The lifting industry was largely built on steel products, with composites only familiar to those working in the aerospace, defence and sporting goods industries. However, that has long since changed, and composite products are now commonly used in combination with cranes and hoists, especially below-the-hook.
We were even involved in delivery of a composite lifting system to support a US Navy drone development project. While the obvious advantages included lightweight in addition to non-conductive and non-corrosive material properties, a traditional steel alternative would have interfered with communication testing.
Composite below-the-hook equipment is well-suited to industries where corrosion resistance, electrical insulation, and low weight deliver clear operational advantages. This includes marine and offshore environments, where non-corrosive materials extend service life; utilities and power generation, where non-conductive designs enhance safety around energised equipment; and chemical or petrochemical facilities, where composites withstand aggressive substances that would quickly degrade steel. Their lightweight nature also benefits manufacturing, construction, aerospace, and defence applications by improving handling efficiency and reducing strain on lifting machinery. Composites also perform reliably in cold storage, renewable energy, and other specialised sectors where temperature extremes, confined spaces, or sensitive loads demand safer, more ergonomic alternatives to traditional steel lifting devices.
Caldwell’s Dura-Lite range includes both lifting beams and spreader beams. Standard models up to 3t capacity are available as well as custom versions. As we know, the two primary considerations when deciding whether a lifting beam or spreader beam is required are lifter weight and headroom. Lifting beams are typically designed for a bending moment versus the spreader beam that incorporates top rigging and is designed for a compressive load.
The fibre-reinforced polymer Dura-Lite composite devices, meeting American Society of Mechanical Engineers (ASME) and other major standards, are assembled with highquality, proven adhesive and are proof tested at the factory to 200% of their rated capacity.
The lugs are manufactured from an innovative strip material. Lug attachment holes include steel bushings to reduce wear. A high-quality, acrylic polyurethane finish provides excellent UV protection and a long-lasting finish.
The composite choice
So, when does it make sense to use a composite lifting beam or spreader beam? Users most often point to the high strength-to-weight ratio, combined with the non-corrosive and non-conductive nature of composites; they are benefits that can improve performance, safety, and longevity in demanding lifting applications.
The benefits of a lighter product are clear. Lighter beams are easier for riggers to manoeuvre, position, and attach, reducing fatigue and the risk of manual handling injuries. Meanwhile, every pound of weight on a below-the-hook device adds to the load the crane or hoist must lift. Lower weight can speed up lifts and rotations, especially in high-cycle environments.’
The lighter weight of composite below-the-hook products also delivers clear advantages in freight and shipping. Reduced mass lowers transport costs, allows more units per shipment, and makes loading and unloading safer and easier. In addition, lighter shipments require less fuel, supporting more efficient and environmentally responsible logistics.
Composite products resist rust, oxidation, and chemical attack, making them ideal for harsh or outdoor environments such as ports, chemical plants, or marine operations. They maintain their strength and structural integrity over time, reducing maintenance requirements, inspection frequency, and the risk of unexpected failure due to corrosion. This durability not only extends the service life of the equipment but ensures safer, more reliable lifting operations.
Being non-conductive, composite beams provide an additional layer of safety when lifting near live electrical equipment or in electrified industrial settings. They reduce the risk of electrical shock or arcing that could occur with metallic beams, making them suitable for applications where both personnel safety and sensitive equipment protection are critical. This property also allows composite beams to be used in environments where grounding or insulation requirements are strict, without compromising performance.
It is important to note that composites should be used when the ambient temperature does not exceed a maximum of 66°C (150°F) or go below -40°C (-40°F).
