India’s ports are handling more cargo than ever. India’s major ports handled a record 854.93 million tonnes of cargo in FY 2024-25, registering a growth of 4.35% over the previous fiscal, the Ministry of Ports, Shipping and Waterways has said. [^1] Container throughput alone increased by 10% in the same period.
But those figures mask a demanding physical reality. Every tonne of that cargo has to be hoisted, shifted, lashed and lowered with the right equipment. Wrong gear is not only expensive, but it is also dangerous.
This guide will explain the major types of material handling equipment used in ports and heavy cargo operations and what each type does and help you match the right equipment to the job.
1. Wire Rope: The Foundation of Heavy Lifting at Ports
Wire rope is the most commonly used component in port lifting and rigging. It is the working link between the crane hook and the load, and its design directly affects the safe capacity of the load.
The construction is as follows:
- Individual wires are twisted together to make strands
- The wire rope is made by twisting strands around a central core
- Strength, flexibility, and fatigue life are dictated by the number of strands, wire count, and core type
In port environments where ropes are exposed to salt spray, abrasion, shock loads and repeated bending, construction quality is everything.
M.A.Zavery & Co. carries Bridon Bekaert, a manufacturer of wire ropes for use in marine, offshore and heavy industry applications. They manufacture Bridon Tiger Blue® 8, Bridon® Zebra ropes and spiral strand products for demanding structural and crane applications.
Wire rope choices for ports should include:
- Breaking force versus working load limit (WLL)
- Lay type (regular lay or Lang’s lay) for flexibility or abrasion resistance
- Surface finish for corrosion protection (galvanised or ungalvanised)
- EN 12385-4 compliance for wire ropes in general lifting applications.
2. Chain Slings for Heavy Cargo Lifting
Chain slings are the choice when loads are heavy, temperatures are high, or surfaces are sharp. Chain: Synthetic chains are quick and light but do not match the strength and durability of alloy steel chains in adverse conditions.
Let’s break it down by grade:
| Grade | Minimum Breaking Load (approx.) | Typical Use |
| Grade 80 | 3x Working Load Limit | General heavy lifting |
| Grade 100 | 25% higher than Grade 80 | Where weight savings matter |
| Grade 120 | Higher still | Specialist overhead lifting |
Steel coils, machinery, structural components and bulk containers are all routine applications for ports where G80 or G100 alloy chain slings are the standard choice.
Thiele, supplied by M.A.Zavery & Co., is a manufacturer of a large range of chain slings and accessories under the TWN product line. Their range includes multi-leg chain slings (TWN 0795, TWN 0797, TWN 0803, TWN 0804), shorteners, connecting links and master link assemblies – all components that port riggers use daily.
The M.A.Zavery range of yoke chain slings is offered in the X-A06 G100 4-Leg configuration and uses the X-001 Welded Master Link to ensure full traceability and compliance with lifting standards.
3. Electric Wire Rope Hoists for Repetitive Port Lifts
Manual hoisting is not practical for the volumes and the loads that port terminals handle. Electric wire rope hoists take over where manual equipment leaves off.
These hoists are suitable for:
- High-cycle lifting operations in cargo handling bays
- Heavy machinery and equipment on board vessels
- Lifting containers and structural elements in fabrication yards
STAHL manufactures the SH Wire Rope Hoist range, available from M.A.Zavery & Co., for industrial and port-adjacent applications. The STAHL SH Ex Wire Rope Hoist is approved for use in potentially explosive atmospheres, such as those found at fuel terminals and chemical ports. Their STD Dual Chain Hoist is designed for use in applications requiring two-point lifting to help keep loads level.
The H-100 Series electric hoist and 1-phase and 3-phase variants in the M.A. Zavery & Co. catalogue cater for light-duty electric lifting requirements under the Elephant brand.
4. Pneumatic Air Hoists for Hazardous Port Environments
Some port zones are vulnerable to explosions – including liquid bulk terminals, petrochemical jetties and LPG handling areas. In these places, electric hoists may not be allowed. Pneumatic (air-powered) hoists bridge this gap.
Air hoists work completely on compressed air, which means:
- No risk of igniting
- They keep working in wet conditions
- They are lighter than their electric counterparts
- They can be safely stalled without damage to the motor
M.A.Zavery & Co. stocks Tiger Lifting’s TAH52 Pneumatic Air Hoist, from 5t to 20t capacity, and the TAH250 Pneumatic Air Hoist for heavier requirements up to 60t. Their Low Headroom Air Trolley and Air Monorail Trolley Hoist let you travel over overhead rail systems in tight cargo holds and dockside structures where headroom is limited.
5. Manual Chain Hoists and Lever Hoists for Precision Positioning
Not every lift in a port or heavy cargo environment is a high-cycle, high-capacity operation. Many tasks require the precise controlled movement of loads — tensioning rigging, final placement of machinery, or holding loads while welding and installing.
Manual chain hoists and lever hoists do these jobs.
Here’s when to use each one:
- Manual chain hoists: Used for vertical lifts requiring the operator to achieve gradual and controlled ascent and descent. Suitable for the direct lifting of loads.
- Lever hoists: Pull and tension in all directions. They work horizontally and at angles and are perfect for rigging work on sloped or irregular cargo.
- M.A.Zavery & Co.’s Elephant brand range includes both types: the C21 Series Manual Hoist, the Super 100 Manual Hoist and the YA Series Lever Hoist. Yale products in the range include the Yalelift 360 ATEX Hand Chain Hoist, which is rated for potentially explosive atmospheres.
6. Winches for Mooring, Tensioning, and Load Control
The one major difference between winches and hoists is that winches are designed to pull and tension over long lengths, not lift vertically.
Winches are used for:
- Port Operations.
- Mooring lines on vessels
- Launching and recovery of buoys or gangways
- Horizontal towing within a vessel’s or berth’s deck
- Maintaining tension in the tasks of structural positioning
M.A.Zavery & Co. provides a full line of manual, stainless steel, electric, and custom special winches for marine and industrial applications from Maxpull. Standard carbon steel will rust quickly in salty port air, and stainless steel versions are a better choice.
7. Shackles, Hooks, and Master Links: The Rigging Hardware
You can’t have a rigging system without the right connectors. Shackles, hooks, and master links are components that connect wire ropes, chain slings, and hoists to form a complete lifting assembly.
Get these correct:
- Bow shackles (omega shackles) suitable for multi-axial loading. Application where slings pull in multiple directions.
- D-shackles (dee shackles): Stronger than bow shackles for straight in-line loads. Use where the pull is straight.
- Self-locking hooks: Prevent accidental release during transit when loads shift position.
- The master links and master link assemblies are the highest point of connection for multi-leg chain slings.
- M.A.Zavery & Co. stocks Thiele TWN shackles (TWN 0861, TWN 0862, TWN 0870, TWN 0871, TWN 0897) and yoke master links that are in accordance with the relevant lifting standards and CE certified.
Wire rope slings for general lifting service EN 13414-1. These standards ensure that all connecting parts in a port lifting assembly are working correctly at their rated capacities.
8. Lifting Clamps for Steel Plate, Pipes, and Structural Members
Ports regularly receive and dispatch structural steel plates, pipes, girders, and beam sections. These loads cannot be safely gripped by normal slings. The lifting clamps grab the material itself. The surfaces are designed for the particular cross section being lifted.
Types used in port and heavy-cargo settings
- Plate Lifting Clamps: Gripping flat steel plate for vertical and horizontal lifts
- Pipe lifting clamps: Envelop pipe profile without crushing or deforming
- Girder/beam stacking clamps: Clamp I-beams and H-sections for stacking and positioning
- Camlok range in stock at M.A.Zavery & Co.: TTR Girder Stacking Clamp, THS Lifting Clamp, TRU Round Stock Grabs and CR Rail Clamps for rail lifting applications.
Thiele’s TWN 0868 pipe lifting clamp and TWN 0872 plate lifting clamp are also included in the M.A.Zavery & Co. product catalogue for operations that require certified forged component performance.
9. Lifting Points and Weld-On Anchors
Lifting points are the link between the load and the rigging. They are installed on top of machinery, containers, or structural members to give a rated anchor point for hooks or slings.
Where port facilities are involved, rotating lifting points are preferred over fixed ones. This is because loads are rarely lifted at perfect vertical angles. Swivel-type lifting points rotate to match the sling angle, ensuring the correct force path and reducing side loading, which can damage fixed eye bolts.
M.A. Zavery & Co. Thiele TWN are available in several types:
- TWN 1896: Swivel lifting point for 360° rotation under load
- TWN 1884: Heavy lifts with a high-capacity swivel ring
- TWN 1827 & TWN 1880: Weld-on lifting points for permanent attachment to structures
- TWN 0122 and TWN 0121: Rotating ring lifting points for multi-directional lifts
10. Selecting the Right Equipment: A Decision Framework
Use the right equipment for the job to avoid accidents and unnecessary cost. Before any port or heavy cargo lift, use this framework:
- Figure out the weight of the load.
Add up the weight of all the rigging hardware itself.
Step 2: Find out the angle of the sling. Slings less than 60 degrees from horizontal cause a drastic increase in the tension on each leg. For a 45° sling angle, the effective tension is about 41% above the load weight.
Step 3. Set the environmental conditions. Corrosive salt air favours galvanised or stainless parts. In explosive atmospheres, the use of ATEX-rated hoists or air-powered hoists is mandatory.
Step 4. Determine the load surface. Protect sharp edges or use a chain alternative. Synthetic options and plate clamps will work on smooth surfaces.
Step 5: Verify certification and conformity to standards. All equipment must be CE marked and carry third-party test certificates and comply with the applicable EN, ISO or IS standards.
Since 1983, M.A.Zavery & Co. has been in business and stocks CE-certified and ISO-compliant equipment in all of these categories, from Bridon Bekaert wire ropes and Thiele rigging hardware to Tiger air hoists and STAHL electric wire rope hoists, giving port operators a single source for complete rigging and lifting assemblies.
Comparison Table: Hoist Types for Port Operations
| Hoist Type | Drive | Typical Capacity | Best Use Case | Environmental Rating |
| Manual Chain Hoist | Hand chain | Up to 10t | Occasional lifts, positioning | Standard |
| Lever Hoist | Lever | Up to 9t | Tensioning, multi-directional | Standard |
| Electric Wire Rope Hoist | Electric motor | 0.5t–80t+ | High-cycle cargo handling | Standard/Ex |
| Pneumatic Air Hoist | Compressed air | 0.5t–60t | Hazardous/wet environments | ATEX zones |
| Electric Chain Hoist | Electric motor | 0.1t–20t | Light-medium duty overhead | Standard/ATEX |
Frequently Asked Questions
What is the most commonly used material handling equipment for ports and heavy cargo?
The most widely used items in port lifting operations are wire rope slings, chain slings, electric wire rope hoists, and shackles. Each has a specific function: wire ropes carry tension loads, chain slings grip heavy and hot loads, electric hoists provide powered lift, and shackles connect all parts into a working assembly.
How do I choose between a chain sling and a wire rope sling for port lifting?
For heavy loads, sharp surfaces, or high working temperatures, choose chain slings; chain is more resistant to abrasion and heat than wire rope. Wire rope slings are used when flexibility and lighter weight are important, or when lifting uneven or bulky loads that require the rope to conform to the surface.
What does Working Load Limit (WLL) mean on lifting equipment?
Working Load Limit (WLL): The maximum load any piece of lifting equipment is designed to lift under normal conditions. It is always below the minimum breaking load with a safety factor built in. Port riggers must ensure that the total weight of the load and rigging hardware does not exceed the WLL of any single piece of equipment used in the lift.
Are pneumatic air hoists suitable for all port operations?
Pneumatic hoists are ideal for environments where electrical equipment is not permitted, such as fuel terminals, chemical jetties and LPG handling zones. They are not suitable where compressed air supply is not available or very high lift cycles are required without a dedicated air compressor system nearby.
How often should port rigging equipment be inspected?
It needs regular inspections. As per Indian regulations under the Factories Act and IS standards and international guidance, examinations should be conducted thoroughly at least once in every 12 months by a competent person, with more frequent examinations depending upon the intensity of usage. Lifting equipment should also be visually checked before each use for wear, deformation, corrosion, or damaged markings.