- Crane-Tec
Top Overhead Crane Questions (and answers)
Updated: Sep 12
With over 35 years of experience designing and installing overhead cranes in just about every industry you can imagine, we've come across lots of questions. Below are the top 12 along with our answers.
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What questions do you have about cranes? Submit your questions to Wally and he'll provide an answer! wbolduc@crane-tec.com
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Here are some common questions that people ask about overhead cranes:
#1 What is an overhead crane?
An overhead crane, also known as a bridge crane, is a type of material handling equipment used to lift and move heavy objects or materials from one location to another within a facility. The crane is typically made up of a runway beam, bridge, hoist, and trolley. The runway beam is mounted on columns or suspended from the ceiling, and the bridge travels back and forth along the beam. The hoist and trolley are attached to the bridge and move along the bridge to lift and lower objects or materials. Overhead cranes are highly versatile and can be customized to suit the specific needs of various applications. They can be operated either manually or by a control pendant or wireless remote control. Overhead cranes are widely used in manufacturing facilities, warehouses, and other industrial settings for tasks such as: 1. Moving and lifting raw materials and finished products 2. Loading and unloading heavy machinery 3. Transporting equipment and parts within a facility 4. Performing maintenance tasks on equipment and machinery
#2 How do overhead cranes work?
Overhead cranes play a critical role in industrial processes by enabling the safe, efficient, and smooth movement of heavy materials, reducing the need for manual handling and increasing productivity. Overhead cranes operate through the use of a runway beam, bridge, hoist, and trolley system that work together to lift and transport heavy objects and materials. Here is an overview of how overhead cranes work: 1. The runway beam is mounted on columns or suspended from the ceiling, and the bridge travels back and forth along the beam. The bridge can be driven by electric motors or manually. 2. The hoist, which is used to lift and lower loads, is attached to the trolley, and the trolley travels along the bridge. The hoist can be manually operated or electric-powered. 3. The operator controls the movement of the crane using various controls, such as a control pendant or wireless remote. 4. The operator positions the crane over the load, and the hoist is lowered and attached to the load using hooks, slings, or other lifting attachments. 5. The hoist lifts the load off the ground and moves it horizontally along the runway beam. 6. The trolley moves the load along the bridge to its destination. 7. Once the load reaches its destination, the hoist lowers it to the ground and releases it from the lifting attachments. Overhead cranes are highly versatile and can be customized to suit the specific needs of various applications. They play a critical role in industrial processes by enabling the safe, efficient, and smooth movement of heavy materials, reducing the need for manual handling and increasing productivity.
#3 What are the different types of overhead cranes?
There are several types of overhead cranes that are designed for different applications and industries. Here are some of the most common types of overhead cranes: 1. Single girder overhead crane: This type of crane has a single beam running across the top of two end trucks, which allows for movement along a single axis. Single girder overhead cranes are efficient and cost-effective and can lift loads up to 20 tons. 2. Double girder overhead crane: This type of crane has two beams running across the top of two end trucks, which allows for additional stability and the ability to lift and transport heavier loads. Double girder overhead cranes are ideal for heavy-duty applications, such as steel mills and foundries, and can lift loads up to 500 tons. 3. Gantry crane: This type of crane has a bridge that is supported by legs on both sides, which allows it to move along the ground rather than being fixed to the building structure. Gantry cranes are useful in outdoor settings and are commonly used in shipyards, construction sites, and container terminals. 4. Jib crane: This type of crane has a horizontal arm (jib) that is attached to a vertical support structure (mast) and can rotate 360 degrees. Jib cranes are ideal for lifting and transporting loads in a specific area and are commonly used for loading and unloading cargo in warehouses and manufacturing facilities. 5. Monorail crane: This type of crane has a hoist and trolley system that moves along a single beam. Monorail cranes are ideal for moving loads along a specific path and are commonly used in assembly lines and painting booths. 6. Underhung crane: This type of crane is similar to a single girder overhead crane, but the beam runs on the underside of a runway beam instead of on top of it. Underhung cranes are ideal for low headroom applications and allow for more usable space in a facility.
#4 What is the weight capacity of an overhead crane?
The weight capacity of an overhead crane can vary widely, depending on the type and configuration of the crane, as well as the specific application and industry in which it is used. The weight capacity of an overhead crane can range from a few hundred pounds to several hundred tons. A standard single girder overhead crane can handle weight capacities between 1 ton and 20 tons, while a standard double girder overhead crane can handle weight capacities ranging from 10 tons to 500 tons or more. Gantry cranes, which are commonly used in outdoor settings and heavy industries such as shipyards and construction sites, can handle even heavier loads, typically between 20 tons and 600 tons or more. The weight capacity of an overhead crane is typically determined by factors such as the strength of its structural components, such as the beams, trolleys, and motors, as well as the overall design of the crane. It is important to determine the appropriate weight capacity for your specific application to ensure safety and efficiency in your operations.
#5 What are the safety features of overhead cranes?
Overhead cranes typically come equipped with a range of safety features to protect workers, equipment, and materials. Here are some of the most common safety features of an overhead crane: 1. Overload protection: This feature is designed to prevent the crane from lifting loads that are too heavy for its weight capacity. The crane is equipped with a load sensing device that monitors the weight of the load and automatically stops the crane from lifting if the load exceeds its capacity. 2. Emergency stop button: A prominent red button is installed at strategic locations on the crane and in the control room to immediately stop the crane in case of an emergency. 3. Limit switches: These prevent the crane from moving beyond set limits in any direction and ensures that the crane does not hit the end truck or other obstacles while traveling along its path. 4. Anti-collision systems: This system monitors the movement of multiple overhead cranes in the same area and activates when the cranes get too close to each other. This prevents collisions and keeps the workers and equipment safe. 5. Fail-safe brakes: These brakes are designed to automatically engage when the crane's power supply is disrupted, and prevent the crane from moving or collapsing. 6. Warning devices: Audible and visible warnings, for example, flashing lights and alarms before the crane starts moving or when it is in motion, can alert nearby workers of crane movement. 7. Crane operator training: All operators should receive specialized training in operating the crane equipment safely.
#6 When do overhead cranes need to undergo inspections and maintenance?
Inspections - Overhead cranes in the workplace need to undergo periodic inspections as required by regulatory bodies such as OSHA, which has set guidelines for crane safety and inspections. Generally, there are three types of inspections that an overhead crane must undergo: 1. Pre-Operational Inspections: These inspections are conducted daily before the start of each shift or before the crane is operated. The crane operator or other trained personnel will conduct a visual inspection of the crane, including its hoist, trolley, and all the safety features like limit switches, load limiters, brakes, and hooks. If any defects are identified, the crane must be tagged out and repaired before being operated again. 2. Frequent Inspections: Frequent inspections cover components that are likely to wear out or malfunction, and these inspections are required to be done on a weekly, monthly or quarterly basis. Consideration is given to the manufacturer’s recommendations on the frequency of inspection. Examples of components include wire ropes, a limit switch, brakes, chains, hooks, and hydraulic systems. 3. Periodic Inspections: Periodic inspections are comprehensive examinations of the whole crane, including its mechanical, structural, and electrical systems. These detailed inspections are conducted every six months to one year, and are carried out by a qualified, licensed inspector. The inspector will review the crane's history, conduct visual, and load testing, and issue a report detailing any repairs or maintenance needed to make the crane safe for use.
It's important to keep maintenance and inspection records on file and to conduct inspections regularly to ensure that the crane is operating safely and properly. Ignoring safety standards and neglecting mandatory inspections could lead to equipment damage, injury, or even fatal accidents. In addition to the three inspections mentioned above, consider the following: 4. Seasonal maintenance: Certain types of industrial cranes, such as outdoor cranes, may require specialized maintenance appropriate to the season. For example, winter maintenance could include winterizing the crane to shield it from snow and ice, while summer maintenance could include checking the cooling system and lubricating moving components that are susceptible to heat damage. 5. Manufacturer's recommendations: It is essential to follow the manufacturer's recommended maintenance schedule and guidelines, such as minimum servicing intervals and requirements for specific components. The manufacturer’s guide will help the maintenance team to identify what parts need preventative maintenance or repair, and when to replace them. Maintenance - Maintenance schedules will depend on the specific requirements of the crane and intensity of use. However, by implementing a comprehensive and preventative maintenance plan, machinery downtime is reduced, the lifespan of the equipment is extended, and most importantly, employee safety is ensured. Overhead cranes need regular maintenance to ensure their proper functioning and to maintain safe working conditions for operators and other personnel in the workplace. Maintenance intervals are necessary to prolong the life of the crane, mitigate wear and tear, and address any identified problems before they cause critical equipment fault or failure. Here are some general guidelines for overhead crane maintenance: 1. Daily maintenance: Operators should conduct a daily visual inspection of the crane, checking for any damage, wear, or signs of malfunction. They should also check all systems, such as the hoist and trolley, brakes, and limit switches, for proper function. 2. Regular maintenance: Regular, scheduled maintenance might include the replacement of wire ropes, lubrication of moving parts, and replacement of worn-out components likes hooks and chains. Maintenance can be scheduled based on the manufacturer's recommendations, or at intervals determined by the crane's usage level, frequency of operation, and specific workplace environmental conditions. 3. Preventative maintenance: Preventative maintenance involves regular inspections, cleaning of equipment, replacement of parts, and other measures to prevent equipment failures or malfunction. It might include replacing old parts before they fail, monitoring the crane's performance for changes in speed or other issues, and checking the lubrication level and quality of various components. 4. Emergency maintenance: Occasional breakdowns may require immediate attention from a certified technician to repair or replace faulty parts promptly, ensuring that work can proceed as planned without further delay. In summary, overhead cranes should undergo regular maintenance to ensure their continued safe functioning. The maintenance schedule, intervals, and type of upkeep depend upon factors such as usage level, operating conditions, and manufacturer specifications. Regular maintenance, combined with prompt emergency repair when necessary, can improve crane performance, prevent unexpected downtime, and decrease the likelihood of accidents or equipment failure.
#7 What are the advantages of using an overhead crane?
Overhead cranes are essential tools in many industrial applications. Here are some advantages of using an overhead crane: 1. High lifting capacity: Overhead cranes have an excellent lifting capacity compared to other lifting equipment, such as forklifts. They can lift and move heavy loads in various directions over long distances, which makes them ideal for industrial and construction applications. 2. Improved safety: Overhead cranes are designed to improve safety by providing hoisting solutions for heavy loads that can be unsafe for manual handling. By using an overhead crane, operators can transport the load quickly and safely, reducing the risk of injury or accidents. Overhead cranes can also help protect workers from back injuries and repetitive strain injuries. 3. Increased efficiency: Overhead cranes can improve the efficiency of manufacturing or construction processes by reducing material handling time, improving production output, and minimizing the number of manual labor hours needed to move heavy loads. 4. Reduced footprint: Overhead cranes can also help optimize space usage in a manufacturing facility as they take up very little floor space and have a high lifting capacity. This makes it easy to move materials from one location to the other in a crowded space without disrupting other floor activities. 5. Wide range of applications: Overhead cranes can be used in various industries, such as manufacturing, construction, mining, and transportation, among others. They can handle different types of loads, including large and bulky items like concrete slabs, steel beams, and heavy machinery, among others. 6. Improved precision: Overhead cranes provide precision and accuracy in lifting and movement of goods and materials, making them ideal when working with heavy loads that require specific and safe positioning in production or storage. In summary, overhead cranes provide high capacity lifting solutions, improved safety, increased efficiency, and a wide range of applications, making them a valuable asset to various industries.
#8 How do you chose the right overhead crane for your application?
Choosing the right overhead crane for your application can be critical to improve productivity in your workplace and avoid possible hazards that could lead to injuries or delays in your operations. Here are some factors you should consider when choosing the right overhead crane for your application: 1. Lifting capacity: The first factor in choosing the right overhead crane is its lifting capacity. You should consider the maximum lifting capacity required for your application based on the maximum weight of the loads to be lifted. 2. Span and lift height: The span and lift height are essential factors in selecting the right overhead crane for your application. You should consider the height and distance required to move the loads and select the crane that matches your specific requirements. 3. Environment: Consider the environment in which the crane will operate. Will you be using it indoors or outdoors? What is the temperature range, humidity, and dust level? The environment may influence your choice of materials used and crane features such as anti-corrosive coatings, seals, and insulation. 4. Speed and accuracy: The speed and accuracy of the crane are also critical to consider. If your application involves heavy lifting that needs precise positioning, you should opt for a crane with a slower speed and higher accuracy. 5. Safety: Safety is crucial in selecting an overhead crane. Consider safety features such as overload protection, emergency stop buttons, limit switches and shock absorbers. 6. Maintenance and repair: Maintenance and repair for your crane should be considered when selecting a crane. Consider the frequency of inspection required, the availability of spare parts, and how easy the crane is to repair. In conclusion, you should choose an overhead crane that matches your specific performance requirements and considers factors such as lifting capacity, span and lift height, environment, speed and accuracy, safety, and maintenance and repair. Consult a reputable crane manufacturer or supplier to help identify the right crane for your specific application.
#9 How do you install an overhead crane?
Installation of an overhead crane is a complex process that requires careful planning and execution. It should only be performed by experienced technicians or professional crane installation companies. Here are the general steps involved in installing an overhead crane: 1. Planning: The first step in the installation process is to plan the installation carefully. Identify the best location for the crane, including the runway, the supporting structure, and anything else that may impact its installation. Ensure that you have the necessary tools, equipment, and workers in place. 2. Unpacking and prep work: Once you have assembled all the necessary equipment, unpack and organize the crane components. Check all components for damages and ensure that all hardware is accounted for. Prepare the area where the crane will be installed, including clearing obstacles and preparing the foundation. 3. Installing the beams: Install the horizontal beams from which the crane will track to support the crane on the runway. These beams should be installed according to the manufacturer's recommendations and typically require welding and cutting. 4. Installing the hoist: Install the hoist onto the bridge using a hoist and chain. The hoist should be carefully positioned and attached to the crane using bolts, nuts, and other relevant hardware. 5. Runway installation: Fasten the crane runway to the beams previously installed. Build the access platforms and catwalks, then proceed to install the electrical and mechanical systems. 6. Wiring: The wiring for the crane must be installed carefully, following regulations for both electrical and mechanical systems. The power supply for the crane should be installed and connected to the main power source, and specific circuits and wiring should be tested. 7. Final testing: After completing installation, conduct a thorough testing program before finalizing the commissioning process. Perform load testing, electrical and mechanical checks, system balancing, and other relevant testing as required by regulations and the manufacturer's instructions. In conclusion, installing an overhead crane is a complex and regulated process that should only be performed by qualified professionals. Proper planning and preparation, including safety protocols and thorough testing, are important to ensure that the crane operates safely and efficiently.
#10. How do you operate an overhead crane safely?
Operating an overhead crane safely requires proper training, knowledge, and adherence to safety guidelines. Here are some tips on how to operate an overhead crane safely: 1. Follow manufacturer guidelines: Always follow the manufacturer's guidelines and operating instructions when operating the crane. Be sure to read the manual before operation and ensure that you are qualified to operate the crane. 2. Inspect the equipment and area: Before operating the crane, perform a visual inspection to ensure that the equipment is in good working order. Check for any signs of wear and tear, damage or defects, missing parts, or loose nuts and bolts. Ensure that the area where the crane is operated is hazard-free. 3. Use personal protective equipment: Always wear personal protective equipment (PPE) such as hard hats, safety glasses, gloves, and steel-toed boots. Your PPE will protect you from any potential harm during the operation. 4. Know the crane's capacity: Know the crane's lifting capacity and never exceed the maximum weight limit. The capacity of the crane should be indicated on the equipment, and you should ensure that you never lift a load that is too heavy. 5. Check the load: Check the load you are lifting for stability, weight, and whether it can be safely carried with the crane. Ensure that the load is evenly distributed and secured to prevent it from slipping or moving. Use slings, chains, and other appropriate lifting gear while attaching the load to the crane's hoist. 6. Communication: Use clear communication with any other personnel involved in the operation. If there is someone directing you via hand signals, only operate the crane when you understand what is required. 7. Know the surroundings: Be aware of any obstacles in the crane's path before moving the load and keep the path clear. Also, remain alert to any personnel, equipment, or machines in the area while operating the crane. By following these safety guidelines, you can ensure that you operate the overhead crane safely, minimizing risks and accidents to yourself and others.
#11 What is a load capacity crane?
A load capacity crane refers to the maximum weight capacity or load that a crane is capable of carrying or lifting safely. This is an important factor to consider when selecting an overhead crane as it determines the amount of weight the crane can handle without compromising safety. The load capacity of a crane can vary widely and depends on various factors such as the type of crane, size of the crane and the intended application of the crane. It is important to ensure that the load capacity of the crane is suitable for the weight of the material being lifted to prevent accidents or damage to the equipment.
#12 What is a material handling crane?
A material handling crane is a type of crane used in industrial settings to lift and move heavy materials from one location to another. Material handling cranes are essential in transporting materials such as steel, concrete, timber, and other heavy items from one point to another with high efficiency and safety. They are usually mounted on tracks, using a hoist and trolley system to move materials within the facility. Material handling cranes can be customized to suit the specific needs of various applications, such as:
1. Gantry cranes: These cranes can be used to lift heavy materials in outdoor settings such as steelyards, construction sites, and loading docks.
2. Jib cranes: These cranes have a vertical pole that can rotate around its axis, making it ideal for lifting items in confined spaces.
3. Bridge cranes: Also known as overhead cranes, these are mounted on tracks and used to transport heavy loads across a warehouse or production facility.
Material handling cranes have revolutionized industrial processes by enabling the safe, efficient, and smooth movement of heavy materials, reducing the need for manual handling and increasing productivity.
What is an industrial overhead crane?
An industrial overhead crane is a type of crane used in manufacturing facilities, warehouses, and other industrial settings to lift and move heavy objects or materials within the facility. The crane is mounted on a steel frame or suspended from the ceiling, with a hoist and trolley system that moves along a runway.
Industrial overhead cranes are highly versatile and can be customized to suit the specific needs of various applications, including:
1. Bridge cranes: These cranes are mounted on tracks and used to transport heavy loads across a warehouse or production facility.
2. Gantry cranes: These cranes use a freestanding structure to support the hoist and trolley system, making them ideal for outdoor applications like loading docks, shipyards, and construction sites.
3. Jib cranes: These cranes have a vertical pole that can rotate around its axis, making them ideal for lifting items in confined spaces.
4. Monorail cranes: These cranes use a single track to transport materials within a facility, and they are ideal for applications that require the lifting and transportation of light to medium loads.
Industrial overhead cranes have revolutionized manufacturing processes by enabling the safe, efficient, and smooth movement of heavy materials, reducing the need for manual handling and increasing productivity.
Overhead Crane Q&A
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