Product Guides
Lever Block Guide: Types, WLL, Selection & Safe Use
Lever blocks: WLL from 750kg to 9t, G80 load chain, AS 1418.2 requirements, chain block vs lever block decision guide, and safe use for Australian tradespeople.
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Chain Sling Guide: Grade 80 vs 100, WLL, Sling Angles & Selection
Chain slings: G80 vs G100 grades, WLL tables, sling angle de-rating, AS 3775 inspection rules and dogging licence requirements for Australian industry.
Read moreEye Bolt Guide: DIN 580 vs BS 4278, WLL Ratings, Angle Loading & Correct Installation for Australian Rigging
Eye bolts: WLL grades, shoulder vs plain shank, AS 3776, proof load ratings, angular load reduction and safe rigging selection for Australian industry.
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Come-Along Winch Guide: Types, Uses & How to Choose
What Is a Come-Along Winch? A come-along (also called a come-along winch, hand puller or wire rope ratchet puller) is a manually operated portable pulling device. It uses a ratchet lever to incrementally wind a length of wire rope or webbing onto a drum, pulling loads horizontally — dragging equipment into position, tensioning fence wire, recovering a bogged vehicle, or applying tension during rigging work. One end hooks to an anchor point, the other to the load. Is a come-along the same as a chain block? No. A come-along is rated for horizontal pulling, not overhead lifting. Chain blocks and lever hoists are designed and certified for vertical lifting of suspended loads. Never use a come-along to lift a load overhead. A come-along winch is a manually operated wire rope ratchet puller — a compact, portable device used to pull loads horizontally across the ground, drag equipment into position, tension fence wire, or recover a bogged vehicle. You hook one end to an anchor, the other end to the load, and work a ratchet lever to wind in the cable. The ratchet locks each stroke, so the load holds position while you reset your grip for the next one. In Australia the same tool is also called a hand winch, cable puller, chain puller, wire rope puller, or come-along tool. All of these terms refer to the same ratchet-and-spool mechanism. The come-along is a pulling tool only — it is not rated for overhead lifting. Understanding this distinction before selecting a come-along or choosing between a come-along, lever hoist, tirfor winch, or chain block is the core of this guide. AIMS has stocked come-along winches in the past and the product type remains relevant for AIMS customers in construction, farming, rigging, and 4WD recovery. For manual lifting requirements, AIMS stocks a full range of chain blocks and lever hoists. Come-Along Winch Selection — Quick Reference The five most common manual pulling/lifting tools compared at a glance. Come-along winches are for horizontal pulling only — never use for overhead lifting. For lifting, use a lever hoist or chain block rated to AS 1418. Tool Typical WLL Use For AU Standard Single-purchase come-along 800 kg – 3 t Horizontal pulling, 3–6 m cable, fast resets Not AS 1418 — pulling only Double-purchase come-along 2× rated WLL (snatch block needed) Heavier horizontal pulls, slower, half load travel per stroke Not AS 1418 — pulling only Webbing strap come-along 800 kg – 2 t 4WD recovery and arborist work — protects tree/vehicle Not AS 1418 — pulling only Tirfor / grip hoist 800 kg – 3 t Continuous long-distance pulls, no reset needed Not AS 1418 — pulling only Lever hoist (for lifting) 250 kg – 9 t Vertical lifting AND horizontal pulling — calibrated load chain AS 1418.2 How a Come-Along Winch Works The mechanism is a wire rope spool mounted in a pressed or cast steel frame with a ratchet drive system. The wire rope is wound onto the spool. One hook attaches to a fixed anchor point; the other, at the free end of the wire rope, attaches to the load. A lever operates the ratchet — each stroke of the lever rotates the spool and winds in a length of cable. The ratchet pawl engages the teeth between strokes, locking the load in position and preventing it from running back while the operator repositions the lever for the next stroke. A direction control — typically a sliding lever or a flip switch on the ratchet mechanism — determines whether the device is in pull mode (winding in cable) or release mode (paying out cable under controlled load). Most come-alongs also have a neutral or freespool position for running cable out rapidly without tension. The lever arm provides the mechanical advantage. Short lever = more strokes per unit of distance, less effort per stroke. Longer lever = more force available per stroke. Most standard come-alongs have a fixed lever arm; some heavier models offer interchangeable handle extensions for difficult pulls. Single Purchase vs Double Purchase The purchase refers to how the wire rope is rigged between the anchor and the load. It is one of the most commonly misunderstood specifications on come-along winch product listings. Single purchase The direct configuration: one end of the cable is fixed to the anchor, the spool winds in the other end. The load moves at the same rate as the cable is wound in. The WLL (Working Load Limit) stamped on the tool is the rated capacity for single purchase. Double purchase A floating snatch block is rigged between the load and the anchor. The cable runs from the spool, through the snatch block attached to the load, and back to a fixed anchor point on the same side as the spool. The load now moves half the distance per metre of cable wound — but the mechanical advantage is doubled. A 1t come-along can effectively move a 2t load under double purchase. The trade-off: it takes twice as many strokes to move the load the same distance. Double purchase is slower but opens up heavier loads than the tool's rated single-purchase capacity. A snatch block is required and is a separate purchase — it is not included with the come-along. Single purchase Double purchase Pull force Rated WLL (e.g. 1t) 2× rated WLL (e.g. 2t effective) Load movement per stroke Full stroke distance Half stroke distance Speed Faster — fewer strokes per move Slower — twice as many strokes Equipment required Come-along + anchor Come-along + snatch block + extra anchor Best for Standard loads within rated WLL Heavier loads, difficult pulls, limited anchor strength Check your product specs: some come-alongs are rated for both configurations and list separate WLL values for single and double purchase. Do not assume the double-purchase capacity is printed on the label — confirm it in the product documentation. Types of Come-Along Winches Standard wire rope come-along The most common type in Australian trade and industrial use. A wire rope spool, steel frame, ratchet pawl, and a reversible handle. Capacities typically range from 800 kg through to 3 t in standard commercial models. Wire rope is durable, abrasion-resistant, and handles rough surfaces and sharp edges better than webbing strap. Correct for industrial and construction applications. Wire rope requires more care to inspect — look for kinks, birdcage (strand separation), broken strands, and corrosion before each use. Webbing strap come-along The strap replaces the wire rope with flat webbing — polyester or nylon. The strap is softer and less likely to damage soft surfaces, paint, or a tree trunk used as an anchor. More commonly specified for vehicle recovery and arborist work where protecting the anchor (a live tree) or the recovered vehicle matters. Less common in Australian industrial supply; more commonly found in 4WD recovery gear catalogues. The strap is more vulnerable to UV degradation and abrasion damage — inspect carefully before use and replace sooner than wire rope equivalents. Tirfor and grip hoist A distinct mechanism often grouped with come-alongs but operating on a different principle — covered in detail in the section below. The tirfor is the go-to for long-distance continuous pulls where a standard come-along would need many resets. Capacity tiers Australian trade and industrial come-alongs are commonly available in the following capacities: WLL (single purchase) Typical application 800 kg Light vehicle recovery, farm fencing, small load positioning 1 t (1,000 kg) General trade use, light machinery, mid-weight vehicle recovery 1.5 t Heavier machinery, construction, medium 4WD recovery 2 t Heavy trade and construction, large vehicle recovery 3 t Heavy industrial, large plant, truck and tractor recovery Buy one size larger than the maximum load you expect to pull. A come-along used regularly at its rated WLL will wear faster and provides no margin for unexpected resistance or a slightly heavier-than-expected load. A 1.5t come-along for a 1t load is a sensible working margin. Come-Along Winch vs Tirfor Winch The tirfor winch (sometimes called a grip hoist, wire rope hoist, or creeper winch — and in Australian trade, frequently referred to simply as a "tirfor" as a brand-generic after the Yale Tirfor) uses a fundamentally different pulling mechanism from a come-along, despite appearing similar and performing the same general function of pulling loads horizontally with a wire rope. How a tirfor works A tirfor has no spool. Instead, a forward-reverse jaw mechanism grips the wire rope at two alternating points — one jaw grips the incoming rope while the other jaw releases and repositions, then the second jaw grips while the first releases and moves. The result is a continuous creeping pull along the wire rope. The rope passes all the way through the mechanism — it has no fixed end wound onto a drum. Key differences Come-along winch Tirfor winch Mechanism Ratchet spool — wire rope winds onto drum Jaw/grip mechanism — rope passes through Pull distance Limited to spool cable length (3–6 m typical) — must reset Unlimited — pull as far as the rope length allows without resetting Cable supplied Fixed — attached to spool Separate wire rope (sold by length) — can be any length Reset required? Yes — when cable is fully wound, unhook, re-anchor closer, resume No — continuous pull to any distance Typical cost Lower — $50–$250 for most AU trade models Higher — $400–$1,500+ for quality models Weight Lighter — 2–5 kg for most trade come-alongs Heavier — 8–20 kg for equivalent capacity Best for Short pulls (3–6 m), intermittent use, portability Long-distance pulls, continuous repositioning, forestry, construction, utility work In Australian 4WD recovery, forum discussions consistently show that come-alongs are adequate for most bog recoveries (typically under 5 m of travel needed) but tirfors are preferred by serious off-road and touring users who may need to pull a vehicle over longer distances or through multiple resets on a difficult recovery. Tirfors are also the standard tool in arborist, forestry, and construction rigging where continuous long pulls are the norm. For the majority of trade and industrial applications — pulling equipment into position, tensioning fence wire, shifting loads by a few metres — a come-along at a fraction of the cost of a tirfor is the correct choice. Come-Along Winch vs Lever Hoist This is the most important comparison in this guide, and the one with the clearest safety implications. A come-along winch and a lever hoist can look superficially similar in use — both are handheld, both apply mechanical pulling force with a lever — but they are fundamentally different tools with different ratings, different load chain types, and critically, different permitted orientations. Come-along winch Lever hoist Load medium Wire rope (steel cable) Load chain (calibrated steel chain) AU standard Not classified as lifting equipment — no AS 1418 rating AS 1418.2 — rated and certified for lifting Permitted use Horizontal pulling only Lifting AND horizontal pulling Vertical (overhead) lift? NO — never Yes — this is the primary design purpose Capacity range Typically 800 kg to 3 t 250 kg to 9 t (standard commercial range) Load retention Ratchet pawl holds the load between strokes Load brake holds load without the operator holding the lever Typical cost Lower Higher — compliant load chain and rated brake mechanism add cost Best for Ground-level pulling, vehicle recovery, repositioning Lifting, overhead rigging, vertical load movement The rule is absolute: never use a come-along winch to lift a load off the ground. The wire rope on a come-along is not load-rated for overhead use. The frame and ratchet mechanism are not designed to hold a suspended load. A lever hoist (rated to AS 1418.2) is the correct tool whenever a load must be lifted vertically — even partially lifted, such as raising a beam to position it on a structural member. This is not a guideline that can be worked around by staying within the WLL. The rating on a come-along is a horizontal pull rating only. Using it for lifting is a misuse of the tool regardless of the load weight. For a lever hoist suitable for both lifting and horizontal pulling, see the Chain Block and Lever Hoist Guide. Come-Along Winch vs Chain Block A chain block (also called a chain pulley block or block and tackle) is an overhead lifting device with a chain loop and a series of load sheaves. It is designed for vertical lifting only — it hangs from a beam, hook, or trolley above the load and lifts the load straight up. A chain block cannot be used horizontally. It is not designed for pulling loads across the ground, and using it in a horizontal orientation puts the chain sheaves and frame in a load path they are not designed for. For horizontal pulling, use a come-along or a lever hoist. Come-along winch Chain block Orientation Horizontal pulling only Vertical lifting only AU standard Not AS 1418 classified AS 1418.3 — manual chain hoists Load medium Wire rope Load chain and hand chain Movement control Ratchet — operator pumps lever Continuous pull on hand chain — smooth lifting and lowering Best for Horizontal pulls, ground-level repositioning Vertical lifts, maintenance on overhead machinery, load positioning directly below a beam In summary: chain block for vertical lifting, come-along for horizontal pulling, lever hoist for both. If in doubt, use the tool rated for the job — the lever hoist is the most versatile manual load-moving tool and the only one suitable for horizontal AND vertical work under a single rated standard. Applications: Where Come-Along Winches Are Used Vehicle recovery Come-alongs are widely used in 4WD off-road recovery in Australia. A bogged vehicle typically needs 3–5 m of horizontal pull to free it from soft ground. A 1.5t or 2t come-along gives a solo operator enough force to free most passenger 4WD vehicles without a second vehicle. One hook goes to the vehicle recovery point; the other to a rated anchor — a tree (with a tree trunk protector strap, not directly on the wire rope), a rated recovery point on a second vehicle, or a ground anchor. Double purchase effectively doubles your available pull force if the bog is severe. Come-alongs in recovery have one significant limitation: if the vehicle needs more than 5–6 m of movement, you will need to reset — anchor the come-along further forward, run the cable out, re-hook, and continue. Each reset adds time and effort. For difficult recoveries over long distances, a tirfor or a dual-snatch-block rigging setup is more efficient. Farm and station work Fence straining is a classic come-along application on Australian farms and stations. Tensioning a run of barbed wire or plain wire fencing requires pulling force over a few metres — exactly what a come-along delivers. Come-alongs are also used to drag logs, pull stumps partway clear, shift portable yard panels, and reposition farm equipment with no wheels or on uneven ground. The portability and low cost make a come-along a standard item in any farm tool kit. Construction and civil work On construction sites, come-alongs are used to pull formwork into position, tension bracing wires, shift prefabricated elements horizontally before they are craned, and reposition heavy equipment that has no wheels or cannot be accessed by forklift. They are particularly useful in confined site conditions where powered equipment cannot reach. Marine and dock work Boat hauling and launch-ramp retrieval, dock line tensioning, and rigging temporary moorings — come-alongs appear in all of these. In marine environments, stainless steel or galvanised components are preferred to resist corrosion. Inspect wire rope more frequently if used regularly in salt or brackish water. Industrial machinery installation Pulling heavy machinery into exact position on a concrete pad — a lathe, a press, a compressor unit — often requires precise horizontal movement of a load that no trolley can manage alone. A come-along anchored to an adjacent machine or a structural column gives controlled incremental positioning. Cable Length and the Reset Limitation The most common practical limitation users discover about come-alongs — and the one that surprises people who have not used one before — is the short effective pull distance per setup. A standard 1t come-along typically has a wire rope length of 3 m. A 2t model might have 4–5 m. When the cable is fully wound in, the come-along has moved the load as far as possible for that setup. If the load needs to travel further, the operator must: Switch the direction lever to release (neutral) Hold the load or block it to prevent it running back Unhook the spool end from the anchor Re-position the anchor point closer to the load's new position Run the cable back out (freewheel) Re-hook and resume pulling This is called a reset. A 10 m vehicle recovery move in soft sand, for example, would require 2–3 resets with a standard come-along. Each reset takes 2–5 minutes. Factor this in when deciding between a come-along and a tirfor for any job requiring continuous long pulls. The reset is not a design flaw — it is a characteristic of the spool-based mechanism. For most applications (positioning machinery, fencing, short recovery pulls), the effective cable length is sufficient and the reset limitation is irrelevant. For applications requiring long continuous pulls, the tirfor is the right tool. How to Use a Come-Along Winch Before you start Inspect the come-along before every use. Check: Wire rope: no kinks, no birdcage (spiral strand separation), no broken strands, no visible corrosion pitting. Any of these defects requires the rope to be replaced before use. Hooks: latch closes and springs back correctly, no distortion, no cracks, no excessive wear at the throat. Ratchet mechanism: pawl springs and engages cleanly, no damaged teeth, direction lever operates freely. Frame: no visible cracks, welds intact, no excessive deformation from previous use. WLL tag: present and legible. Do not use a come-along without a legible WLL rating. Step-by-step use Identify a rated anchor point. The anchor must be capable of holding the rated pull force without moving or failing. Suitable anchors: a tree with a sling (minimum 100mm diameter, tree protector strap over the bark), a rated tow point on a vehicle, a structural column, a purpose-built ground anchor. Unsuitable anchors: fence posts, soil stakes, temporary signage, unrated cleats. Set the direction lever to release/freewheel. Run the cable out to the load — do not drag the come-along to the load with cable under tension. Hook the spool end of the cable to the anchor point. Ensure the hook latch is closed and properly seated in the fitting or sling. Hook the free end of the cable to the load. Use a rated shackle or the hook directly into a rated load point. Never wrap wire rope directly around an anchor or load point without a sling or shackle — the sharp bend reduces the effective WLL. Set the direction lever to pull. Clear all bystanders from the load line. A wire rope under tension stores elastic energy — if it fails, it can snap back violently. Establish a safety zone clear of the rope and load path. Apply tension gradually. Work the handle with smooth, even strokes. Listen and feel for the ratchet engaging cleanly. Do not shock-load — do not apply sudden jerking force to a slack rope. Maintain a straight pull line. Side-loading a come-along — pulling at an angle to the spool axis — reduces effective WLL and puts lateral stress on the frame. Use a snatch block to redirect the line if a straight pull is not possible. When the load is in position, set the lever to neutral before unhooking. Never release a loaded hook under tension. Safety Rules Never use a come-along for overhead lifting. This is the primary rule. A come-along is a pulling tool, not a lifting device. No exception for low loads, short lifts, or "just for a moment." Use a rated lever hoist or chain block for any lift. The consequences of a come-along failure under a suspended load are severe. Never exceed the WLL. The WLL on the label is the maximum load the tool is designed to handle. Operating above it is a misuse of the tool and risks mechanism failure, rope failure, or hook distortion — any of which can cause load drop or snap-back. Never use a damaged wire rope. A kinked, birdcaged, or broken-strand wire rope has significantly reduced strength — sometimes to less than half its rated capacity at the damage point. Replace the rope, not just the come-along. Never shock-load. Jerking tension into a slack rope creates a dynamic load several times the static weight. Apply tension gradually. Maintain a clear safety zone around the load line. Wire rope under tension can fail without warning. Keep all people clear of the potential snap-back arc. Use rated hardware throughout the rigging. Every shackle, sling, chain, and anchor point in the system is a potential failure point. The WLL of the rigging system is the lowest WLL of any single component. A 2t come-along rigged with 800 kg shackles has an effective WLL of 800 kg. AU standards note: Come-along winches are not classified under AS 1418 (lifting equipment standards) in Australia — they are pulling tools. For any application requiring a certified lifting device with documented WLL compliance under Australian standards, specify a lever hoist (AS 1418.2) or chain block (AS 1418.3). For industrial workplaces subject to WHS regulations, confirm the tool's intended use with your safety officer before use in a lifting application. How to Choose a Come-Along Winch Capacity (WLL) Match the WLL to the maximum load you will pull — and add a working margin. For vehicle recovery, size up to at least 1.5t for most passenger 4WD vehicles (which weigh 1,800–2,500 kg gross — you will rarely need to move the full vehicle weight, but a margin is sensible). For farm and construction use, estimate the heaviest single load you will pull and buy the next size up. A 2t come-along for a 1t application gives you a safe working margin and longer tool life. Cable length Standard cable lengths: 3 m for 1t models, 4–5 m for 1.5–2t models. If your application regularly requires pulls longer than the cable length (vehicle recovery across long soft ground, pulling materials over long distances), factor in reset frequency or consider whether a tirfor is a better fit for the job. Single vs double purchase For most applications — standard loads within the WLL, adequate anchor points — single purchase is sufficient. If you anticipate regularly pulling loads near or at the rated WLL, or if your anchor points are marginal, a double-purchase rigging setup with a snatch block gives you significantly more pulling force at the cost of speed. For vehicle recovery, many experienced off-road users keep a small snatch block in the recovery kit specifically for double purchase rigging on difficult recoveries. Wire rope vs webbing strap Wire rope for industrial, construction, and farm applications where abrasion, rough edges, and long-term heavy use are the norm. Webbing strap for vehicle recovery applications where you want to protect vehicle anchor points, a tree anchor, or reduce the risk from rope snap-back (webbing stores less elastic energy than wire rope of the same length under the same tension). Webbing strap requires more frequent inspection for UV damage, abrasion, and contamination. Frame quality Look for drop-forged steel hooks (not cast — cast hooks can crack without deforming, giving no visual warning before failure). Quality models have a pressed or fabricated steel frame with a permanent WLL tag that cannot be easily removed. Avoid come-alongs with no WLL marking or with poorly finished castings. Brands in Australia In the Australian market, Beaver Products and Austlift are recognised industrial lifting and rigging brands that supply both chain blocks and come-along winches to Australian trade. For 4WD recovery specifically, ARB and Fulton Hopkins stock come-alongs targeted at the vehicle recovery market. At the general trade and hardware level, Kincrome and other professional hand-tool suppliers cover the working trade segment. For industrial and rigging-grade supply, confirm the WLL certification documentation is available for the specific model before purchasing for a workplace application. For manual lifting and pulling equipment stocked by AIMS, see the chain blocks range — lever hoists and chain blocks for rated lifting and horizontal pulling applications — and the complete Chain Block Guide covering capacity, use, and selection. For workshop applications where a component needs to be secured once it has been moved into position — for cutting, filing, drilling, or fitting — an engineer's bench vice is the standard clamping solution, rated for sustained bench-work forces on ferrous and non-ferrous materials. Pull it. Position it. Get it done. Shop come-alongs, chain blocks & lever hoists from Austlift & Beaver From Austlift wire rope cable pullers to Beaver worm drive hand winches — AIMS Industrial stocks manual lifting and pulling equipment across all WLL ratings for construction, mining, and industrial maintenance, ready to ship Australia-wide. Browse come-alongs & winches Chain blocks & lever hoists Talk to a specialist Frequently Asked Questions What is a come-along winch? A come-along winch is a manually operated wire rope ratchet puller — a portable tool used to pull loads horizontally across the ground. One hook attaches to a fixed anchor point, the other to the load, and a ratchet lever progressively winds in the wire rope to pull the load toward the anchor. The ratchet locks each stroke, holding the load in position while the operator repositions the lever. Come-along winches are used in vehicle recovery, farm work, construction, and industrial load positioning. They are pulling tools only — not rated for overhead lifting. What is another name for a come-along winch? In Australia, come-along winches are also called hand winches, cable pullers, wire rope pullers, chain pullers, and come-along tools. In the US, the same type is often called a cable puller or hand cable puller. The term "hand winch" is the most common in Australian trade use when referring to a general class of manually operated wire rope pulling tools. Tirfor winch, lever hoist, and chain block are related but distinct tools — each works differently and has different permitted applications. What is the difference between a come-along winch and a lever hoist? A come-along winch uses a wire rope and ratchet spool mechanism. It is rated for horizontal pulling only — never for overhead lifting. A lever hoist uses a calibrated load chain and is rated to AS 1418.2 for both lifting and horizontal pulling. The lever hoist is the more versatile tool: it can substitute for a chain block in many lifting applications as well as handle horizontal pulls. The come-along is a lower-cost pulling-only tool. Never use a come-along to lift a load off the ground — use a lever hoist or chain block for any lifting application. Can you use a come-along winch to lift loads vertically? No. A come-along winch is not rated for overhead lifting. The wire rope is not certified for vertical load suspension, the frame and ratchet mechanism are not designed to hold a suspended load, and come-along winches are not classified under AS 1418 (Australian lifting equipment standards). Using a come-along to lift a load is a misuse of the tool regardless of the load weight. For overhead lifting, use a lever hoist (AS 1418.2) or chain block (AS 1418.3). For any combination of lifting and horizontal pulling, a lever hoist is the correct choice. What is a tirfor winch and how is it different from a come-along? A tirfor (also called a grip hoist or wire rope hoist) uses an alternating jaw-grip mechanism to pull a continuous wire rope through the device — there is no spool. The rope passes all the way through, meaning a tirfor can pull a load over any distance without resetting, provided the rope is long enough. A come-along winds wire rope onto a spool, limiting the effective pull to 3–6 m before a reset is required. Tirfors are heavier and more expensive than come-alongs but are preferred for long-distance continuous pulls in forestry, construction, and 4WD recovery over large distances. For short-distance pulls (under 5 m), a come-along at a fraction of the cost is adequate. What is the difference between single purchase and double purchase on a come-along winch? Single purchase is the direct configuration — one end of the cable anchors, the spool winds in the other. The load moves at the same rate as the cable winds. Double purchase uses a floating snatch block between the load and anchor: the cable runs from spool, through the snatch block on the load, and back to a fixed anchor point. This doubles the mechanical advantage — a 1t come-along can effectively pull 2t — but the load moves half the distance per stroke and twice as many strokes are required. Double purchase requires a separate snatch block and an additional anchor point. The WLL printed on the tool is for single purchase; check the manufacturer's specification for double-purchase capacity. How much weight can a come-along winch pull? Standard commercial come-along winches in Australia are available from 800 kg through to 3 t WLL (Working Load Limit) in single-purchase configuration. Double-purchase rigging with a snatch block can effectively double the available pull force at the cost of speed and additional equipment. For workplace use, always confirm the WLL is appropriate for the maximum expected load plus a safety margin — do not use a tool at or near its rated maximum on a regular basis. The WLL is the maximum rated pull; design to work well within it for tool longevity and safety. How long is the cable on a standard come-along winch? Wire rope cable length on standard come-along winches varies by capacity: 1t models typically have 3 m of cable; 1.5–2t models commonly have 4–5 m. After the cable is fully wound in, the come-along cannot pull the load any further from that anchor position — a reset is required to move the anchor point closer and resume. For applications requiring more than the cable length per pull, factor in reset frequency or consider a tirfor winch which allows continuous pulls to any distance. How do I reset a come-along winch mid-pull? When the cable is fully wound and the load needs to travel further: (1) block or support the load to prevent it running back; (2) switch the direction lever to neutral or release; (3) unhook the spool-end hook from the anchor; (4) move the come-along or re-anchor it at a new position closer to the load's current position; (5) run the cable out using the freewheel function; (6) re-hook to the new anchor; (7) switch back to pull mode and continue. Each reset typically takes 2–5 minutes. For a difficult vehicle recovery requiring multiple resets, a tirfor winch or a longer rope with a snatch block redirect is more efficient. Are come-along winches suitable for 4WD vehicle recovery? Yes — come-along winches are a practical 4WD recovery tool for most standard recoveries where the vehicle needs to be pulled 3–5 m to free it from soft ground. A 1.5t or 2t come-along provides sufficient force for most passenger 4WD vehicles. Anchor to a tree with a tree trunk protector sling, a second vehicle's rated recovery point, or a rated ground anchor — never to a fence post. Use double purchase (with a snatch block) for deeper bogs or when the first pull is not sufficient. For long-distance recoveries or very difficult terrain, a tirfor winch is better suited due to its unlimited continuous pull capability without resetting. What should I check before using a come-along winch? Before every use, inspect: (1) Wire rope — no kinks, birdcage (strand separation), broken strands, or corrosion; replace immediately if any are found. (2) Hooks — latches close correctly, no distortion, cracks, or excessive throat wear. (3) Ratchet mechanism — pawl springs and engages cleanly, no damaged or missing teeth, direction lever operates correctly. (4) Frame — no visible cracks, welds intact, no significant deformation. (5) WLL tag — present and legible; do not use if the WLL cannot be confirmed. A come-along showing any of these defects should be taken out of service immediately. What is the difference between a come-along winch and a chain block? A chain block is a vertical lifting device — it hangs overhead from a beam, crane hook, or trolley and lifts loads straight up using a load chain and hand chain operated through a series of sheaves. It cannot be used horizontally. A come-along winch is a horizontal pulling tool — it pulls loads across the ground and cannot be used for overhead lifting. For horizontal pulling, use a come-along or lever hoist. For vertical lifting, use a chain block or lever hoist. For both horizontal and vertical use in one tool, a lever hoist (rated to AS 1418.2) is the correct choice. For metric to imperial socket cross-references and 1/4", 3/8" and 1/2" drive sizes, see our Socket Size Chart. People Also Ask — Come-Along Winches Q: What is a come-along winch used for? A come-along (ratchet lever winch or hand winch) is a portable, hand-operated pulling tool used to move or position heavy loads where powered machinery isn't available. Common uses include vehicle recovery, log pulling, fence wire tensioning, machinery positioning on worksites, and general rigging applications requiring controlled pulling force. Q: What is the difference between a come-along and a chain block? A chain block (chain hoist) is designed for vertical lifting of suspended loads and has fine load control. A come-along is primarily a horizontal pulling tool — it is not rated for overhead lifting in most jurisdictions. Chain blocks should be used for vertical work; come-alongs for horizontal pulling, angled recovery, and tensioning applications. Q: What safe working load (SWL) do I need for a come-along? Choose a come-along rated equal to or greater than the maximum load you expect to move. For vehicle recovery, select a rated capacity at least equal to the vehicle's gross vehicle mass (GVM). Dynamic shock loads during a pull can significantly exceed the static weight — this is why never operating beyond the rated SWL is critical. Q: How do you rig a come-along correctly? Anchor the come-along to a solid, rated anchor point using appropriate rated rigging hardware — shackles and slings matched to the load. Connect the hook to the load via a rated sling or chain. Keep all personnel well clear of the load and any tensioned rope or wire during the pull, as a sudden release can cause serious injury. Q: How do you inspect a come-along before use? Check that hook latches close and seat fully. Inspect the wire rope or chain for kinks, broken wires, deformation, or corrosion. Confirm the ratchet clicks firmly with no slippage or skipping. If any component is bent, cracked, corroded, or shows signs of overload, remove the tool from service and attach a tag-out label before sending for inspection. See AIMS's full lifting chain links range — trade pricing and Australia-wide despatch.
Read moreTurnbuckle Guide: Types, Sizes & How to Choose
Turnbuckle Guide: Types, Uses & How to Choose the Right One A turnbuckle is one of those pieces of hardware that quietly holds a lot together — from tensioned wire rope on a suspension bridge to the shade sail stretched over your backyard. Simple in concept, varied in execution, and critical to get right when load-bearing is involved. Choose the wrong size, the wrong material, or the wrong end fitting and you are looking at premature failure, slippage, or a safety incident. This guide covers everything you need: what turnbuckles are, how they work, the different end fittings and body styles, material and size selection, working load limits, installation technique, and the most common failure modes to avoid. Whether you are a rigger, tradesperson, fabricator, or DIYer tensioning a shade sail or fence wire, this is the reference you need. If you work with wire rope, slings, or rigging hardware more broadly, our Wire Rope, Slings & Rigging Guide covers the full rigging ecosystem that turnbuckles operate within. What Is a Turnbuckle? A turnbuckle — also called a rigging screw, bottle screw, or stretching screw — is a mechanical device used to apply tension or adjust the length of cables, ropes, tie rods, or other tensioning elements. It consists of a central body (the frame) threaded at both ends, with each threaded end accepting a fitting (hook, eye, or jaw) that connects to the line or structure being tensioned. The body itself is threaded with a right-hand thread at one end and a left-hand thread at the other. When you rotate the body clockwise, both end fittings are drawn inward simultaneously — shortening the overall assembly and increasing tension. Rotate counterclockwise and the assembly lengthens, releasing tension. This bidirectional thread design means you can tension or de-tension a line without needing to rotate the fittings themselves or the cable attached to them. The result is a compact, precise, field-adjustable tensioning device that can be used anywhere a controlled, variable amount of tension is needed across a fixed span. The term "rigging screw" is used interchangeably with "turnbuckle" across Australia and the UK, while "bottle screw" is common in British engineering contexts. "Turnbuckle" is the most widely recognised term globally and in Australian trade usage. For the purposes of this guide, we use all three interchangeably — they describe the same device. How Does a Turnbuckle Work? The operating principle is straightforward: a turnbuckle converts rotational motion into linear tension adjustment. Here is the mechanism step by step. The central body has a threaded hole at each end. One end has a right-hand (standard) thread and the other has a left-hand (reverse) thread. The end fittings — which connect to your cable, rod, or anchor point — thread into these holes from opposite directions. When you rotate the body clockwise (as viewed from one end), the right-hand threaded fitting is drawn in from the right, while the left-hand threaded fitting is simultaneously drawn in from the left. Both fittings move toward the centre of the body at the same time. The overall length of the assembly decreases, and the line or cable attached to both ends is pulled tighter. Rotate the body counterclockwise and the reverse happens: both fittings are pushed outward simultaneously, increasing the overall length of the assembly and reducing tension on the line. The amount of adjustment available is called the "take-up" — typically expressed as the range of travel available (e.g., 50mm take-up means the assembly can extend or contract 50mm from its mid-point). We cover sizing and take-up selection in detail in the sizing section below. Most turnbuckles have a hexagonal section, a slot, or a central hole through the body to allow you to insert a bar or pin for leverage when tensioning by hand. On smaller turnbuckles you can often tension by hand; on larger sizes, a lever bar through the body is the normal method. Never use a wrench on the body to tension — this can introduce torque into the cable and damage the threads. Once the desired tension is reached, the turnbuckle body should be locked to prevent it from working loose under vibration or dynamic load. Locking methods include wire locking (seizing wire through the body and fittings), lock nuts on the fitting threads, plastic lock nuts, or thread-locking compound. We cover this in the installation section. Types of Turnbuckle End Fittings The end fitting is the part that connects the turnbuckle to your cable, wire rope, rod, or anchor point. Choosing the right fitting type for each end is essential — the fitting must match the connection method at both ends of your assembly. A turnbuckle assembly typically has two end fittings, which can be the same type on both ends or a mix of different types. The most common combinations are eye and eye, jaw and jaw, hook and eye, jaw and eye, and hook and hook. Each fitting type has a specific application profile. Eye and Eye Turnbuckle An eye and eye turnbuckle has a closed round loop (the "eye") at each end. Each eye is designed to accept a shackle, bolt, pin, or clevis as the connecting hardware. The eye does not open — it is a fixed, closed loop — so the connecting hardware (typically a bow shackle or D-shackle) is threaded through the eye to make the connection. Eye and eye turnbuckles are the most versatile general-purpose configuration. They are suitable for static and low-dynamic loads, and the use of shackles at each end allows easy disconnection and reconnection without disturbing the turnbuckle adjustment. Common applications include fencing, shade sails, rigging anchors, structural tensioning, and any application where the connection point is a fixed pin or bolt. The main limitation of the eye fitting is that it cannot swivel independently — load applied at an angle to the eye plane will introduce bending stress. If your application involves rotation or multi-directional load, a jaw fitting or swivel eye may be more appropriate. Jaw and Jaw Turnbuckle A jaw fitting — also called a clevis fitting — is a forked end with a pin through both tines of the fork. The pin is removable (it is held in by a split pin or cotter pin), allowing the fitting to be connected directly to a plate, lug, or anchor eye without needing a separate shackle. The jaw can align to flat surfaces that an eye cannot easily mate with. A jaw and jaw turnbuckle is well suited to structural connections where the turnbuckle connects directly to fabricated steelwork, plate lugs, or machinery anchor points. The ability to pin directly to a plate reduces the number of hardware components in the assembly and lowers the overall assembly length. This configuration is widely used in industrial rigging, structural bracing, and heavy plant tensioning. Jaw fittings can carry load across the full width of the fork, distributing load over a larger area than an eye fitting of equivalent diameter. They are generally preferred for applications where a positive, locked mechanical connection is required and the connection geometry is planar. Hook and Eye Turnbuckle A hook and eye turnbuckle combines a closed hook on one end and an eye on the other. The hook end allows quick, toolless attachment and release — you simply open the hook, engage the connection point, and close the hook keeper. The eye end connects via a shackle or pin in the usual way. Hook and eye turnbuckles are popular in light to medium-duty applications where convenience of connection matters: fencing, shade structures, theatrical rigging, tensioning stays on display structures, and general-purpose tie-down applications. They are not appropriate for overhead lifting or any application where accidental disengagement of the hook would cause a safety incident. The hook should always have a safety latch (keeper) and the keeper should be verified as closed and engaged before any load is applied. Note that hooks reduce the safe working load (SWL) of the assembly compared to equivalent eye or jaw fittings because the hook geometry introduces stress concentration at the tip of the hook under load. Always check the WLL rating of the complete assembly, not just the body. Hook and Hook Turnbuckle A hook and hook turnbuckle has hooks at both ends, providing maximum convenience of attachment and release at both ends of the assembly. This configuration is most common in very light-duty applications, theatrical and event rigging where assemblies need to be set up and struck frequently, and temporary tensioning applications. Hook and hook turnbuckles are not appropriate for heavy industrial rigging, overhead load-bearing applications, or any situation where load is dynamic or shock-loaded. The hook configuration is the weakest end fitting option, and with hooks at both ends, the SWL of the complete assembly is correspondingly limited. If you are selecting a hook and hook turnbuckle for any load-bearing purpose, verify the rated SWL of the complete assembly (not just the thread size) and apply an appropriate safety factor. For critical applications, upgrade to eye and eye or jaw and jaw. Jaw and Eye Turnbuckle A jaw and eye turnbuckle combines a jaw fitting on one end and an eye on the other, providing the direct pinned connection of the jaw at one end with the shackle-based flexibility of the eye at the other. This is a common configuration when one end of the turnbuckle assembly connects to fabricated steelwork (jaw) and the other connects to a wire rope fitted with a thimble and shackle (eye). The jaw and eye combination is widely used in industrial and marine rigging where the termination conditions at each end differ. It is a practical middle ground that avoids carrying two jaw-pin assemblies when one end is a standard shackle connection. Turnbuckle Body Styles Beyond end fitting type, turnbuckles are also differentiated by their body (frame) design. The body style affects weight, adjustability visibility, resistance to contamination, and appearance. The three main body styles are open body, closed body, and pipe body. Open Body Turnbuckle An open body turnbuckle has a rectangular or oval frame that leaves the threaded shanks of the end fittings exposed and visible on both sides of the body. You can see how far each fitting has been threaded into the body, which gives you a direct visual check of the thread engagement — a critical safety consideration. Most standards require that a minimum number of thread turns remain engaged (typically the shank thread length should not be more than two-thirds of the way into the body). Open body turnbuckles are the most common type in industrial and rigging applications. The open frame allows you to insert a lever bar through the body for tensioning, provides good visibility of thread engagement, and allows you to lock the assembly with seizing wire through the openings in the frame. They are lighter than closed body designs of equivalent strength. The main disadvantage is that the open frame allows ingress of dirt, moisture, and debris, which can accelerate corrosion of the threaded sections. In marine or high-corrosion environments, this must be managed with appropriate material selection (stainless steel) and periodic maintenance. Closed Body Turnbuckle A closed body turnbuckle has a solid cylindrical or hexagonal body, with the end fittings threaded into each end of the cylinder. The threaded sections are completely enclosed, protecting them from environmental contamination. This makes closed body designs well-suited to food processing, pharmaceutical, marine, and coastal applications where hygiene or corrosion protection is critical. The closed body design is typically heavier than an open body of equivalent rating because more material is required to form the enclosed cylinder. Thread engagement cannot be visually verified without removing the fitting, which means you must track adjustment during installation rather than relying on visual inspection. Tensioning is typically done with a wrench on hex flats on the body or by inserting a bar through a hole drilled through the centre of the body. Closed body turnbuckles are commonly used in architectural applications (tensioned cable facades, balustrade wire, frameless glass balustrade tensioning rods) where appearance matters and the clean cylindrical profile is preferred to the open frame aesthetic. Pipe Body Turnbuckle A pipe body turnbuckle is essentially a closed body turnbuckle made from a length of structural pipe or tube, with internal threads tapped at each end. This design is common in custom fabrication and structural applications where a high take-up range is required — simply using a longer length of pipe increases the available travel. Pipe body turnbuckles are often fabricated in-house or made to order for specific structural applications. They are heavier and bulkier than standard open or closed body designs but offer greater adjustability and can be sized to carry very high loads in compression as well as tension (the pipe body resists buckling under compressive load better than an open frame). In standard product catalogues, the three body styles are sometimes listed as "open", "closed" and "hex body" — the hex body being a closed design with a hexagonal (rather than round) cross-section, which provides convenient wrench flats for tensioning without needing a central hole. Stainless Steel vs Galvanised Turnbuckles Material selection is one of the most important decisions in specifying a turnbuckle. Get this wrong and you will deal with premature corrosion, galvanic corrosion between dissimilar metals, or mechanical failure. The two dominant materials for turnbuckles in Australian industrial and trade applications are stainless steel and hot-dip galvanised (HDG) steel. Here is how to choose. Stainless Steel Turnbuckles Stainless steel turnbuckles are manufactured from either grade 304 (18/8 austenitic stainless) or grade 316 (marine-grade stainless, also called 316L or A4). Grade 316 contains molybdenum, which significantly improves its resistance to chloride-induced pitting corrosion — the primary failure mode in marine and coastal environments. Grade 304 stainless is appropriate for inland, non-marine applications where corrosion resistance and appearance are important but chloride exposure is low. It resists atmospheric oxidation well and maintains its appearance without surface treatment. It is not appropriate for direct marine exposure — within around 5km of salt water, chloride attack on 304 stainless can cause pitting and crevice corrosion. Grade 316 stainless is the correct choice for any marine, coastal, or chloride-exposed application. It is significantly more resistant to salt water corrosion than 304. For boat rigging, dock hardware, coastal fencing, marine structures, and any application within approximately 1–5km of the ocean (depending on exposure), 316 is the minimum acceptable specification. In splash zones or direct immersion applications, 316 should be considered mandatory. Stainless steel turnbuckles are also appropriate where appearance is important — for architectural cable systems, tensioned wire balustrades, shade sail tensioning in visible locations, and any application where the hardware is a visible design element. Stainless maintains its bright silver finish without painting or galvanising, though it may dull slightly over time and can be polished back to a bright finish if required. One important note on stainless: stainless steel is susceptible to galling — a form of adhesive wear where the threads of the fitting seize into the body threads under load. This is particularly common in stainless-to-stainless threaded connections under high stress. Galling can permanently seize a turnbuckle during tensioning, making it impossible to adjust. To prevent galling, apply an anti-seize compound (copper-based or nickel-based) to the threads before assembly, tension slowly, and avoid over-tensioning. Hot-Dip Galvanised Turnbuckles Hot-dip galvanised (HDG) turnbuckles are mild steel bodies coated with a thick layer of zinc applied by immersion in molten zinc. The zinc coating provides sacrificial cathodic protection to the underlying steel — if the coating is scratched or abraded, the zinc corrodes preferentially and protects the steel underneath. HDG turnbuckles are significantly more cost-effective than stainless steel equivalents, especially in larger sizes. They are the standard choice for heavy industrial rigging, rural fencing, structural bracing, general engineering applications, and any situation where appearance is secondary to function and load capacity. HDG is appropriate in inland and semi-rural environments where chloride exposure is low. In coastal environments, galvanising offers less corrosion protection than 316 stainless — the zinc coating will be attacked by salt air and will need periodic inspection and recoating. For long-term coastal use, stainless steel is generally more cost-effective over the asset's lifetime even though it costs more upfront. One practical consideration with HDG turnbuckles is thread fit. The zinc coating adds thickness to the threads of the fittings, which can make them harder to thread into the body and may reduce the precision of the thread fit. Inspect threads before use and run a thread die over any rough or burred threads before assembly. Other materials exist for specialised needs — aluminium alloy (lightweight/aerospace), 316L titanium (high-performance marine), electroplated zinc (light-duty indoor only), and bronze (non-sparking environments) — but for the vast majority of Australian trade applications, the choice is HDG vs stainless 316. How to Size a Turnbuckle Turnbuckle sizing involves two key parameters: the thread diameter (also called the body or fitting diameter) and the take-up. You also need to consider the overall length of the assembly in your application. Here is how to work through each parameter. Thread Diameter The thread diameter — often expressed as M6, M8, M10, M12, M16, M20, M24 and so on — is the primary load-bearing dimension of the turnbuckle. It determines the rated working load limit (WLL) of the assembly. Larger thread diameters carry higher loads. To select the correct thread diameter, you must know the maximum working load the turnbuckle will be subjected to, and then select a turnbuckle with a rated WLL equal to or greater than that load. Always apply an appropriate safety factor (see the WLL section below). As a general reference, indicative WLL ranges for eye and eye turnbuckles in grade 316 stainless are approximately: M6: approximately 250–500kg WLL M8: approximately 500–800kg WLL M10: approximately 800–1,200kg WLL M12: approximately 1,200–2,000kg WLL M16: approximately 2,500–4,000kg WLL M20: approximately 4,000–6,000kg WLL M24: approximately 6,000–10,000kg WLL These are indicative only — always verify the rated WLL for the specific product and manufacturer you are using, as ratings vary by standard, design, and quality. Do not use published tables from one manufacturer to rate a product from another. Take-Up The take-up is the range of adjustment available — how much shorter or longer the turnbuckle can make the assembly. A turnbuckle with 50mm of take-up can adjust the assembly length by 50mm from maximum extension to minimum length (or approximately 25mm either side of the midpoint). To size the take-up, consider: Installation tolerance: How much adjustment do you need to take up slack in the cable, wire rope, or rod when first installing? A longer take-up gives you more room to work with imprecise cable cut lengths. Operational adjustment: Will the turnbuckle need to be re-tensioned periodically as the line settles or stretches? More take-up gives you headroom for future adjustment without replacing the hardware. Thread engagement: Regardless of take-up available, you must maintain adequate thread engagement at all times. Most standards require that at least the equivalent of 1× the thread diameter remains engaged (i.e., for an M12 turnbuckle, at least 12mm of thread must remain engaged in the body). Do not run the fitting out to maximum extension — leave a margin. Standard catalogue turnbuckles are available with take-ups typically ranging from around 50mm for small sizes up to 300mm or more for large industrial sizes. If your application requires more adjustment range than standard products provide, consider using a longer pipe body design or installing two turnbuckles in series (though this adds complexity and another potential failure point). Overall Assembly Length When calculating the cable or rod length required for your installation, remember that the turnbuckle has a measurable body length that must be accounted for. At maximum extension, the overall assembly length (end-to-end of the fittings) will be longer than at minimum. Plan your cable lengths around the mid-adjustment position so you have equal take-up and release available. Overall assembly lengths are listed in product datasheets. For accurate installation planning, use the full extended length to calculate your cable cutting length, then tension up to the desired final length. This ensures you always have thread fully engaged and adjustment available in both directions. Turnbuckle WLL and Safe Working Load Every load-bearing turnbuckle has a rated Working Load Limit (WLL), sometimes also called Safe Working Load (SWL) or Rated Capacity. These terms are used interchangeably in Australian industry (WLL is the preferred term under AS 4991 and AS 3569). The WLL is the maximum load that the turnbuckle is rated to bear in normal service conditions, inclusive of an appropriate design factor. Turnbuckle WLLs in Australia are typically set in accordance with AS 3569 (Steel Wire Ropes) and AS 4991 (Lifting Components) or equivalent international standards (DIN 1478, BS 4429, ISO 2415). Products certified to these standards will have their WLL marked on the body and will be supplied with documentation from the manufacturer. Design Factor and Safety Factor The WLL already includes a built-in design factor — typically 4:1 for rigging hardware, meaning the proof load (the load at which the hardware is proof tested without permanent deformation) is 2× the WLL, and the minimum breaking load (MBL) is 4× the WLL or higher. This built-in factor is not an excuse to operate at the WLL in all circumstances. In practice, you should further derate the WLL for the conditions of your application: Dynamic loads: If the load will be dynamic (shock-loaded, cyclically varying, subject to vibration), derate the WLL significantly — typically to 50% or less. Dynamic loads can be many times the static weight of the load, and fatigue failure can occur well below the static WLL. Angular loads: If the cable or rod connected to the turnbuckle is not in line with the turnbuckle axis (i.e., there is an angle between the line of pull and the axis of the turnbuckle), the effective load on the fitting increases with the angle. At 30° off-axis, the load on the fitting increases significantly; at 60°, it can more than double. Size up if angular loading applies. Temperature extremes: At elevated temperatures (typically above 200°C), the rated capacity of most steel hardware decreases. Low temperatures increase brittleness in carbon steel hardware — use stainless or alloy steel hardware rated for low-temperature service if required. Corrosion and wear: Corroded, worn, or damaged hardware should be retired regardless of its nominal WLL. Inspect turnbuckles periodically and replace any with cracked, pitted, or deformed bodies, bent fittings, or damaged threads. Proof Loading and Inspection In Australian industrial rigging applications, turnbuckles may need to be proof-loaded, inspected, and tagged per AS 4991 and relevant state OHS regulations. For standard non-lifting applications (fencing, shade sails, structural bracing), proof loading is not required, but verify that the product WLL exceeds your maximum load by an appropriate margin and comes from a documented source. Common Turnbuckle Applications Turnbuckles appear across a remarkably wide range of industries and applications. Understanding where and how they are used helps in selecting the right type and specification for your own application. Wire Rope and Industrial Rigging The most demanding and regulated use of turnbuckles is in industrial rigging — tensioning wire rope stays, bracing cables, and structural tensioning members in industrial plant, mining, construction, and marine engineering. In these applications, turnbuckles are sized strictly to their rated WLL, proof-tested where required, and regularly inspected as part of a documented rigging management system. In rigging applications, turnbuckles are typically jaw and jaw or jaw and eye configuration, galvanised or stainless depending on environment, and selected to match the wire rope diameter and grade of the rigging assembly. The turnbuckle WLL should be at least equal to the WLL of the wire rope it tensions — the turnbuckle should not be the weakest link in the assembly. For comprehensive guidance on wire rope grades, terminations, and rigging hardware integration, see our Wire Rope, Slings & Rigging Guide. Shade Sails Shade sails are one of the most common consumer applications for turnbuckles in Australia. A typical residential shade sail installation uses 4–6 turnbuckles (one at each corner anchor point) to tension the sail after it is attached. The turnbuckles allow the sail to be tightened seasonally and retensioned after settling. For shade sail applications, stainless steel 316 turnbuckles are strongly preferred — the combination of UV exposure, moisture, and coastal environments means galvanised hardware will rust and stain the sail fabric. Eye and eye configuration is standard, with bow shackles connecting the sail's corner ring to the turnbuckle eye and the anchor bolt to the other eye. Sizing for shade sails: M6 to M10 is typical for residential sails. The load is a combination of the pre-tension in the sail (usually low in a properly installed domestic sail), wind uplift, and sail dead weight. For large commercial shade sails, structural engineering advice should be sought and turnbuckle sizing done to a calculated load, not estimated. Fencing and Gates Turnbuckles are widely used in wire fencing — both rural/agricultural and industrial security fencing — to tension fence wires after straining. A turnbuckle installed at one or both ends of a fence run allows the wire to be tightened initially and re-tensioned over time as wires stretch or posts settle. In agricultural fencing, HDG open body turnbuckles are standard — they are economical, easy to install, and available in the farm supply trade. In security fencing (cyclone wire, chain mesh), larger turnbuckles may be used at corners and strainer posts to maintain tension in the mesh. Gate bracing is another common application: a diagonal turnbuckle assembly across a gate frame can correct sagging and restore a gate to level after the frame has distorted. This is a low-load application where a light-duty hook and eye or eye and eye turnbuckle in M6–M8 is typically adequate. Structural Tensioning and Construction In construction and structural engineering, turnbuckles are used in tensioned bracing systems — the diagonal bracing members in steel frame buildings, towers, and structures that provide lateral stability. In this application, the turnbuckle (often called a "rigging screw" or "tensioner" in structural drawings) is installed in-line in the diagonal brace member and tensioned to introduce pre-stress into the bracing system. Structural turnbuckles in buildings are typically specified by a structural engineer and must conform to the engineer's design loads, connection details, and any relevant standards (AS 4100 for structural steel, AS 3569 for wire rope). Do not substitute unapproved hardware in structural applications. Road and highway guardrail cable systems are another large structural application — turnbuckles tension the wire rope cables that run between posts on W-beam and cable barrier systems. These are maintenance-critical: barrier cable tension must be checked and adjusted regularly to maintain crashworthiness. Marine and Sailing Marine rigging is one of the most demanding turnbuckle environments. Bottle screws and rigging screws in sailing applications are almost exclusively grade 316 stainless, often to ISO 2415 or BS 4429, sized by a naval architect or rigging specialist. Jaw and jaw or jaw and fork configurations pin directly to chainplates; toggle joints are sometimes added to manage angular loads. Locking is critical — seizing wire on the body and cotter pins on fitting pins. Marine turnbuckles are typically replaced on a mileage or age schedule regardless of apparent condition. Architectural and Aesthetic Applications Tensioned stainless cable systems for balustrades, cable trellis, wire facades, and cable-supported roof structures use closed body 316 stainless turnbuckles selected as much for aesthetics as function. Architectural grade turnbuckles are polished or satin-finished, often with swivel connections at one or both ends to handle angular loads. Lower loads than industrial rigging, but finishing standards and dimensional tolerances are higher. How to Install and Use a Turnbuckle Correct installation is essential for safe, effective turnbuckle operation. The following procedure applies to the majority of general-purpose tensioning applications. For certified lifting rigging or structural applications, follow the relevant standard and any site-specific procedures. Step 1: Inspect the Hardware Before Installation Before fitting, inspect every component. Check the turnbuckle body for cracks, deformation, or corrosion. Check that the threads on the body and fittings are clean, undamaged, and fully formed. Verify that both end fittings thread freely into the body by hand — they should turn smoothly with no binding. Inspect all associated hardware (shackles, pins, wire rope, thimbles) for damage, corrosion, and correct rating. If any component is damaged, corroded, worn, or in doubt, do not use it. Replace before proceeding. Step 2: Apply Anti-Seize to Threads For stainless steel assemblies, apply a thin coat of anti-seize compound (copper-based or nickel-based) to the threads of both fittings before threading into the body. This is not optional for stainless — without anti-seize, galling (thread seizure) during tensioning is a genuine risk and can permanently lock the turnbuckle. For galvanised assemblies, anti-seize is less critical but still beneficial for ease of future adjustment and removal. Step 3: Set Initial Thread Engagement Thread both end fittings into the body by hand to the midpoint of their adjustment range — equal take-up in both directions and maximum thread engagement. Before tensioning, verify adequate thread engagement: at least 1× the thread diameter engaged at each end (e.g., 12mm for M12). On open body turnbuckles, visually confirm fitting shanks are not running close to the body ends. Step 4: Connect to Anchor Points Connect the assembly to both anchor points before tensioning. Eye fittings: install shackles through the eyes onto anchor points or thimbles. Jaw fittings: insert the jaw pin through the jaw and connecting plate, then install the cotter pin. All pins must be fully seated and locked before any tension is applied. Step 5: Tension the Assembly Rotate the turnbuckle body to tension. For small turnbuckles (M6–M10), hand tension may be sufficient; for larger sizes, use a lever bar through the body openings. Tension progressively — a few turns, check tension, repeat. Monitor thread engagement throughout on open body designs. Do not over-tension: apply the required working tension, not maximum possible. Over-tensioning damages threads, can yield the cable, and overloads anchor points. Step 6: Check Alignment Verify that the turnbuckle body is in line with the direction of load. Significant angular offset introduces bending stress into the fitting and body beyond what the WLL accounts for. Correct misaligned anchor points rather than accepting angular loading. Step 7: Lock the Turnbuckle Once correct tension is achieved, the turnbuckle must be locked to prevent the body from rotating under vibration, dynamic load, or gravity and backing off over time. There are several locking methods: Seizing wire: Stainless seizing wire through the open body frame and around fitting shanks — the most secure method and the only one acceptable in certified rigging. Lock nuts: Run lock nuts tight against the body face after tensioning. Prevents backing-out if the body rotates. Split pins: Through holes in the body aligned with the fitting shank — locks the fitting positively. Check manufacturer's instructions. Thread-locking compound: Loctite or equivalent resists self-loosening in low-vibration applications. Makes future adjustment difficult — use only where re-tensioning is not anticipated. Lock nuts are the minimum for shade sail and light fencing. Seizing wire or split pins are required for industrial rigging and any vibration-exposed application. Step 8: Tag and Record In regulated applications, tag the assembly with installation date, WLL, and next inspection date. Record in a maintenance log. Comply with AS 4991 and any site WorkSafe requirements. Common Turnbuckle Failures (and How to Avoid Them) Understanding how turnbuckles fail in service helps you avoid those failures through correct selection, installation, and maintenance. These are the failure modes seen most often in practice. Thread Stripping Thread stripping — where the threads in the body or on the fitting shank are damaged or pulled out under load — is typically the result of one of three causes: insufficient thread engagement (running the fitting out too far), overloading beyond the WLL, or thread damage from corrosion, galling, or impact before or during installation. Prevention: always verify adequate thread engagement before and after tensioning. Use open body turnbuckles where thread engagement can be visually monitored. Never run a fitting out to less than 1× diameter of thread engagement. Replace turnbuckles with any thread damage before putting them in service. Thread Galling (Stainless Steel) Galling is a form of adhesive wear unique to austenitic stainless steel — the thread surfaces weld together momentarily under the contact pressure of tensioning, tearing material from both surfaces and ultimately seizing the threads completely. It can happen quickly, even on the first installation, if the threads are dry and tensioning is done fast. Prevention: always apply anti-seize to stainless threads. Tension slowly and smoothly. If you feel unusual resistance during tensioning, stop — do not force through it. If a fitting has galled into the body, it cannot be freed without machining or destruction of the assembly. Corrosion and Pitting Corrosion is the most common cause of in-service turnbuckle degradation. In HDG hardware, zinc coating is sacrificed over time — once the coating is gone, the underlying steel corrodes rapidly. In stainless hardware, chloride attack causes pitting, particularly at crevices (thread roots, under contacting surfaces, in closed body designs where moisture is trapped). Prevention: match material to environment (see the material selection section). Inspect turnbuckles at regular intervals — annually at minimum, more frequently in aggressive environments. Retire any hardware with significant pitting, surface cracking, or corrosion that reduces visible cross-section. Fatigue Cracking Turnbuckles under cyclic loading — vibration, wave loads, repeated tension cycles — can fail by fatigue at thread roots, fitting-to-shank transitions, and jaw fork corners. Fatigue cracks develop internally without visible warning until fracture. Apply appropriate dynamic load derating, inspect with dye penetrant or MPI where fatigue is a concern, and follow manufacturer replacement intervals in high-cycle service. Self-Loosening (Backing Off) In any vibration-exposed or dynamically loaded application, a turnbuckle without adequate locking will back off — the body rotates under dynamic load, the fittings thread out, tension is lost, and eventually the fitting can unthread completely. This is particularly dangerous in overhead or structural applications. Prevention: always lock turnbuckles after tensioning using appropriate method (see installation step 7). Inspect locking devices at each scheduled inspection. Re-tension and re-lock if locking hardware shows signs of wear, corrosion, or loosening. Overload and Yielding Applying loads beyond the rated WLL — whether through underspecification, shock loading, dynamic amplification, or angular loading beyond the rated axis — can yield (permanently deform) the turnbuckle body or fittings. Yielded hardware shows as bent fittings, elongated eye holes, deformed jaw forks, or a body that cannot be tensioned to the original position. Prevention: correct specification for the actual (not estimated) load case. Apply conservative safety factors for dynamic applications. Inspect for deformation after any unusual load event. Remove any hardware that shows evidence of overload from service, even if no cracking is visible — yielded hardware has compromised residual strength. Turnbuckle vs Alternatives Turnbuckles are the default choice for in-line tension adjustment, but they are not the only option. In some applications, an alternative may be more appropriate. Tensioning Clips and Inline Tensioners For light-duty wire fencing and garden wire applications, inline wire tensioners (spring tensioners, ratchet tensioners) can tension wire without the need for a turnbuckle assembly. These are less adjustable and carry lower loads than a proper turnbuckle but are faster to install and require no separate shackles or hardware. Suitable for low-load fencing applications only. Hydraulic or Mechanical Tensioners In post-tensioned concrete and large structural applications, hydraulic stressing jacks apply and measure precise tension in high-strength strand. Turnbuckles are not used in these applications — loads are too high and precision requirements exceed manual adjustment capability. Ratchet Straps and Load Binders For vehicle load restraint, ratchet straps and chain load binders are used — not turnbuckles. These are rated for transport dynamics and covered by NHVR Load Restraint Guide requirements. Standard turnbuckles are not rated for transport restraint. Swageless Fittings and Toggle Tensioners In architectural cable systems (balustrades, wire facades, trellis), proprietary swageless fittings and toggle tensioners integrate tension adjustment into the end fitting itself for a lower-profile installation. More expensive than standard turnbuckles and require system-matched components, but offer superior aesthetics. Frequently Asked Questions What is a turnbuckle used for? A turnbuckle is used to tension or adjust the length of cables, wire ropes, rods, or other line elements across a fixed span. Common applications include wire rope rigging, shade sail tensioning, fencing wire tensioning, structural bracing, marine rigging, and architectural tensioned cable systems. The turnbuckle allows precise, field-adjustable tension to be applied and re-adjusted over time without replacing the cable or rod. What are the different types of turnbuckle end fittings? The main end fitting types are: eye (a closed loop connecting via shackle or pin), jaw/clevis (a forked fitting with a removable pin for direct plate or lug connection), and hook (an open hook for quick attachment and release). Turnbuckles can have matching fittings on both ends (eye and eye, jaw and jaw, hook and hook) or mixed fittings (jaw and eye, hook and eye). The right combination depends on the connection method at each end of your assembly. What is the difference between stainless steel and galvanised turnbuckles? Stainless steel (especially grade 316) offers superior corrosion resistance, maintains a clean appearance, and is required for marine, coastal, and food/pharma applications. It is more expensive but has a longer service life in aggressive environments. Galvanised steel is lower cost and suited to general industrial, rural, and inland applications where appearance is secondary. In coastal environments, 316 stainless is more cost-effective over the long term. Stainless requires anti-seize on threads to prevent galling; galvanised does not. How do I size a turnbuckle for my application? Sizing involves two steps: first, determine the maximum load the turnbuckle will be subjected to and select a thread diameter with a rated WLL that exceeds that load by an appropriate safety margin (typically at least 2× for static applications, more for dynamic). Second, select the take-up (adjustment range) to suit your installation — enough to take up any slack in the initial installation and allow for future re-tensioning. Ensure that at all positions, minimum thread engagement (at least 1× the thread diameter) is maintained in the body. What are common turnbuckle failures and how do I avoid them? The most common failures are thread stripping (caused by insufficient thread engagement or overloading), thread galling in stainless steel (prevented by applying anti-seize before installation), corrosion and pitting (prevented by matching material to environment and regular inspection), self-loosening under vibration (prevented by proper locking after installation), and fatigue cracking under dynamic loads (addressed by conservative sizing and regular inspection). Correct specification, installation, locking, and inspection intervals eliminate most turnbuckle failures in practice. What is an alternative to a turnbuckle? For light-duty wire fencing, inline wire tensioners or ratchet tensioners are simpler alternatives. For transport load restraint, ratchet straps and chain load binders are used (standard turnbuckles are not rated for transport restraint). For architectural wire tensioning, proprietary toggle tensioners and swageless fittings offer lower-profile alternatives. In heavy structural or post-tensioned applications, hydraulic stressing equipment is used. For the majority of general tensioning applications, however, a correctly specified turnbuckle remains the most practical and cost-effective solution. Browse our range of turnbuckles and rigging hardware at AIMS Industrial — stainless steel and galvanised, in eye and eye, jaw and jaw, and hook and eye configurations, available for fast dispatch Australia-wide. Need to size a metric bolt? Our Metric Bolt Size Guide covers M3 through M24 with coarse and fine threads.
Read moreWire Rope Slings & Rigging Guide: Hitches, Sling Angles, Shackles & Clips
What is a shackle? A shackle is a U-shaped lifting fitting closed by a pin, used to connect a wire rope sling, chain sling, or synthetic sling to a load or lifting point. The two main types are bow shackles (D-shape with a wider curve — handles loads from multiple angles, ideal for sling-to-load connections) and dee shackles (straight sides — narrower, used for inline tension where loads pull straight through the pin). Lifting-rated shackles are stamped with a Working Load Limit (WLL) and manufactured to AS 2741. Wire rope construction Wire rope is constructed from individual steel wires twisted into strands, and strands twisted around a central core. The construction designation — for example 6×19 or 6×36 — describes the number of strands and the number of wires per strand. Understanding these designations is the foundation of correct wire rope selection. 6×19 classification A 6×19 rope has 6 strands, each containing 16 to 26 wires. The relatively fewer, larger wires per strand make this rope stiffer and more resistant to surface abrasion — the thick outer wires resist wear from contact with sheaves, drums, and abrasive loads. The trade-off is reduced flexibility and lower fatigue resistance from repeated bending. 6×19 is the standard choice for lifting slings, boom pendants, and static or semi-static applications where abrasion resistance matters more than flexibility. 6×36 classification A 6×36 rope has 6 strands, each containing 27 to 49 wires. More, finer wires per strand produce a significantly more flexible rope with higher fatigue resistance from repeated bending cycles. The finer wires are more susceptible to surface abrasion than 6×19. 6×36 is the preferred choice for crane hoist ropes, running ropes on winches and machinery, and any application involving continuous bending over sheaves or drums. 7×7 and 7×19 — aircraft cable construction These smaller-diameter constructions (7 strands of 7 or 19 wires) are sometimes called "aircraft cable" in trade catalogues. They offer high flexibility in small diameters but are not rated for overhead lifting applications. They are appropriate for marine rigging, guy wires, safety lines, and similar light-duty control and tension applications. Do not use 7×7 or 7×19 construction for vertical lifting of personnel or equipment in industrial applications. Core type: IWRC vs fibre core The core runs through the centre of the rope and supports the strands. Two core types are standard: IWRC (Independent Wire Rope Core): A wire rope core — essentially a smaller wire rope at the centre. IWRC provides superior crush resistance, maintains rope geometry under side loads, and increases the rope's overall breaking strength by approximately 7.5% compared to the equivalent fibre core rope. IWRC is the correct choice for cranes, hoists, and any application where the rope passes over sheaves or is wound on a drum under tension. Fibre core (FC): A core of synthetic or natural fibre. More flexible than IWRC, provides cushioning between strands, and is preferred in applications where flexibility is prioritised over crush resistance. Less suitable for heavy drum-winding or applications involving significant side loading. Common in sling construction and lighter-duty lifting applications. Grade and finish Wire rope is available in several strength grades: IPS (Improved Plow Steel), EIPS (Extra Improved Plow Steel), and EEIPS (Extra Extra Improved Plow Steel) — each progressively stronger. For general industrial and lifting use, EIPS is the standard grade. Finish options include bright (uncoated), galvanised, and stainless steel. Galvanised wire rope offers corrosion protection for outdoor and marine environments. Stainless steel (typically 316 grade) is used where maximum corrosion resistance is required — marine, food processing, chemical environments — but carries a significant cost premium and has lower strength than equivalent carbon steel rope. WLL, SWL, and Rated Capacity — Australian terminology The terminology used in Australian rigging and lifting has changed, and using the wrong terms creates both compliance and safety risks. WLL (Working Load Limit) is the current standard term for the maximum load a piece of rigging equipment — sling, shackle, hook, hoist — is rated to carry under normal conditions. WLL is calculated by dividing the minimum breaking load (MBL) by a design factor (safety factor). For wire rope slings the design factor is 5:1; for chain slings it is 4:1; for synthetic slings it is 5:1. A sling with a 50 kN MBL and a 5:1 design factor has a WLL of 10 kN (approximately 1 tonne). SWL (Safe Working Load) is the old term, replaced by WLL. Australian Standard AS1418.1-2002 removed SWL from the standard for cranes, hoists, and winches. In the current framework, WLL is used for items below the hook (slings, shackles, hooks) and Rated Capacity is used for the crane or hoist itself. You will still encounter SWL on older equipment and in older documentation — treat it as equivalent to WLL for practical purposes, but specify WLL in new work. ⚠️ WLL is not a safety factor — it already includes oneA common misunderstanding is treating WLL as a conservative limit that can be exceeded with care. It cannot. The WLL is the maximum permissible working load. The safety factor (4:1 or 5:1) is built into the WLL calculation to account for dynamic loading, shock loading, and the statistical variation in rope and hardware strength. Exceeding the WLL eliminates that safety factor and takes the equipment into territory where failure probability rises sharply. For lifts with significant shock loading or dynamic movement, apply an additional service factor — not by exceeding the rated WLL, but by selecting equipment with a higher WLL. For a complete breakdown of Australian rigging terminology — including why SWL was retired, how to calculate WLL from MBL, sling angle derating tables, and the weakest link rule — see our SWL vs WLL vs MBL Guide. Sling types: wire rope, chain, and synthetic Three sling types dominate industrial lifting: wire rope, alloy chain, and synthetic (web or round). Each has specific strengths, limitations, and correct applications. Selecting the wrong type for the environment or the load is a common source of premature failure and unsafe lifts. Factor Wire rope sling Alloy chain sling Synthetic (web / round) Design factor 5:1 4:1 5:1 Heat resistance Moderate (derate above 100°C) High (usable to 400°C alloy chain) Poor — nylon degrades above 90°C; polyester above 150°C Sharp edges Tolerates moderate contact Best — chain handles sharp edges well Very poor — must be protected from any sharp contact Load surface protection Poor — will mark and damage soft surfaces Poor — will mark surfaces Excellent — wide flat web protects polished and fragile loads Flexibility Good Good — adjustable length via shortening clutch Excellent — most flexible and lightest Corrosion resistance Moderate (galvanised or SS available) Moderate (stainless available at cost) Good — polyester resists most chemicals Inspection ease Moderate — look for broken wires, kinks Easy — look for stretch, link wear, deformation Easy — cuts, burns, chemical attack visible Typical application General heavy industrial, outdoor, crane lifts Hot work, foundries, sharp-edged loads, adjustable lifts Finished surfaces, machinery, precision loads For Grade 80 and Grade 100 chain sling configurations, WLL tables, and sling angle de-rating calculations, see the Chain Sling Guide. Hitch types and WLL factors Every lift uses one of three fundamental hitches — or a combination of them. The hitch configuration directly affects the effective WLL of the sling, and this is not a minor adjustment. Getting the hitch type wrong can mean working at twice the intended WLL without realising it — or losing half the sling's capacity through incorrect wrapping. Vertical hitch (straight hitch) The sling runs vertically from the hook to the load, with one eye on the hook and the other attached directly to the load. The sling's full rated WLL applies. This is the baseline: all WLL ratings on sling tags are referenced to vertical hitch. Use for loads with a reliable lifting point directly above the centre of gravity, such as an engineered lifting lug or a certified lifting point on machinery. Choker hitch The sling wraps around the load and the eye is passed through the opposite eye (or a dedicated choker fitting), forming a self-tightening loop that grips the load as tension builds. Effective WLL is 75–80% of the vertical WLL when the choke angle is 120° or greater. At tighter choke angles, the WLL reduces further. The choker hitch is useful for irregularly shaped loads with no lifting lug, but it must not be used on loads that would be damaged by constriction, and the rope must seat fully into the choke before the lift begins. Basket hitch The sling cradles the load beneath it — both eyes to the hook, load supported in the bight of the rope. When the legs hang vertically (90° to horizontal), each leg carries half the load, effectively giving up to 200% of the vertical WLL. This is the only hitch that multiplies capacity. The multiplication factor reduces as the basket angle narrows — see the sling angle section below. The load must be balanced; an unbalanced load in a basket hitch will slide to the low side and potentially roll off the sling. Sling angle: the most misunderstood factor in rigging Sling angle — the angle between the sling leg and the horizontal — is the single most commonly underestimated factor in rigging calculations. Most people intuitively feel that two sling legs sharing a load must be safer than one. They are, but only when the angle is favourable. As the angle decreases (the legs spread wider, or in a basket hitch, the horizontal distance between hook and load attachment increases), the tension in each leg rises sharply — far beyond what simple geometry suggests. At 90° (sling legs perfectly vertical), the tension in each leg equals half the load weight — this is the ideal case. At 30° from horizontal (a very wide spread or a long, flat basket hitch), the tension in each leg equals the full load weight. Adding a second leg has provided zero additional capacity. Below 30°, the tension exceeds the load weight in each leg — the two-leg arrangement is actually more dangerous than a single vertical sling of the same rating. The angle factor (reduction multiplier applied to the sling WLL) at common angles: Sling angle from horizontal Angle factor Effective WLL — 2-leg bridle at 1t per-leg rating Note 90° 1.000 2.00 t Ideal — legs perfectly vertical 75° 0.966 1.93 t Negligible reduction 60° 0.866 1.73 t Commonly used; acceptable 45° 0.707 1.41 t Significant reduction — recalculate 30° 0.500 1.00 t ⚠️ Each leg carries the full load — no benefit from two legs <30° <0.500 <1.00 t 🚫 Dangerous — leg tension exceeds load weight. Do not rig below 30° Most rigging standards — including Australian practice guidance — set 30° as the minimum permissible sling angle. Rigging below 30° is prohibited on most Australian worksites. If the geometry of the lift forces a low sling angle, the correct response is to use longer slings (raising the hook point relative to the attachment points increases the angle), not to accept the reduced capacity. In practice: before any multi-leg lift, sketch the geometry and calculate or estimate the sling angle. If in doubt, measure the height from attachment point to hook and the horizontal distance between attachment points, then calculate: sling angle = arctan(height ÷ half-horizontal-distance). If this gives an angle below 60°, reconsider the rigging arrangement. Shackles: D shackle vs bow shackle, screw pin vs safety bolt Shackles connect slings to loads, slings to hooks, and hardware to hardware. They are the most commonly purchased rigging item — d shackle and bow shackle together represent some of the highest search volumes in the rigging category for a reason. For a full guide to shackle grades, WLL tables and AS 3776, see our Bow Shackle & D-Shackle Guide. Getting the shackle wrong does not always produce an immediate failure — it can produce a slow-developing failure as the pin loosens under load rotation, or a sudden failure when a D shackle is side-loaded beyond its rated direction. D shackle (chain shackle) The D shackle has a narrow, D-shaped bow designed to carry load in one direction: along the axis of the shackle body, through the pin. It is strongest in this straight-line configuration. Side loading — force applied across the width of the bow — drastically reduces the shackle's capacity and can cause the bow to open or distort without the pin failing first. D shackles are the correct choice for single-point connections where the load direction is predictable and stable: connecting a sling eye to a chain link, attaching a single-leg sling to a machined lifting lug, or creating a point-to-point connection in a rigging assembly. They are not suitable for connecting multiple sling legs or for applications where the load direction may rotate or shift. Bow shackle (anchor shackle) The bow shackle has a wider, rounded bow that can accommodate multiple sling eyes or accept load from multiple directions without the severe derating that affects a D shackle under side load. This makes the bow shackle the correct choice for multi-leg sling assemblies, angled loads, and any application where load direction may shift during the lift. Bow shackles have a lower WLL than D shackles of the same pin diameter because the wider bow creates higher bending stress in the body. They also take up more space — relevant when working in tight rigging assemblies. For most crane lifting and rigging work on construction and industrial sites in Australia, the bow shackle is the standard general-purpose choice. Screw pin vs safety bolt (bolt-type) shackle Both bow and D shackles are available with two pin types, and the choice matters as much as the shackle type. Screw pin shackles have a threaded pin that is wound in by hand. They are fast to connect and disconnect, making them convenient for frequent pick-and-place operations where the rigging configuration changes between lifts. However, a screw pin can rotate and unwind under vibration or load rotation — particularly when used in a choker hitch where the sling naturally rotates as it tightens. If a screw pin shackle is used in any application involving vibration, rotation, or sustained load, the pin must be moused (secured) with wire through the pin hole to prevent it backing out. Safety bolt (bolt-type) shackles have a smooth, unthreaded bolt pin locked by a nut and cotter pin (split pin). They cannot unwind under vibration or load rotation. They take longer to fit and remove, making them less convenient for frequent re-rigging but correct for permanent or semi-permanent installations, vibrating machinery, rotating loads, and any overhead lift where a dropped pin is a hazard. Safety bolt shackles are the required type for most permanent lifting point installations on Australian industrial sites. Key rules for shackle use: Never side-load a D shackle — use a bow shackle if the load direction is not strictly axial. Never cross-load a shackle pin — the load must bear on the bow, not the pin. Never use a shackle as a hook by passing the pin through a load rather than the bow through the attachment point. Mouse screw pin shackles in any application with vibration, rotation, or sustained load. Rated shackles in Australia should comply with AS2741-2002. Check for a WLL stamp on the bow. Wire rope fittings and terminations Wire rope slings and assemblies require end terminations — the fittings that connect the rope end to the load, the hook, or the next piece of hardware. Termination type significantly affects the efficiency of the connection: how much of the rope's breaking strength is retained at the termination. Termination efficiency Termination type Efficiency (% of rope MBL retained) Notes Poured socket (zinc or resin) 100% Highest efficiency; used on crane ropes and critical installations; requires professional fitting Swaged (mechanical press fitting) 95–100% Common on factory-made slings; requires swaging press; reliable and compact Flemish eye splice (mechanical) 90–95% The standard for wire rope slings; splice unwinds the strands and reforms around a thimble; professional fabrication Hand-tucked splice 80–90% Older method; less consistent than mechanical splice; rarely used in new sling fabrication Wedge socket 75–90% Field-fittable without special tools; efficiency variable — depends on correct wedge seating and wire tail management Wire rope clips (U-bolt grips) 75–80% Field-fittable; efficiency and safety entirely dependent on correct installation — see section below Thimbles A thimble is a grooved metal insert that fits inside the eye of a wire rope sling at the termination point. Its purpose is to protect the wire rope from the sharp-radius bending it would experience if the eye were draped directly over a hook or shackle pin. Without a thimble, the wires at the eye contact point are bent sharply, reducing the effective strength of the termination and accelerating fatigue at that point. All rigging-grade wire rope slings should be thimbled. The d/d ratio (ratio of the thimble pin/contact diameter to the rope diameter) should be a minimum of 6:1 for the thimble to preserve the full rated efficiency of the termination. Wire rope clips — never saddle a dead horse Wire rope clips (also called Crosby clips, bulldog grips, or U-bolt rope clamps — distinct from the U-bolt fastener family covered in our U-Bolt Guide) are the most field-accessible way to form an eye in a wire rope. They are also the most commonly misused rigging component on Australian worksites. The consequences of incorrect clip installation are severe — not a gradual failure but a sudden, complete loss of termination under load. A wire rope clip consists of a U-bolt and a saddle (bridge). The correct installation rule, universally taught in rigging courses and remembered as a mnemonic: ✅ "Never saddle a dead horse"The saddle (bridge) always bears on the live rope — the load-carrying section. The U-bolt always bears on the dead end (the short tail). Installing the saddle on the dead end and the U-bolt on the live rope crushes the load-bearing wires and can reduce termination efficiency to below 50%, with the additional risk of the tail pulling through under load.If you're forming a thimble eye: the saddle bears on the rope coming off the thimble (the live section running to the load); the U-bolt bears on the tail coming back alongside the thimble. Additional clip installation requirements: Minimum number of clips: The number of clips required depends on rope diameter. General guidance: 3 clips for rope up to 19 mm; 4 clips for 20–25 mm; 5 clips for 26–32 mm. Always verify with the clip manufacturer's data — fewer clips than specified dramatically reduces holding capacity. Clip spacing: Space clips at a minimum of 6 rope diameters apart, measured between the U-bolt centres. Clips packed too closely together cannot develop the friction grip needed for rated holding capacity. Tightening torque: Clip nuts must be tightened to the manufacturer's specified torque — not "hand tight plus a bit". Under-tightened clips slip; over-tightened clips crush wires. Retighten after the initial load is applied — the rope will compress and seat under the first load, reducing nut tension. Dead end tail length: The tail beyond the last clip must extend at least 6 rope diameters past the clip to ensure adequate holding length. Inspection and discard criteria Wire rope and rigging equipment must be inspected before each use and formally inspected at regular intervals in accordance with AS4991 (lifting components) and the relevant equipment standard. The person performing the inspection must be competent to identify the defects listed below. Rigging hardware that fails inspection must be taken out of service immediately — not tagged for later assessment, not returned to the yard for review. Out of service means out of service. Wire rope — discard when any of the following are present Broken wires: 6 or more broken wires in any one rope lay length in running rope (rope wound on drums or passing over sheaves); 3 or more broken wires in a single strand within one lay length. For slings, any broken wires in the eye or termination zone are cause for immediate discard. Kinks: Any kink — a permanent deformation where the wires have been displaced from their helical path — is a discard condition. Kinks cannot be straightened without permanently compromising the rope structure at that point. Birdcaging: A sudden release of load or a severe shock load can cause the strands to spring outward from the core, creating a birdcage appearance. Discard immediately. Corrosion: Surface rust on its own may not be cause for discard (lubricate and re-inspect), but pitting — corrosion that has penetrated below the wire surface — is a discard condition. Significant internal corrosion may not be visible externally; core-level corrosion is indicated by a rope that is stiffer than normal, dry, and discoloured when the strands are opened. Diameter reduction: A reduction in overall rope diameter of more than 3% from the nominal diameter indicates internal core failure or severe internal wear. Measure with a calliper at multiple points. Heat damage: Blue or straw discolouration of the wires indicates the rope has been exposed to temperatures that may have altered the wire's mechanical properties. Discard. Synthetic slings — discard when any of the following are present Any cut, abrasion, or tear that penetrates the load-bearing fibres (not just the outer jacket) Burns or heat damage visible as glazed, melted, or charred fibres Chemical attack — stiffness, brittleness, or discolouration from exposure to acids, alkalis, or solvents Missing, illegible, or detached identification label (the tag is mandatory — a sling without a legible WLL tag must not be used) Knots — never tie a knot in a synthetic sling to shorten it; this creates a stress concentration and reduces capacity by 50% or more Shackles — discard when any of the following are present Deformation of the bow — any visible bending or opening of the bow shape Wear on the pin or the inside of the bow exceeding 10% of the original diameter Cracks, gouges, or impact marks on the bow body Thread damage on screw pin shackles preventing full seating of the pin Missing cotter pin (split pin) on safety bolt shackles — never replace with wire or improvised locking methods No WLL marking — unrated shackles must not be used in lifting or rigging applications Inspection tagging All rigging equipment used in Australian industrial workplaces must be tagged and current. Colour coding for inspection tags follows a national cycle — the current colour indicates the equipment has passed inspection in the current period. Equipment with an out-of-date or missing tag must not be used, regardless of its apparent condition. The inspection tag confirms competent inspection, not just physical serviceability. Related rigging guides: Electric Chain Hoist Guide · Jib Crane Guide · Snatch Block Guide · Turnbuckle Guide For transport applications — securing loads on flatbeds, trailers, and low loaders — chain tie-down systems with load binders are the heavy-duty alternative to synthetic webbing straps. Load binders apply rated tension across Grade 70 transport chain under the NHVR Load Restraint Guide 2025. See the Load Binder Guide for ratchet vs lever binder comparison, G70 chain sizing, and NHVR-compliant lashing calculations. Frequently asked questions What is the difference between WLL and SWL? WLL (Working Load Limit) is the current Australian standard term for the maximum load a piece of rigging equipment is rated to carry under normal conditions. SWL (Safe Working Load) is the old term, removed from Australian Standard AS1418.1 in the 2002 revision. They describe the same concept — the maximum permissible working load, calculated by dividing the minimum breaking load by a design (safety) factor. For lifting equipment above the hook (the crane itself), the current term is Rated Capacity. Use WLL for all rigging hardware — slings, shackles, hooks, and lifting points. What is a wire rope sling? A wire rope sling is a length of wire rope with formed eyes at one or both ends, used to connect a load to a crane hook or other lifting device. The eyes are typically formed using a Flemish splice around a steel thimble, or by swaged ferrule, providing a rated connection point. Wire rope slings are available in single-leg, two-leg, three-leg, and four-leg configurations. The WLL of a multi-leg sling assumes a specific angle — always check the tag for the rated angle and derate if the actual rigging angle is shallower. What is sling angle and why does it matter? Sling angle is the angle between the sling leg and the horizontal. As the angle decreases (the sling legs spread further apart), the tension in each leg increases for the same total load. At 60° from horizontal, each leg of a two-leg bridle carries 15% more than it would at 90°. At 45°, it carries 41% more. At 30°, each leg carries the same tension as if it were supporting the entire load alone — two legs provide no additional capacity at this angle. Below 30°, the tension in each leg exceeds the load weight, and this configuration is prohibited in most Australian rigging standards. Always rig with sling angles above 30° and calculate the reduced WLL for any angle below 90°. What is the difference between a D shackle and a bow shackle? A D shackle (chain shackle) has a narrow, D-shaped bow designed for in-line loading only. It is strong in its intended direction but degrades rapidly under side loading. A bow shackle (anchor shackle) has a wider, rounded bow that can accept load from multiple directions and can accommodate multiple sling eyes. The bow shackle is the standard choice for crane lifting and multi-leg sling assemblies. D shackles are used for single-point in-line connections where the load direction is controlled. Never side-load a D shackle. What is the difference between a screw pin and safety bolt shackle? A screw pin shackle has a threaded pin that is wound in by hand — fast to connect and disconnect, suitable for frequent re-rigging. However, screw pins can rotate and unwind under vibration or load rotation. If used in vibrating or rotating applications, the pin must be moused (wired shut). A safety bolt (bolt-type) shackle has a smooth pin locked by a nut and cotter pin — it cannot unwind and is the required type for permanent installations, overhead lifts, and any application involving vibration or load rotation. What does "never saddle a dead horse" mean in rigging? It is a mnemonic for correct wire rope clip installation. The saddle (bridge) of the clip always bears on the live rope — the load-carrying section. The U-bolt always bears on the dead end (the short tail). Installing the saddle on the dead end crushes the load-bearing wires and dramatically reduces termination efficiency, creating a high risk of the tail pulling through under load. Every wire rope clip installation must follow this rule, plus the correct number of clips for the rope diameter (minimum three for most sizes) and the specified tightening torque. How many wire rope clips do I need? The minimum number of clips depends on rope diameter. As a general guide: 3 clips for wire rope up to 19 mm diameter; 4 clips for 20–25 mm; 5 clips for 26–32 mm. Always check the clip manufacturer's specification for the exact rope diameter in use — the manufacturer's data takes precedence. Clips must be spaced a minimum of 6 rope diameters apart and tightened to the specified torque. Retighten after the first load is applied, as the rope will compress and seat, reducing nut tension. What is the difference between 6×19 and 6×36 wire rope? Both designations describe 6-strand wire rope. 6×19 has 16–26 wires per strand — fewer, larger wires that make it stiffer and more abrasion-resistant but less flexible and less fatigue-resistant. It is the standard for lifting slings, pendants, and static applications. 6×36 has 27–49 wires per strand — more, finer wires that make it flexible and fatigue-resistant, suitable for running ropes on cranes, winches, and sheave systems where repeated bending is the primary demand. The finer wires in 6×36 are more susceptible to surface abrasion than 6×19. What is IWRC in wire rope? IWRC stands for Independent Wire Rope Core — a small wire rope that runs through the centre of the main rope, supporting the strands. IWRC provides superior crush resistance and maintains rope geometry under side loads and drum-winding pressure, adding approximately 7.5% to the rope's overall breaking strength compared to an equivalent fibre core rope. IWRC is the correct core type for crane hoist ropes, winch lines, and any application involving drum winding or significant side loading. Fibre core (FC) is more flexible and used in slings and light-duty applications where flexibility matters more than crush resistance. When should I discard wire rope? Discard wire rope immediately if you find: 6 or more broken wires in any one rope lay length (in running rope); 3 or more broken wires in a single strand within one lay; any kink (permanent bend deformation); birdcaging (strands sprung outward from the core); pitting corrosion below the wire surface; reduction in overall rope diameter exceeding 3% of nominal; or heat discolouration (blue or straw tint on the wires). In slings, any broken wires at the eye or termination zone are an immediate discard condition regardless of quantity. Can I shorten a synthetic sling by tying a knot? No. Tying a knot in a synthetic sling creates a severe stress concentration at the knot and reduces the sling's capacity by 50% or more — while the WLL tag still shows the unmodified rating. The correct way to shorten a sling is to use a shortening clutch, a connecting link, or a shackle to take up slack in the configuration. Synthetic slings with knots must be removed from service. What Australian standards apply to lifting slings and rigging? Key standards: AS3569 (steel wire ropes — product specification), AS1666 (wire rope slings), AS3637 (web slings), AS3776 (lifting components — shackles), AS2741 (shackles), AS4344 (chain slings), AS4991 (lifting components — general requirements), and AS1418.1 (cranes, hoists and winches — general requirements, which defines WLL and Rated Capacity). All rigging equipment used in Australian industrial workplaces must be inspected regularly by a competent person and tagged under the current colour code cycle. AIMS Industrial stocks wire rope slings, synthetic web slings, chain slings, and rigging hardware including shackles, thimbles, wire rope clips, and swaged ferrules. For help selecting the right sling type, configuration, and WLL for your application, contact our team. People Also Ask — Wire Rope Slings and Rigging Q: What is the minimum safety factor for wire rope slings in Australia? Under AS 2741, the minimum design factor (safety factor) for wire rope slings used in general lifting is 5:1, meaning the minimum break force of the rope must be at least five times the working load limit (WLL). Some applications — including crane main hoisting ropes and man-riding applications — require higher design factors. Always confirm the design factor with the sling manufacturer's data. Q: How often should wire rope slings be inspected? Wire rope slings must be inspected before each use by the operator and formally inspected by a competent person at intervals determined by frequency of use and operating conditions — at minimum annually. AS 2741 specifies discard criteria including broken wires, kinking, crushing, corrosion, and heat damage. Any sling showing these defects must be removed from service immediately and destroyed to prevent re-use. Q: What information must be on a wire rope sling tag? Under AS 2741, the sling tag must show the manufacturer's identification, sling construction (e.g. 6 × 19), diameter, working load limit for each configuration used (vertical, choker, basket), and the standard to which the sling is manufactured. A manufacture date or year stamp is not mandated by AS 2741, though many manufacturers include it. Missing or illegible tags are grounds for taking the sling out of service. Q: What reduces the working load limit of a wire rope sling? WLL is reduced when a sling is used in choker hitch (typically 75–80% of vertical WLL), basket hitch at angles (reduces with increasing sling angle from vertical), or when the sling passes around sharp edges or small-radius bends. Damage, corrosion, and kinking also permanently reduce capacity. Always apply the most conservative load reduction factor relevant to the lift configuration. Q: Can wire rope slings be repaired? No. Damaged wire rope slings must not be repaired and returned to service. Once a sling fails any inspection criterion under AS 2741 — broken wires, kinking, crushing, corrosion, heat damage, or damaged fittings — it must be removed from service and rendered unserviceable (typically by cutting) before disposal. Repairs to wire rope slings are not permitted under Australian rigging standards. For pulling and positioning gear, browse the AIMS manual winch range (hand winches, worm-gear, and cable winches). See AIMS's full metal & wire gauges range — trade pricing and Australia-wide despatch. Q: What is the most efficient way to terminate a wire rope sling eye? A poured socket (zinc or resin) retains 100% of the rope's minimum breaking load and is the highest-efficiency termination, though it requires professional fitting. Swaged (mechanical press) fittings retain 95-100% and are common on factory-made slings. A Flemish eye splice around a thimble — the standard for wire rope slings — retains 90-95%. Hand-tucked splices (80-90%) and wedge sockets (75-90%) are lower efficiency and less consistent. Wire rope clips (U-bolt grips) retain only 75-80% and are entirely dependent on correct field installation. Q: Why do wire rope slings need a thimble? A thimble is a grooved metal insert fitted inside the eye of a wire rope sling at the termination point. Without it, the wires at the eye contact point bend sharply over a hook or shackle pin, reducing the effective strength of the termination and accelerating fatigue. All rigging-grade wire rope slings should be thimbled. The d/d ratio (thimble pin/contact diameter to rope diameter) should be a minimum of 6:1 to preserve the full rated efficiency of the termination. Q: How much load can a basket hitch carry compared to a vertical hitch? When the sling legs hang vertically (90° to horizontal) in a basket hitch, each leg carries half the load — giving up to 200% of the vertical hitch WLL. This is the only hitch configuration that multiplies rated capacity. The multiplication factor reduces as the basket angle narrows, and the load must be balanced or it will slide to the low side and potentially roll off the sling. Q: What's the difference between IPS, EIPS and EEIPS wire rope? These are progressively stronger wire rope grades: IPS (Improved Plow Steel), EIPS (Extra Improved Plow Steel), and EEIPS (Extra Extra Improved Plow Steel). EIPS is the standard grade for general industrial and lifting use. Finish options — bright (uncoated), galvanised, or stainless steel — are selected independently of grade based on the corrosion environment.
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