EXPERT COLUMN | THE CALDWELL GROUP
Battery lifting beams are primarily used for the safe removal and installation of forklift batteries.
lifting beams
Fork trucks have batteries much like cars, but they are set lower, weigh more and are harder to remove – that’s where battery lifting beams come in, explains Jeff Ferchen, director of business development at The Caldwell Group.
B
attery beams can be both lifting beams and spreader beams. Lifting beams are designed for a bending
moment versus a spreader beam that incorporates top rigging and is designed for a compressive load. Battery lifting beams are primarily used for the safe removal and installation of forklift batteries, even if they can be used to handle other loads. Many varieties are available, but typical requirements are low headroom, acid-resistance, non-conductive material and adjustability to handle batteries that vary in length, width and hook-up points. Batteries range in size, depending upon the dimensions and lift capacity of the fork truck. Typical industrial batteries used in the manufacturing space can measure 38in-long by 38in-wide by 23in-tall. They have small radius holes on the top of the unit to help grab the battery and lift it out. Beams serve a specialised role in forklift ownership, enabling safe removal and installation of heavy industrial batteries used in many manufacturing environments. They are compact in nature; ensure balanced lifting; minimise strain on operators; and reduce the likelihood of battery or truck damage. Our 7,000lb capacity Model 36L low
headroom battery lifting beam, for example, boasts many of the features of other similar
12 | November 2025 |
www.hoistmagazine.com
models, but in even lower headroom (18.28in) design. It weighs 110lbs and offers standard spread of 45in; it can be adjusted to handle batteries of different lengths. Although in many ways they are like car
batteries, these distinctive batteries are buried much deeper, weigh more and are generally more difficult to remove because they are often encased under the seat of the driver or in other hard-to-reach places, depending on the manufacturer.
Capacity and headroom There are many ways to remove batteries by conventional sling methods, but beams are the most efficient because they lift straight up and out of the box. The biggest considerations when selecting
a battery lifting beam are capacity and headroom. Headroom is a major issue, due to the top-mounted battery cages that are ubiquitous in these applications. Next is the location of the battery manufacturer’s hook-up points, which likely will not suit traditional sling hooks or slings that may be readily available, used for other applications or every day fabrication work. We have made several custom sizes, in terms of both length and capacity, but most people can use the standard versions, at least in the industrial market.
If standard sling hooks won’t work, we supply fabricated bent bar ‘J’ hooks and specific ‘J’ hooks with a smaller throat and specific angle to ‘seat’ the hook into the holes. Sometimes, larger hooks have to be inverted, while tip loading of traditional hooks should always be guarded against, because sling hooks are not designed to be loaded near the tip of the hook. Beams vary from hickory or other woods to
steel, depending upon the customer budget. Wood is non-conductive but over time it can develop hairline cracks, which can cause safety issues. Fibreglass battery lifting beams are heavy-duty, yet lightweight – they weigh 70% less than other beams. In the US, the standard that drives the manufacturing and safety of fork trucks is the ANSI / ITSDF B56.1 safety standard for low lift and high lift trucks. It applies to trucks that are powered (electric, internal combustion and so on) and are used for lifting, lowering and transporting loads. It is always worth checking local guidance and standards for best practices. Key considerations you might find referenced include confirming beam capacity, inspecting for wear and ensuring proper attachment to the lift truck. Common issues arise from worn components, inadequate operator training or ignoring load balance requirements.
Battery
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