Electric Hoist Selection Guide: Capacity, Duty Cycle and Mounting
Choosing the right electric hoist is a decision that affects not just the cost of the lift but the reliability, safety and productivity of your entire lifting operation. Unlike a manual chain block, an electric hoist is a powered device whose performance depends on a specific set of parameters matched to your application. See our Manual vs Electric Hoist comparison if you are still deciding between the two.
Rated Capacity
This is the maximum load the hoist is designed to lift, expressed in kilograms or tonnes. Electric hoists are manufactured in standard capacity increments, typically from 0.25 tonnes to 32 tonnes for standard models. Going above 32 tonnes requires purpose-built or split-drum hoists.
If your load is 5.2 tonnes, select a 6.3 t (or larger) hoist — not a 5 t hoist with “a bit of margin.” The rated capacity is an absolute limit, not a soft target. Operating near 100% of rated capacity shortens motor life, increases heat in the brakes, and may void the manufacturer’s warranty.
FEM / ISO Duty Cycle Classification
The duty cycle describes how intensively the hoist will be used. A workshop hoist that lifts once every few hours has an entirely different duty requirement from a hoist running on a production line lifting 30 times per hour. The two standards used to classify hoist duty cycles are FEM (European Federation of Material Handling) and ISO (the newer, harmonised international standard):
| FEM Class | ISO Class | Usage Level | Typical Application |
|---|---|---|---|
| M1 | 1A | Very light — infrequent lifting | Occasional maintenance lifts, rare use |
| M2 | 2A | Light — occasional lifting | Small workshops, infrequent production |
| M3 | 2B | Moderate — normal service | General workshops, warehouses |
| M4 | 2C / 3A | Moderate — frequent lifting | Active workshops, light production lines |
| M5 | 3B / 4A | Frequent — heavy service | Continuous production, foundries |
| M6 — M8 | 4B — 8C | Very heavy — continuous | Steel mills, continuous casting, shipyards |
Selecting a hoist with the wrong duty class is the single most common specification mistake. A hoist rated for M2 duty running at M4 intensity will overheat the motor, burn the brakes and fail prematurely. Always specify the duty cycle based on actual or projected usage, not best-case scenarios.
Mounting Type
How the hoist is mounted determines which models are suitable:
- Top-running (T-type): The hoist runs on the top flange of a crane rail (typically 100 mm or 125 mm rail). Used for free-standing runway beams or overhead crane girders where the hoist travels along the top of the rail.
- Underhung (U-type): The hoist hangs below the bottom flange of the crane rail. This is the most common mounting type and is compatible with standard I-beam runways. The underhung design keeps the hoist lower to the load, requiring less beam depth.
- Leg-mounted (D-type): The hoist suspends from legs that clamp onto a round beam, angle iron, or pipe. Used for fixed installations without a travelling rail, or where minimal runway depth is available.
Lifting Speed
Standard electric hoists typically offer two lifting speeds — a standard speed (often around 8 m/min) and a precision/low speed (around 0.8 m/min) for accurate positioning. Some applications (such as foundry ladle lifts or high-bay storage) may require faster lifting speeds, which means a higher-power motor and a derated capacity at the increased speed.
Power Supply
Most industrial electric hoists in India operate on 3-phase 415V AC, 50Hz. Single-phase 230V models are available for lighter capacities in workshops and small premises where 3-phase power is not available. Voltage and frequency must match the local supply — a 60Hz hoist will run at reduced speed on 50Hz mains and may overheat.
Hook Height and Chain Length
The rated hook height (maximum lifting height) is a factory-set parameter. Chain length can be extended, but every additional chain length adds weight that the motor must lift, and the chain must be properly spliced at the extension point. The rated height is typically expressed as the distance from the bottom of the hook to the underside of the runway beam or the hoist mounting point.
Selection Checklist
Capacity: What is the maximum load you need to lift? Select a rating at least equal to that, preferably the next standard size up.
Duty cycle: How many lifts per hour, how many hours per day? Match to the FEM/ISO class table above.
Mounting: What type of beam or rail is available? Top-running, underhung, or leg-mounted?
Hook height: What is the maximum lifting height required?
Power: Is 3-phase 415V available, or do you need single-phase 230V?
Travel: Does the hoist need to travel along a runway beam? If so, specify the rail type and travelled distance to select the correct end car.
Control: Pendant control (wired, within arm’s reach), cordless remote, or integration with a crane controller?
Brands We Carry
Sealinkers distributes electric hoists from leading manufacturers including Kito and Duro. Both brands offer comprehensive ranges from 0.25 t to 32 t, with duty classes from M1 through M5 standard and M6+ on special order. Kito hoists carry a reputation for compact design and reliability, while Duro models offer competitive pricing with full CE certification under the EU Machinery Directive.
For advice on selecting the right hoist for your specific application, contact our technical team with the load, lift height, duty cycle and mounting details — we will recommend the correct model and supply it complete with all statutory documentation and test certificates.
