The standard chain lever load binder that is used for truck cargo securement operates on an over-center principle that has been used for over a century on suitcases, tool boxes and camera cases. The safety hazards associated with the uses and misuses of the load binder were identified decades ago and various inventors patented innovations that eliminated or mitigated the safety shortcomings. Furthermore, their ideas were not only effective, they were economical, versatile, and efficient. These patents are now in the public domain and many companies manufacture and/or distribute entire lines of securement that include not only the standard chain lever load binder but most of the alternative designs as well. This case study takes the position that the standard chain lever load binder should be banished. Since the appropriate bodies, after all these years, have not arranged for its demise, this paper appeals to the product liability system for safety relief. Engineering analysis and tests are provided to the legal profession to help them protect us by making the cost advantage of the standard binder too expensive. This paper explores some of the remarkable properties of the standard load binder, e.g.,
• Load binders develop very large chain tensions and very high levels of recoverable energy. The standard chain lever load binder does not enable the tension and energy levels to be safely maintained or released.
• The handle slack on the standard load binder cannot be fine-tuned; consequently, a scenario is frequently encountered where the chain is either too loose or too tight to secure with the binder handle. This is the major motivation for resorting to a “cheater bar.”
• A complete analysis of the securement forces acting on the cargo and load binder is seldom possible because the system is a “moving target.” The handle loading is randomly applied by human exertion which changes with handle orientation. The boundary conditions depend not only on the cargo and securement strategy, but on the loading itself. Unknown friction characteristics of the loading affect the distribution of chain forces.
• On one side of the load binder the chain tension can always be predicted using only the handle torque. This cable tension is independent of the boundary conditions and any axial handle force components.
• When the load binder system is rigid, it gives rise to three singularities. The mechanical advantage is unbounded at the two extreme handle orientations. When the binder is suspended in a taut condition, any lateral force on the binder develops infinite cable forces.
• Handle slack has a profound effect on the handle resistance, the resilience, the chain tension, and the latching capability.