Before any lifting operation, crane operators must conduct the necessary safety checks within the workplace, identifying potential risks and ensuring that lifts are performed safely.
A recommended safety checklist includes:
- Ensuring that attached loads are fully secured
- Assessing the environment or location where the crane is operating
- Confirming the load doesn’t overturn
- Inspecting shackles and slings to ensure they are in good working condition
- Checking proximity to potential hazards
- Prioritising the safety of personnel involved in the lift
- Verifying that the crane is not overloaded
- Avoiding working under suspended loads
- Maintaining visibility of the crane and its surroundings
- Regular maintenance of the crane to optimise its performance based on usage
To ensure the safety of both your team and equipment, all lifting accessories must undergo inspections as per the LOLER (Lifting Operations and Lifting Equipment Regulations) every six months. Other types of lifting equipment should be checked every 12 months. This requirement is often stipulated by insurance companies, with some insurers offering direct inspection services. However, many crane providers also offer these inspections along with regular maintenance schedules.
It’s essential to maintain records of all examinations and inspections, detailing any defects and necessary corrective actions. While lifting equipment records should be kept until the equipment is no longer in use, records for lifting accessories must be retained for at least two years.
Common Causes of Crane Failure
Crane failures, while not uncommon, can often be prevented with regular maintenance and inspection. One of the most frequent causes of failure is electrical faults, especially as cranes experience continuous use, causing certain components to wear out over time. Electrical faults can vary widely and are often unpredictable, making it vital to maintain and inspect all electrical parts of the crane.
Some common electrical issues include:
- Sticking or welded contacts: This occurs when a contactor either fails to energise (the motor doesn’t start when commanded) or fails to de-energise (the motor doesn’t stop when the run command is removed). Regular inspection and cleaning of contacts can help prevent this issue.
- Electronic component failures: As cranes are used consistently, electronic components—such as mechanical parts, electrical controls, and hydraulic system components—can fail. To minimise the risk of breakdown, ensure that these components are regularly checked and maintained.
To make your maintenance routine easier, our experts have created a free checklist to help identify and prevent these common issues.
Types of Crane Systems for Manufacturing Facilities
Choosing the right crane system for your manufacturing facility depends on various factors, including the fabric of the building and surrounding operating conditions.
Below are some common types of crane systems used in manufacturing:
Overhead Cranes
Overhead cranes are designed to integrate into the structure of the building, allowing them to lift heavy loads across the entire floor space. They are especially suited for industries such as construction, manufacturing, and warehousing due to their flexibility in moving heavy loads in multiple directions. Since overhead cranes are permanently suspended from the roof, they do not restrict the floor layout, providing ample space for operations below.
Gantry Cranes
Gantry cranes function similarly to overhead cranes but operate on their own independent structure. The size and design of the rails are determined by the crane’s working load. Gantry cranes are used in various industries, including steel, aircraft, and heavy construction, and can also be applied in harsher environments with special protective coatings to safeguard components and running gear.
Jib Cranes
Jib cranes are ideal for smaller industrial facilities. They consist of a horizontal beam supported by a fixed vertical column, allowing them to rotate and extend to reach specific areas. Their compact nature makes them suitable for factories with limited space, and they are commonly used in tasks like plastic injection molding, parts assembly, and other operations where manual handling is prohibited.
Light Track Cranes
Light track systems are designed to maximise floor space and operate within specific workstations, either built into the framework of the building or as freestanding units. They are used for lifting lighter loads and are often manually or electrically operated. Light track cranes are ideal for facilities with limited height, such as flour mills, engine assembly workshops, and paint shops, supporting lifts of up to 2 tons.
We’ve covered essential safety regulations and overhead and gantry crane systems suitable for manufacturing industries. By following proper maintenance procedures and selecting the right crane, you can ensure your facility operates efficiently and safely.
