains Reduce Fuel Consumption in Mobile Cranes?

Lower chain weight translates directly into fuel savings during both transport and lifting operations.

For mobile cranes moving between sites across Queensland or New South Wales, every kilogram counts when you’re calculating fuel costs over thousands of kilometres annually. The savings don’t stop at transport either. During lifting operations, lighter hoisting systems reduce the load on hydraulic pumps and diesel engines.

Let’s break down the fuel savings:

Lower Tare Weight and Payload Capacity Increase

Reducing your crane’s tare weight by 900kg means you can carry that much more payload without exceeding road limits. 

State transport authorities enforce certain weight restrictions to ensure road safety and infrastructure protection. When you switch to lightweight chains, mobile cranes gain 800-1000kg extra payload capacity.

Also, lower tare weight helps comply with Australian road transport regulations, especially when moving equipment between Brisbane and Sydney on public highways. If the crane exceeds legal weight limits, overweight fines can reach thousands of dollars per incident. Repeated violations lead to permit suspensions.

Based on our research, fleet operators report 12-15% fuel savings during transport between sites because lighter vehicles consume less diesel per kilometre travelled.

Reduced Engine Load During Operations

Your hydraulic pumps work less hard on every single lift throughout the day with lighter hoisting systems. They need less hydraulic pressure during lifting cycles, which directly reduces strain on diesel engines.

Better yet, the construction teams won’t have to deal with as many maintenance issues because engines wear more slowly when they’re not constantly running at peak capacity.

Over time, the reduced weight cuts fuel costs, especially in operations where cranes run daily. Even modest efficiency gains can lead to significant savings on diesel bills across large fleets. Your accountant will thank you when those fuel invoices start dropping.

Helpful Tip: Track your fuel consumption for 30 days before and after switching chains to calculate your actual ROI.

Grade 100 vs Grade 120 Chains for Crawler Cranes and Mobile Equipment

In general, we recommend Grade 100 chains for standard lifting operations and moderate-duty mobile cranes. But if you want maximum strength and longer service life for heavy-duty applications, Grade 120 is worth the investment. The price gap between them typically sits at 15-20% higher for Grade 120.

However, the choice depends on your lifting requirements, operational intensity, and how often you’re replacing chains. When you know your actual usage patterns and calculate the total ownership costs, the decision becomes much clearer.

In this section, we’re going to cover the main differences and help you work out which grade suits your operations.

Strength-to-Weight Comparison

Grade 120 chain provides 120,000 PSI minimum tensile strength compared to 100,000 PSI for Grade 100, at the same weight. Think of it like having 20% more lifting capacity without adding bulk.

As Grade 120 chains allow crawler cranes to handle heavier loads without adding counterweight or equipment, it keeps overall machine weight down.

Pro Tip: Use Grade 120 for mining and infrastructure work where load demands fluctuate throughout the day.

Maintenance Cost and Operational Savings

The real savings appear in reduced replacement cycles, lower fuel costs, and fewer unplanned maintenance shutdowns.

When it comes to maintenance, Grade 120 chains last 40% longer than Grade 100 equivalents because the superior alloy steel resists wear and stress cracking better under heavy loads. This means your replacement frequency drops significantly, which translates to less downtime and better project planning.

The operational savings add up quickly, too. Suppose you’re running a crawler crane on a mining site six days a week. With Grade 100 chains, you might need replacement every 18 months. But Grade 120 chains push that timeline out to 25-28 months.

When you factor in reduced fuel consumption and fewer emergency replacements, the price difference typically recovers within 18-24 months.

Making the Switch to Lightweight Chain Technology

Mobile crane operators face rising fuel costs and frequent maintenance schedules that eat into profits. But lightweight chain technology solves both problems without compromising safety or lifting capacity. The switch from Grade 80 to Grade 100 or Grade 120 chains delivers measurable savings from day one.

We’ve covered how modern alloy steel reduces weight, the fuel savings during transport and operations, and why Grade 120 outperforms Grade 100 for demanding applications. 

Now you know exactly what separates efficient crane operations from those that drain your budget unnecessarily.

When you’re ready to upgrade your crane systems and start cutting operational costs, we’ll be there every step of the way.