Crane breakdowns are a nightmare. The cost to repair a broken crane always outweighs the cost of regular maintenance and this is before you factor in the forced pauses in production ...which inevitably cost your business even more.
There’s no secret answer to reducing crane breakdowns. It’s a case of being attentive, implementing preventative measures, and inspections (both daily checks and regular maintenance).
This blog was written to help you identify where you should start, making sure you’re efficient with your time and best-supported to reduce breakdowns.
The importance of completing daily and pre-operational checks before using your crane is vital. Reviewing your machine on a shift by shift allows you to identify operational issues long before they turn into major issues.
Always from ground level, you should be checking wire ropes and cables for visible damage. Ensuring that crane buffers are in place, the physical structure of the crane appears sound and there are no signs of oil leaks across the crane.
As well as visual checks, be sure to see how the crane runs without a load attached, whether the various limit switches are operational and if any audible warning devices are fitted and functioning.
This is far from an exhaustive list of precautions before operating. This is a reminder to complete your daily checks as they’re the primary means of identifying issues before they escalate and compromise your crane. We recommend that you still regularly inspect and maintain equipment which is currently not in use to minimise any chance of being surprised when the crane returns to service.
For a more extensive list of checks, download our daily & pre-op checklist template. It contains an easy-to-use list of all the major touch points you should review before operating your crane.
Our experts have created a handy checklist of the areas you should review daily to keep your cranes running and avoid downtime
The most important thing on any crane is the actual load path. So things like the hoist rope and hoist brake are of primary importance, they should be checked thoroughly at regular intervals along with a visual inspection of the rope and operational checks on the brake before each shift.
Can you identify signs of wear on your wire rope? Is there birdcaging, corrosion or severe wear and tear? The best way to prevent damage to or failure of these wire ropes is to ensure you complete your daily checks.
Consider the unexpected. There are certain things you simply can’t vouch for but you can ensure that all safety devices functioning correctly before starting.
As with all daily checks, they are to be carried out on the ground.
Climate and environmental factors all play a part in crane wear and tear and, subsequently, how you should maintain them.
Water is the enemy of most cranes and it has a way of negatively impacting many of a crane’s composite parts. Damp & humid environments will likely affect the hoist rope and brakes to a greater degree. Causing ropes to rust easier and brakes to stick and as such, they require more attention.
It’s not just moisture, dust also has an impact on your equipment. Becoming abrasive and deteriorating ropes, rope guides, brakes and any open gears.
Frequent servicing of your cranes is crucial to reducing breakdowns. Many of these inspections are already enshrined in law including:
The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) which requires companies to have a thorough examination carried out on their cranes, at regular intervals (no more than 12 months apart) to ensure they are safe to use.
The Provision and Use of Work Equipment Regulations 1998 (PUWER), regulation 5 which requires every employer to ensure that work equipment, including cranes, is maintained and kept in good working order.
We go into more detail about how these regulations are crucial to minimising crane downtime here.
Adhering to PUWER is necessary to mitigate crane malfunctions and breakdowns. Many organisations offer preventative maintenance in which you can schedule maintenance to the manufacturer’s recommendation. Tailoring a series of preventative maintenance sessions around your specific needs, work schedule and equipment helps prevent costly breakdowns and production stoppages.
As discussed at the beginning of this blog, thorough, daily checks of your equipment are crucial to reducing crane breakdowns. Having a systematic approach to these checks and methodically crossing off each inspected area ensure that nothing slips through the cracks. That’s why we’re sharing with you the daily inspection checklist we use. Click through to download the document and print it out to use onsite.
The key to reducing the regularity of crane breakdowns is to ensure perform checks and observations ahead of any use. We've made this easier with our downloadable checklist. Just print it out and use before every shift.
Our experts have created a handy checklist of the areas you should review daily to keep your cranes running and avoid downtime