Design of load-handling equipment
Load-handling equipment must withstand extreme stresses in daily lifting operations. We support manufacturers and operators with precise FEA simulations and standard-compliant calculations to proactively ensure the safety of persons and loads and minimize liability risks.
Simulation and design of load-handling equipment
Safe & standard-compliant according to the Machinery Directive
The reliability of lifting gear, spreader beams, and grippers is a decisive safety and quality feature for every operation. We support you in precisely predicting the mechanical strength of these critical structures.
Our calculations capture the stress distributions within the components as well as at connection points with high local resolution. This applies equally to the new design of specialized lifting tools as well as to the safety assessment and adaptation of existing geometries to new areas of application. Through the sound calculation of load-handling equipment, we create the basis for a safe and economical design concept.
Our range of services for load-handling equipment design
Simulation of load capacities and deformations
We create detailed analyses, strength proofs, and simulations for the load-bearing capacity of lifting gear and lifting tackle. In doing so, we support you with verifiable documentation for design, safe operation, and the preparation of certifications. Results from the structural analyses can be used directly for the targeted weight and geometry optimization of the systems.
Learn moreFEA Analysis / Structural Simulation
FEA analyses are a valuable tool for product development, making the behavior of components and assemblies visible under various loads.
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Static Strength Verification
A static strength verification checks whether a component can withstand the intended loads safely and permanently.
Learn moreWeld Calculation
Load-compliant design of weld seams for static and cyclic stress.
Why a sound design of load-handling equipment makes sense for you
Measurable benefit. Computational security.
You must guarantee personal safety in the lifting area through seamless load-bearing capacity and stability proofs.
You want to secure complex geometries and special constructions where classic analytical formulas reach their limits.
You require verifiable calculation documentation for commissioning and CE marking according to the Machinery Directive 2006/42/EC.
You need to project the exact intensity of use (service life, load cycles) to effectively prevent fatigue fractures in continuous operation.
You want to reduce material costs and dead weight through data-driven analyses without compromising the required safety factors.
Your advantages through our load-handling equipment design
Measurable benefit. Verifiable quality.
With careful simulations, precise stress calculations, and robust analyses, we create a reliable basis for the planning, design, and safe operation of your lifting equipment.
Standard-compliant proof for certification
Calculations and proofs according to relevant standards for load-handling equipment design such as DIN EN 13155, (parts of DIN EN 13001), or Eurocode 3. We provide you with the complete, verifiable technical documentation for your declaration of conformity.
Optimized system protection
We identify critical weak points, evaluate connections such as weld seams and bolts in a targeted manner, and perform stability proofs against buckling and denting – for maximum operational safety.
Planning certainty & time savings
Validated data minimize the liability risk of in-house designs and accelerate the approval process. You benefit from smooth audits and avoid expensive rework after production.
Our expertise for your project
We look forward to your inquiry!
We accompany you through all steps of the design of load-handling equipment – from the initial concept phase and FEA simulation to the creation of verifiable documents for your documentation.
Do you have questions, need an assessment, or want to start right away?
We look forward to your message – by phone, email, or in person.
Your contact: Jonas Compart
elbcore engineers GmbH
Lerchenstraße 28a
22767 Hamburg
Strong across all industries
Our services are applied industry-wide
Our engineering services are used in a wide variety of industries – wherever safety, efficiency, and technical precision are required.
Plant & vessel construction
Electrical engineering
Mechanical engineering
Metal / steel construction
Shipbuilding
Special machine construction
Valve & pump technology
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Frequently asked questions about the design of load-handling equipment (FAQ)
Quick answers. Clear solutions.
Here you will find answers to the most common questions regarding the calculation and strength proof of load-handling equipment.
For which types of load-handling equipment do you perform design and calculation?
Our range of services includes a variety of lifting gear, lifting tackle, and handling systems. We calculate and optimize both standardized equipment and highly specific special designs. These include, among others:
- Spreader beams: Lifting, load, beam, and crane spreaders
- Gripping and clamping tools: Grippers, tongs, clamps, and spreaders
- Positive-locking components: C-hooks, crane forks, loading forks, and telescopic forks
- Fixtures & structures: Turning and rotating devices, assembly fixtures, special tools, as well as heavy machine frames and supports
No matter how complex your individual geometry or kinematics – we provide the appropriate, standard-compliant strength proof.
Why is an FEA calculation often necessary for load-handling equipment?
Many load-handling devices are individual special designs tailored exactly to customer-specific lifting tasks. Analytical manual calculations quickly reach their limits with complex geometries or integrated kinematics. FEA simulation makes it possible to precisely map any assembly digitally and identify weak points exactly.
Which standards must be considered for the design of load-handling equipment?
The selection of regulations depends heavily on the intended use and the load cycles. For loose load-handling equipment under 16,000 load cycles, DIN EN 13155 applies. For a higher intensity of use, DIN EN 13001 takes effect. In addition, we use Eurocode 3 for steel structures, as well as the FKM guideline for mechanical components.
Do self-built load-handling devices for internal use also need to be certified?
Yes. Load-handling equipment falls fully within the scope of the Machinery Directive 2006/42/EC. This means that even for purely internal in-house use, a strength proof must be provided, a declaration of conformity issued, and a CE marking applied to guarantee legal safety.
In which project phase should the design and FEA simulation ideally take place?
Ideally, you should integrate the calculation as early as the design phase. This allows necessary optimizations to the geometry or weld seams to be implemented cost-effectively on the digital model before material is purchased, manufactured, or a prototype is built.
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