Overhead crane installation covers more than putting steel in the air. It starts with a detailed site assessment, moves through assembly and load testing, and finishes with LOLER certification before the crane enters service. Lifting Systems has been delivering crane installations across the UK since 1994 – managing the full process from initial site assessment to sign-off. |
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Overhead crane installation is a precise process that requires planning, preparation, and attention to detail. Whether it’s your first crane installation or one of many, understanding the process can help ensure your project stays on track, within budget, and keeps your workforce safe. At Lifting Systems, we’ve been delivering professional overhead crane installation across the UK since 1994.
Preparing for Installation
Before the crane installation team arrives, the project lead collaborates with the client or general contractor to assess the site and create a detailed plan. This involves:
- Understanding the Site Layout: The team evaluates the workspace to identify potential risks and ensure the area is ready for the overhead crane and gantry system.
- Establishing Access Points: Planning how tools, access equipment, and the overhead crane will be safely transported into the building.
- Setting Up Staging Areas: Ensuring machinery or equipment is moved to create a clear space for assembly.
- Identifying Hazards: Checking for electrical or gas lines, lighting fixtures, and other potential obstacles that could impact the installation process.
This initial assessment is crucial to minimise delays and avoid complications once the installation begins.
Once site preparation is complete, the installation follows a defined sequence:
Delivery
The crane and gantry components are delivered to site. Delivery is coordinated around site access constraints and the staging areas established during preparation.
Assembly
Components are positioned and secured according to the project specifications. This includes the bridge beams, end carriages, hoist unit, and electrical connections.
Load Testing
Before the crane enters service, it is load tested to confirm it can safely handle its rated capacity. Testing covers hoist operation, trolley travel, bridge travel, and all safety devices.
Commissioning and LOLER Sign-Off
All controls and safety devices are confirmed operational. Where the safety of lifting equipment depends on its installation conditions, LOLER requires it to be thoroughly examined by a competent person after installation and before it is first put into service. Lifting Systems provides the Report of Thorough Examination on completion.
Installing the Crane
Once the team has prepared the site, the overhead crane and gantry are delivered to the location. The installation process includes:
- Assembly: Positioning and securing the overhead crane components in place according to the project specifications.
- Load Testing: Ensuring the overhead crane is fully operational by testing key functions such as up-and-down hoist operation, trolley travel, bridge travel, and safety devices. This ensures the system can handle its intended load and complies with safety standards.
Key Considerations Before Installation
Selecting the right overhead crane for your facility is as important as the installation process itself. Consider the following questions to guide your decision:
- In which directions will the overhead crane move (up/down, left/right, forward/back)?
- How often will the overhead crane be used?
- How will the overhead crane be supported?
- How high will the overhead crane need to lift?
- What is the distance between the floor and the lowest point of the ceiling?
Answering these questions ensures that the equipment meets your operational needs and helps streamline the installation process.
How Long Does Overhead Crane Installation Take?
Installation timescales depend on crane type, size, and site complexity. On-site time is only part of the picture – lead time from order through to installation also includes design and fabrication.
As a general guide:
- Smaller single girder cranes on a straightforward site: generally the quickest to install.
- Larger or more complex installations, including those requiring purpose-built runway steelwork: may take several days.
- Multi-crane systems or large-capacity cranes: programme timescales are agreed at the project planning stage.
Lifting Systems will confirm expected timescales during the planning and quotation phase. Contact us to discuss your project.
Load Testing and LOLER Certification
As part of Lifting Systems’ commissioning process, the crane is load tested before handover to confirm safe operation at its rated capacity. It confirms that the crane and its supporting structure can safely carry the rated capacity under operational conditions.
Where the safety of lifting equipment depends on its installation conditions, LOLER requires it to be thoroughly examined by a competent person after installation and before it is first put into service. For a newly installed overhead crane, this means a LOLER thorough examination must take place before first use. The outcome is a written Report of Thorough Examination – a legal document that must be retained and made available to the enforcing authority if required.
Lifting Systems carries out load testing and LOLER thorough examinations as part of its standard commissioning process.
Partnering with Lifting Systems
At Lifting Systems, we pride ourselves on being one of the leading manufacturers and installers of overhead cranes and gantry systems. Our installation team works closely with you to ensure a smooth process from start to finish.
Whether you’re planning your first installation or managing another project, we’re here to help you every step of the way. Get in touch to discuss your next overhead crane installation.
FAQs
What does the overhead crane installation process involve?
Installation begins with a site assessment to understand the workspace, access constraints, and any hazards. The crane is then delivered, assembled, and secured to the project specifications. Before the crane enters service, it is load tested and undergoes a LOLER thorough examination carried out by a competent person.
Does a new overhead crane need a LOLER inspection before it can be used?
Yes. Under LOLER (Lifting Operations and Lifting Equipment Regulations 1998), all lifting equipment must be thoroughly examined before it is first put into service. A newly installed overhead crane requires this examination before first use. The result is a written Report of Thorough Examination, which must be kept as a legal record.
What is load testing and why is it done?
Load testing verifies that the crane can safely handle its rated capacity. It covers hoist operation, trolley travel, bridge travel, and all safety devices. It is a standard step in commissioning any new overhead crane and is required before the crane enters service.
What questions should I answer before choosing an overhead crane?
Key questions include: In which directions will the crane move? How often will it be used? How will it be supported? How high does it need to lift? And what is the available headroom (floor to lowest ceiling point)? Getting clear answers to these during planning helps ensure the right crane is specified for your facility.
How do I get started with an overhead crane installation?
Contact Lifting Systems to discuss your project. We’ll work with you from initial site assessment through to installation, load testing, and LOLER sign-off.
