TL;DR
Under LOLER, gantry cranes used only for lifting goods are generally subject to a thorough examination every 12 months, while lifting accessories such as slings, shackles and hooks are examined every six months. Different intervals may apply under a written examination scheme or where the equipment is used to lift people. PUWER also requires equipment to be suitable, properly maintained and used by trained personnel. Many electrical, mechanical and operational failures can be reduced through regular inspection and planned maintenance.
Table of Contents
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.
Recommended safety checklist
- 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.
PUWER and Your Legal Obligations
Alongside LOLER, gantry crane operators in the UK must also comply with the Provision and Use of Work Equipment Regulations 1998 (PUWER). Where LOLER governs the lifting operation itself, PUWER governs the equipment more broadly – covering its suitability for purpose, maintenance condition, and safe use.
Under PUWER, employers must ensure that:
- All work equipment, including gantry cranes, is suitable for its intended use
- Equipment is maintained in efficient working order and good repair
- Operators are provided with adequate training, instruction and supervision
- Any risks from use of the equipment are identified and controlled
- Equipment is subject to inspection where it is exposed to conditions that could cause deterioration
Together, LOLER and PUWER form the backbone of gantry crane legal compliance in the UK. Failing to comply can lead to HSE enforcement action, may affect insurance cover or claims, and can place personnel at serious risk.
Who Is Responsible? Duty Holders Explained
Under LOLER and PUWER, legal responsibility for gantry crane compliance does not rest solely with the crane operator. The regulations assign duties to several parties:
- Employers are responsible for ensuring all lifting equipment is thoroughly examined at the required intervals and that records are properly maintained
- The person planning the lifting operation must have the necessary competence to ensure that the lift is properly planned, appropriately supervised and carried out safely. Depending on the organisation and complexity of the lift, this person may be formally designated as an appointed person
- Equipment owners have a duty to ensure any crane supplied for use – whether owned or hired – meets legal requirements before it is put into service
- Crane operators carry responsibility for conducting pre-use checks and reporting any defects before undertaking a lift
If you are unsure who holds each duty within your organisation, a lifting equipment specialist can help you establish a clear compliance structure before your next inspection is due.
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.
Mechanical and Structural Wear
- Wire rope deterioration: Wire ropes on gantry crane hoists are subject to fatigue, corrosion and strand breakage over time. Regular visual inspection and replacement at the intervals specified by the manufacturer is essential.
- Brake wear: Hoist and travel brakes are safety-critical components. Worn or poorly adjusted brakes can lead to load drift or inability to hold a suspended load – both serious risks.
- Wheel and rail wear: Gantry crane wheels and runway rails are subject to significant wear, particularly in high-cycle applications. Worn wheels or misaligned rails can cause tracking issues, derailment or structural loading outside design limits.
Operator Error
- Overloading: Operating a gantry crane beyond its rated Safe Working Load (SWL) is one of the most common causes of structural failure. Always confirm load weights before lifting.
- Side loading: Gantry cranes are designed to lift vertically. Pulling loads at an angle places lateral stress on the structure and hoist that the equipment is not rated to handle.
- Bypassing limit switches: Hoist upper limit switches are a safety device, not a positioning tool. Bypassing or overriding them removes a critical layer of protection.
Environmental Factors (Outdoor Gantry Cranes)
- Corrosion: Outdoor and exposed gantry cranes are particularly vulnerable to corrosion on structural members, fasteners and running gear. Protective coatings and regular inspection help extend service life.
- Wind loading: Outdoor gantry cranes should not be operated in wind speeds exceeding the manufacturer’s rated limit. Securing the crane properly when not in use prevents uncontrolled movement.
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.
FAQs
How often does a gantry crane need a LOLER inspection?
Lifting accessories used with a gantry crane (such as slings, shackles and hooks) must be inspected every 6 months under LOLER. The crane itself must be inspected every 12 months, or more frequently if specified by a thorough examination or if it is used to lift people. Your appointed competent person can advise on the correct interval for your specific setup.
What are the most common causes of gantry crane failure?
The most common causes of gantry crane failure are electrical faults (sticking contactors, component failures), mechanical wear (wire rope fatigue, brake wear, wheel and rail wear), operator error (overloading, side loading, bypassing limit switches) and environmental factors such as corrosion on outdoor cranes. The majority of these failures are preventable through a structured planned maintenance programme.
Who is responsible for gantry crane inspections under LOLER?
The duty to arrange LOLER inspections sits with the employer or equipment owner. The thorough examination must be carried out by a competent person with sufficient practical and theoretical knowledge of the equipment to identify defects and assess their significance. The person must be sufficiently independent and impartial and should not be responsible for assessing their own routine maintenance work.
What records do I need to keep for gantry crane compliance?
You are legally required to keep records of every thorough examination carried out on your lifting equipment. For the crane itself, records should be kept throughout the life of the equipment. For lifting accessories (slings, shackles, hooks), records must be retained for at least two years. Records should detail the date of examination, the findings, any defects identified and the corrective actions taken.
Does PUWER apply to gantry cranes?
Yes. PUWER (Provision and Use of Work Equipment Regulations 1998) applies to all work equipment including gantry cranes. It requires that equipment is suitable for its intended use, properly maintained, and that operators are adequately trained. PUWER works alongside LOLER – both regulations apply simultaneously to gantry crane operations.
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.
Lifting Systems has been manufacturing and installing crane systems across the UK since 1994. If you need support with LOLER compliance, planned maintenance, or selecting the right gantry crane for your facility, contact our team for expert advice.
