What tensile overload is
Tensile overload is a single event failure. The applied load exceeds the ultimate tensile strength of the chain, plates yield and fracture, or pins pull out. Unlike fatigue, the break is not progressive and the fracture faces show significant deformation.
Common causes
- A jam, blockage or foreign object stalling the driven machine
- Starting a loaded conveyor direct on line with no soft start
- Two chains on one drive fighting unequal, one carrying all the load
- A chain undersized for the actual duty or for a service factor never applied
Warning signs
- A clean break with necking, distortion or oval pin holes
- Both plates of the same link failed together
- Repeat failures at the same position, often at the drive sprocket
- Damage to sprocket teeth or the machine frame at the same time
Prevention and correction
- Fit shear pin, torque limiter or slip clutch protection to the drive
- Apply the correct service factor at the design stage
- Use soft start or variable speed starting on heavy conveyors
- Balance load across multiple chain strands and check tension equally
Fix it with the right product
Talk to us about drive sizingNeed a second opinion?
Send us the chain, the running hours and a photo. Our engineers will confirm the failure mode and quote the right replacement.
All chain failure modes
Chain ElongationFatigue FailureSide Plate CrackingPin and Bush WearRoller Wear and SpallingAbrasive WearAdhesive WearCorrosionStress Corrosion CrackingHydrogen EmbrittlementGallingSurface PittingTensile OverloadShock LoadingImpact FractureLubrication StarvationTight Links and KinkingMisalignmentChordal ActionSprocket Tooth Wear
Same & Next-Day Delivery Areas
Roller chain supply across South Yorkshire & the North
Dispatched from our Rotherham depot — order by 1pm for next-working-day delivery, or collect same-day within our 30-mile radius.
RotherhamDepot location
Sheffield9 mi · ~25 min
Barnsley6 mi · ~15 min
Doncaster16 mi · ~30 min
Mexborough3 mi · ~8 min
Maltby5 mi · ~12 min
Wath-upon-Dearne4 mi · ~10 min
Wakefield20 mi · ~35 min
Leeds25 mi · ~45 min
Huddersfield30 mi · ~50 min
Scunthorpe22 mi · ~35 min
Mansfield28 mi · ~45 min
Chesterfield18 mi · ~30 min
Worksop14 mi · ~25 min