{"id":3325,"date":"2026-05-14T03:45:00","date_gmt":"2026-05-14T03:45:00","guid":{"rendered":"https:\/\/sprocket-chain.net\/?p=3325"},"modified":"2026-05-14T03:45:00","modified_gmt":"2026-05-14T03:45:00","slug":"leaf-chain-and-hoist-chain","status":"publish","type":"post","link":"https:\/\/sprocket-chain.net\/ru\/leaf-chain-and-hoist-chain\/","title":{"rendered":"Leaf Chain and Hoist Chain: AL\/BL Series, Forklift Mast Drives and Safe Working Loads"},"content":{"rendered":"
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Lifting & Hoisting<\/div>\n
ASME B29.8 \u00b7 ISO 4347 \u00b7 EN 14659<\/div>\n<\/div>\n

Leaf Chain and Hoist Chain: AL\/BL Series, Forklift Mast Drives and Safe Working Loads<\/h1>\n

Leaf chain is not roller chain with the rollers removed. It is a structurally distinct product category with its own fatigue standards, inspection requirements, and mandatory retirement criteria \u2014 and mixing up these criteria with roller chain practice is responsible for the majority of serious leaf chain failures in forklift and hoist applications.<\/p>\n

Confirm Your Leaf Chain Specification and Replacement Interval<\/a><\/p>\n<\/div>\n<\/div>\n

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An investigation into a forklift mast chain failure at a Incheon logistics terminal in 2024 found that the AL1022 leaf chain on the mast had been replaced at 3% elongation \u2014 the same threshold the maintenance team applied to the drive roller chains on the same vehicles. This was incorrect. For leaf chain in lifting service, ASME B29.8 requires retirement at 2% elongation for standard service and 1.5% elongation for applications where the chain is exposed to corrosion or shock loads. The chain that failed had been measured at 2.1% elongation and returned to service. The failure was a fatigue crack through a link plate \u2014 not a single-event overload, but the cumulative result of running a chain at cyclic loads above the fatigue limit for several hundred additional cycles after the retirement threshold had been passed.<\/p>\n

Leaf chain failures in lifting equipment are not failures of the chain material or the chain manufacturer’s specification. They are almost always failures of the inspection and retirement programme. Understanding why leaf chain has different retirement criteria from roller chain \u2014 and why those criteria exist \u2014 is the foundation of a safe hoist chain maintenance programme.<\/p>\n

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What Leaf Chain Is \u2014 Structure and Why There Are No Rollers<\/h2>\n
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Leaf chain consists of alternating sets of link plates joined by hardened steel pins. There are no bushings, no rollers, and no outer link plates in the conventional roller chain sense \u2014 every plate in a leaf chain is an inner plate that bears directly on the pin surface. The strength of leaf chain comes from the total cross-sectional area of the link plates at the pin hole, multiplied by the number of plate strands in the chain series.<\/p>\n

The absence of rollers is deliberate. Leaf chain is designed exclusively for reciprocating linear motion over a sheave (pulley), not for engagement with a sprocket tooth at speed. In a forklift mast drive, the chain wraps around a fixed or moving sheave at the top of the inner mast and connects the carriage to the mast structure. The chain’s function is to transmit the hydraulic cylinder force into carriage lift force \u2014 a pure tension application with no angular velocity component at the contact surface. Rollers would add weight, cost, and failure modes without adding any functional benefit in this application.<\/p>\n<\/div>\n

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Leaf chain anatomy<\/div>\n
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Link plates<\/div>\n
High-carbon steel, heat-treated. Multiple plates per strand. Each plate bears direct tensile load through the pin hole.<\/div>\n<\/div>\n
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\u0411\u0443\u043b\u0430\u0432\u043a\u0438<\/div>\n
Case-hardened. Larger diameter relative to pitch than roller chain pins \u2014 designed for high cyclic bending and shear under repeated lifting loads.<\/div>\n<\/div>\n
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No bushings or rollers<\/div>\n
Plates articulate directly on the pin surface. Pin wear = inner plate hole enlargement = elongation.<\/div>\n<\/div>\n
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Lacing pattern<\/div>\n
Plates interleaved in alternating sets \u2014 the AL\/BL series codes define how many plates per set and the pitch.<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n

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AL vs BL Series: The Naming System and What Each Series Represents<\/h2>\n

ASME B29.8 defines two leaf chain series \u2014 AL (even lacing) and BL (balanced lacing). The letter prefix encodes the lacing pattern, which determines the plate distribution across the pin. The number that follows encodes first the pitch group and then the lacing count.<\/p>\n

In AL-series chain, the plates are arranged in sets of equal count on each side of the centre line \u2014 2\u00d72, 3\u00d73, 4\u00d74, and so on. In BL-series chain, the centre set has additional plates that are not mirrored on both sides \u2014 the lacing is asymmetric through the chain cross-section. BL chain is generally heavier and stronger per pitch than AL chain of similar designation, and it is the standard specification for forklift mast chains in medium and large industrial trucks. AL chain is more commonly found in lighter industrial hoist and balancer applications.<\/p>\n

\n\n\n\n\n\n\n\n\n\n\n\n\n
\u041d\u043e\u043c\u0435\u0440 \u0446\u0435\u043f\u0438.<\/th>\n\u0420\u044f\u0434<\/th>\n\u0428\u0430\u0433 (\u043c\u043c)<\/th>\nPlate Width (mm)<\/th>\n\u041c\u0438\u043d\u0438\u043c\u0430\u043b\u044c\u043d\u0430\u044f \u0440\u0430\u0437\u0440\u044b\u0432\u043d\u0430\u044f \u043d\u0430\u0433\u0440\u0443\u0437\u043a\u0430 (\u043a\u041d)<\/th>\nASME Safe Working Load (kN)<\/th>\nTypical Forklift Capacity<\/th>\n<\/tr>\n<\/thead>\n
AL622<\/td>\nAL (even)<\/td>\n19.05<\/td>\n8.9<\/td>\n69.0<\/td>\n17.2<\/td>\nLight hoist, balancer \u22641.5 t<\/td>\n<\/tr>\n
AL844<\/td>\nAL (even)<\/td>\n25.40<\/td>\n11.2<\/td>\n133.0<\/td>\n33.2<\/td>\nLight reach truck 1.5\u20132.5 t<\/td>\n<\/tr>\n
BL634<\/td>\nBL (balanced)<\/td>\n19.05<\/td>\n9.4<\/td>\n133.0<\/td>\n33.2<\/td>\nCounterbalance truck 1.5\u20133 t<\/td>\n<\/tr>\n
BL846<\/td>\nBL (balanced)<\/td>\n25.40<\/td>\n11.2<\/td>\n182.0<\/td>\n45.5<\/td>\nStandard counterbalance 2\u20133.5 t<\/td>\n<\/tr>\n
BL1022<\/td>\nBL (balanced)<\/td>\n31.75<\/td>\n12.7<\/td>\n222.0<\/td>\n55.5<\/td>\nMost common 3\u20135 t counterbalance<\/td>\n<\/tr>\n
BL1034<\/td>\nBL (balanced)<\/td>\n31.75<\/td>\n14.3<\/td>\n311.0<\/td>\n77.8<\/td>\nHeavy-duty 4\u20137 t counterbalance<\/td>\n<\/tr>\n
BL1246<\/td>\nBL (balanced)<\/td>\n38.10<\/td>\n15.8<\/td>\n400.0<\/td>\n100.0<\/td>\nVery heavy 6\u201310 t forklift<\/td>\n<\/tr>\n
BL1666<\/td>\nBL (balanced)<\/td>\n50.80<\/td>\n19.0<\/td>\n756.0<\/td>\n189.0<\/td>\nHeavy stacker\/reach truck \u226510 t<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n
Counter-intuitive: the safe working load of a leaf chain in lifting service is only 25% of its minimum break load \u2014 not 50% or 33% as commonly assumed from general lifting equipment practice.<\/strong> ASME B29.8 specifies a design factor of 4:1 (minimum break load \u00f7 safe working load = 4). The reason this factor is higher than for many other lifting components is fatigue, not static strength. Leaf chain is subjected to repeated tension-relaxation cycles with every lift cycle \u2014 a forklift performing 60 lifts per hour over an 8-hour shift generates 480 stress cycles per day. Fatigue crack propagation in high-carbon steel link plates begins at stress levels well below the static yield strength, and the 4:1 design factor provides the margin needed to achieve the required cyclic life between the inspection intervals defined in ASME B29.8.<\/div>\n

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How Leaf Chain Fails: Fatigue Fracture vs Overload \u2014 and Why This Changes Everything About Inspection<\/h2>\n

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Overload failure \u2014 where a chain is pulled to its minimum break load in a single event \u2014 is not the dominant failure mode in forklift and hoist chain applications. Statistical analysis of leaf chain field failures consistently shows that more than 85% of failures in properly rated lifting systems are fatigue failures \u2014 crack initiation and propagation under repeated cyclic loads that are individually well within the chain’s structural capacity.<\/p>\n

The practical implication is profound. An overloaded chain gives visible warning before failure \u2014 the links deform plastically and the elongation becomes visible before fracture. A fatigue crack in a leaf chain link plate is typically 0.2\u20130.5 mm wide on the plate surface, oriented perpendicular to the chain axis, and nearly invisible until it has propagated to approximately 50% of the plate cross-section \u2014 at which point remaining static strength may be reduced to near the working load and fracture is imminent. By the time the crack is visible to an inspector performing a routine visual check, it may have been propagating for several hundred lift cycles.<\/p>\n

This is why the elongation threshold for leaf chain (2% for standard service) is lower than for roller chain (3%), and why visual inspection for cracks, corrosion, and plate deformation is mandatory in addition to elongation measurement. The elongation alone does not reveal the fatigue state of the plates \u2014 a chain can be within the elongation limit and still have fatigue cracks developing in the plate sections adjacent to the pin holes.<\/p>\n

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Leaf Chain Inspection Requirements: ASME B29.8 and EN 14659 Mandated Checks<\/h2>\n

Both ASME B29.8 (North American standard) and EN 14659 (European standard, adopted in Korean OEM equipment documentation) specify minimum inspection content for in-service leaf chains. The inspection interval is typically defined by the forklift OEM in the maintenance manual \u2014 most Korean and Japanese forklift OEM service documentation specifies annual inspection as a minimum, with more frequent inspection for high-cycle operations (chains performing more than 200 lift cycles per day should be inspected every 6 months).<\/p>\n

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01<\/div>\n
Elongation Measurement<\/div>\n

Measure 12-link span at three positions on the chain. Retire when measured elongation exceeds 2.0% (standard), 1.5% (corrosive or shock load service), or manufacturer’s lower threshold if specified. Elongation in leaf chain is caused by pin hole wear \u2014 the same mechanism as roller chain but without the bushing providing an intermediate wear surface.<\/p>\n<\/div>\n

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02<\/div>\n
Plate Crack Inspection<\/div>\n

Clean the chain thoroughly before inspection. Inspect each link plate surface under adequate lighting \u2014 a 10\u00d7 magnifier or penetrant dye test is required at least at alternating inspection intervals. Cracks are typically transverse (perpendicular to chain axis) and initiate at the pin hole edge. Any visible crack is an immediate retirement criterion \u2014 no elongation check is required.<\/p>\n<\/div>\n

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03<\/div>\n
Corrosion Assessment<\/div>\n

Light surface rust on the plate faces is tolerable if confined to the surface and removable with a clean cloth. Deep pitting, flaking rust, or corrosion at the pin-plate interface that is not removable requires retirement. Pitted link plates have a stress concentration factor significantly higher than a smooth plate \u2014 even shallow pitting of 0.2 mm depth at the pin hole edge can reduce the fatigue life by 40\u201360%.<\/p>\n<\/div>\n

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04<\/div>\n
Pin Rotation and Tight Links<\/div>\n

Check that all pins rotate freely within the plate holes \u2014 seize pins indicate corrosion at the bearing interface and potential fatigue crack initiation. Flex the chain laterally at each link: any resistance or springing-back indicates a tight link requiring further investigation. Tight links in a leaf chain are not simply an elongation concern \u2014 they indicate overloading or corrosion at that joint which may have initiated a plate crack.<\/p>\n<\/div>\n

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05<\/div>\n
Anchor Pin and Anchor Link Condition<\/div>\n

The anchor link (end connection to the carriage or mast anchor pin) carries the full static load of the rated capacity at all times. The anchor pin and link geometry must be checked for wear at each inspection \u2014 visible contact wear on the anchor pin or deformation of the anchor link around the pin are immediate retirement criteria. Anchor link wear is frequently overlooked because it is concealed in the mounting bracket.<\/p>\n<\/div>\n<\/div>\n

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Elongation Retirement Limits: 12-Link Measurement Reference Values<\/h2>\n

The 12-link caliper method used for roller chain also applies to leaf chain. Measure pin-centre to pin-centre across 12 links and compare to the nominal value. Retire when the measured span reaches or exceeds the values in the table below.<\/p>\n

\n\n\n\n\n\n\n\n\n\n
\u0426\u0435\u043f\u043d\u0430\u044f \u0441\u0435\u0440\u0438\u044f<\/th>\n\u041d\u043e\u043c\u0438\u043d\u0430\u043b\u044c\u043d\u044b\u0439 \u0448\u0430\u0433 (\u043c\u043c)<\/th>\n12-\u0437\u0432\u0435\u043d\u043d\u044b\u0439 \u041d\u043e\u043c\u0438\u043d\u0430\u043b\u044c\u043d\u044b\u0439 (\u043c\u043c)<\/th>\nRetire at 2% (mm)<\/th>\nRetire at 1.5% (mm)<\/th>\nApply 1.5% threshold when:<\/th>\n<\/tr>\n<\/thead>\n
AL622 \/ BL634<\/td>\n19.05<\/td>\n228.6<\/td>\n233.2<\/td>\n231.0<\/td>\nOutdoor\/cold store use, acid\/alkali exposure, visible surface corrosion, shock loads<\/td>\n<\/tr>\n
AL844 \/ BL846<\/td>\n25.40<\/td>\n304.8<\/td>\n310.9<\/td>\n309.4<\/td>\nSame as above<\/td>\n<\/tr>\n
BL1022 \/ BL1034<\/td>\n31.75<\/td>\n381.0<\/td>\n388.6<\/td>\n386.7<\/td>\nSame as above<\/td>\n<\/tr>\n
BL1246<\/td>\n38.10<\/td>\n457.2<\/td>\n466.3<\/td>\n464.1<\/td>\nSame as above<\/td>\n<\/tr>\n
BL1666<\/td>\n50.80<\/td>\n609.6<\/td>\n621.8<\/td>\n618.7<\/td>\nSame as above<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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Leaf Chain Lubrication: Why This Is More Critical Than for Roller Chain<\/h2>\n

Leaf chain has no bushing \u2014 the pin surface bears directly on the inner plate hole. This means the pin-hole interface has no intermediate wear component that can absorb damage before the structural element (plate) is affected. In roller chain, the bushing wears before the link plate hole enlarges. In leaf chain, the plate hole is the direct bearing surface. If this surface runs dry, the hole enlarges rapidly through abrasive wear, accelerating elongation and \u2014 more critically \u2014 creating stress concentrations at the hole edge that initiate fatigue cracks.<\/p>\n

The correct lubrication for forklift mast chains is a chain-specific oil applied to the inner plate surfaces at each lubrication event \u2014 not grease. Grease is too viscous to penetrate the pin-plate interface by capillary action and instead builds up on the plate outer surfaces where it collects contamination and provides no benefit at the actual bearing point. SAE 30\u201340 mineral chain oil, or an equivalent synthetic PAO oil for cold store applications, applied with a brush or spray to the inner plate faces at each weekly maintenance event, is the correct method. ASME B29.8 recommends lubrication at intervals not exceeding 250 operating hours under normal conditions and 50 operating hours in environments where the chain is exposed to contamination.<\/p>\n

For forklift operations in cold storage environments (\u221220\u00b0C to \u221210\u00b0C), standard mineral oil thickens to the point where it provides no penetrating action at the pin-plate interface. A synthetic PAO-based chain lubricant specified for sub-zero operation (typically rated to \u221240\u00b0C pour point) must be used for cold store forklift mast chains. The service life of leaf chain in cold store applications without correct low-temperature lubrication is typically 40\u201360% of that in ambient temperature service, and the elongation rate accelerates sharply when the chain warms up from \u221220\u00b0C to operating temperature during the first 30 minutes of each shift (the temperature cycling itself causes differential thermal expansion at the pin-plate interface that creates abrasive fretting).<\/p>\n

\"\u0428\u0435\u0441\u0442\u044c<\/p>\n

Forklift Mast Chain Replacement: What Must Always Be Done in Pairs<\/h2>\n

On forklifts with two mast chains \u2014 which includes virtually all counterbalance forklifts with rated capacities from 1 t to 10 t \u2014 the two chains must always be replaced simultaneously, never individually. This requirement appears in every major forklift OEM service manual and is a mandatory requirement under EN 14659 for new chain installations.<\/p>\n

The reason is differential elongation. A new chain installed on one side of the mast will gradually elongate, while the older chain on the other side (if not yet retired) will elongate at a different rate due to its accumulated wear history. This differential elongation causes unequal load distribution across the two chains \u2014 the shorter (newer) chain carries a disproportionate share of the lift load as the tilt geometry of the carriage shifts. In the worst case, a forklift with one new and one worn chain may load the newer chain at 110\u2013130% of the rated capacity while the worn chain carries 70\u201390%, accelerating the fatigue of the new chain significantly.<\/p>\n

Simultaneously with chain replacement, check and replace the mast sheaves if any wear grooves are visible on the sheave contact surface. For drive sprockets on electric forklift traction chains, matched sprockets for forklift drive and traction systems<\/a> are available in standard and custom bore configurations. A worn sheave groove concentrates the chain load at a narrower contact arc than the design geometry, increasing the per-plate stress at the wrap points and accelerating the fatigue of the new chain. Sheave condition is directly linked to chain service life \u2014 replacing chains without checking sheaves is the second most common cause of premature leaf chain failure after incorrect lubrication.<\/p>\n

\"\u0437\u0432\u0435\u0437\u0434\u043e\u0447\u043a\u0430<\/p>\n

\u0427\u0430\u0441\u0442\u043e \u0437\u0430\u0434\u0430\u0432\u0430\u0435\u043c\u044b\u0435 \u0432\u043e\u043f\u0440\u043e\u0441\u044b<\/h2>\n
\nCan leaf chain be repaired by shortening it if one section is near the elongation limit?<\/summary>\n
No. Shortening a leaf chain by removing a link section is not acceptable for lifting service under ASME B29.8 or EN 14659. Removal of any link requires installation of a connecting pin \u2014 field-installed connecting pins in leaf chain are not manufactured to the same interference fit as factory-assembled pins, and the connecting pin joint is therefore a reduced-strength point in the chain. More fundamentally, a chain that has been shortened because one section was at the elongation limit still contains all the other worn links \u2014 the elongation of the remaining sections continues to accumulate, and the shortened chain will reach the retirement threshold again in a shorter time than a new full-length chain. Always replace the full chain, not individual sections. In lifting applications, partial chain repair is not a cost-saving measure \u2014 it is a liability-increasing one.<\/div>\n<\/details>\n
\nWhat is the maximum recommended service life for forklift mast leaf chain regardless of measured elongation?<\/summary>\n
Most forklift OEM service documentation recommends a maximum service life of 5 years regardless of measured elongation or apparent visual condition. This calendar limit exists because fatigue crack propagation and corrosion can occur within the pin-plate interface in ways that are not detectible by external inspection \u2014 particularly in environments with humidity, temperature cycling, or mild chemical exposure. A chain at 1.2% elongation after 5 years may be structurally compromised by sub-surface fatigue cracks that have not yet propagated to the plate surface. Korean industrial safety regulations require annual forklift inspection by a certified inspector; the inspection records should document whether the calendar-based replacement limit has been applied in addition to the elongation measurement record.<\/div>\n<\/details>\n
\nHow is BL1022 identified if the chain markings are no longer readable?<\/summary>\n
Measure three values: pitch (10-link span \u00f7 10), plate width (outer width of one plate set), and count the number of plates per set across the chain width. For BL1022: pitch = 31.75 mm, plate width \u2248 12.7 mm, and the lacing pattern shows two plates on each outer face with additional inner plates giving the “balanced” BL designation. The critical confirmatory check is to compare the pin diameter against the ASME B29.8 table for the measured pitch \u2014 BL1022 has a specific pin diameter that distinguishes it from AL-series chains at the same 31.75 mm pitch. If these measurements do not match a published ASME B29.8 or EN 14659 designation, the chain may be a proprietary OEM specification and must be ordered through the original equipment manufacturer or a confirmed cross-reference source.<\/div>\n<\/details>\n
\nIs stainless steel leaf chain available and when should it be specified?<\/summary>\n
Yes \u2014 stainless steel leaf chain in 304 and 316L is available for the most common BL series sizes. The application cases are: cold store forklifts where brine or de-icing chemicals create a corrosive environment that accelerates carbon steel corrosion; food processing lift trucks that are pressure-washed with chlorinated sanitisers; and marine terminal material handling where salt spray exposure is continuous. Stainless leaf chain has a lower fatigue strength than the equivalent carbon steel chain due to the lower yield strength of austenitic stainless \u2014 this means the retirement elongation limit for stainless leaf chain is typically 1.5% rather than 2%, regardless of the service environment. For cold store applications specifically, the combination of stainless plates, synthetic lubricant, and more frequent inspection (every 6 months rather than annually) gives the best combination of corrosion resistance, service life, and safety margin.<\/div>\n<\/details>\n

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AL and BL Leaf Chain Stocked for Same-Week Despatch<\/h2>\n

BL634 through BL1666 in carbon steel and stainless variants. Supply as full-length coil or cut-to-length per your specified number of links. Material certificates and traceability documentation available on request for lifting equipment compliance records.<\/p>\n<\/div>\n

Browse Leaf Chain Range<\/a>
\nRequest BL Series Specification Advice<\/a><\/div>\n<\/div>\n<\/div>\n

\u0420\u0435\u0434\u0430\u043a\u0442\u043e\u0440: Cxm<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"

Lifting & Hoisting ASME B29.8 \u00b7 ISO 4347 \u00b7 EN 14659 Leaf Chain and Hoist Chain: AL\/BL Series, Forklift Mast Drives and Safe Working Loads Leaf chain is not roller chain with the rollers removed. It is a structurally distinct product category with its own fatigue standards, inspection requirements, and mandatory retirement criteria \u2014 and […]<\/p>","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":""},"categories":[6634],"tags":[72,78,58],"class_list":["post-3325","post","type-post","status-publish","format-standard","hentry","category-chain-sprocket","tag-chain","tag-chain-sprocket","tag-sprocket"],"_links":{"self":[{"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/posts\/3325","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/comments?post=3325"}],"version-history":[{"count":2,"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/posts\/3325\/revisions"}],"predecessor-version":[{"id":3327,"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/posts\/3325\/revisions\/3327"}],"wp:attachment":[{"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/media?parent=3325"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/categories?post=3325"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/sprocket-chain.net\/ru\/wp-json\/wp\/v2\/tags?post=3325"}],"curies":[{"name":"WP","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}