Material Handling Equipment for Ports and Heavy Cargo
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