Overhead crane manufacturing is a complex process requiring precision, safety considerations, and innovative engineering. At Bramley Engineering, we specialise in bespoke crane design and build solutions, overcoming challenges that many manufacturers struggle with. Here’s how we navigate the 5 most common obstacles in crane design and manufacturing, which are:
- Structural Integrity & Wind Loading – Outdoor cranes must withstand wind forces; poorly designed gantry columns can increase material costs.
- Hazard Risk & Prevention – Risks include finger trapping, untrained user access, environmental exposure (dust, rain, food-grade conditions).
- Delivery & Installation Problems – Large cranes can be difficult to transport and assemble, sometimes reducing load capacity.
- Compliance with Safety Regulations – Meeting LOLER and industry safety standards is essential to avoid fines and accidents.
- Cost-Effective, Sustainable Design – Balancing affordability with durability and efficiency while maintaining structural resilience.
1. Structural Integrity and Wind Loading
When designing an overhead crane or gantry crane, structural integrity is crucial. Outdoor overhead gantry cranes face significant challenges from wind loading, which can impact stability and efficiency. Many manufacturers struggle or fail to address this adequately, leading to compromised safety and often unnecessarily increased material costs.
Our Solution: Bramley Engineering designs gantry columns that are virtually see-through, significantly reducing wind resistance. We’re known for this unique design that enhances the column’s strength while allowing for more cost-effective steel without sacrificing durability. This ensures your outdoor cranes remain stable and efficient in high-wind environments.
2. Hazard Prevention in Crane Design
Overhead crane designs must proactively mitigate potential hazards. The most common hazards fall into two categories:
People Hazards
- Finger trapping and entanglement – Poorly designed cranes can pose serious risks of workplace injuries to operators.
- Untrained user risks – Some cranes are accessible to untrained personnel, increasing the likelihood of accidents if they can access the controls.
Our Solution: We incorporate control enclosures to lock crane control mechanisms and pendants away from untrained users, ensuring only authorised personnel are able to operate the equipment.
Environmental Hazards
- Wind and rain exposure – Outdoor cranes must withstand varying weather conditions. A common problem with overhead travelling cranes is the travelling beam being taken by the wind and colliding with the end stops of the gantry.
- Food-grade environments – Standard lubricants are unsuitable for food manufacturing plants.
- Dust accumulation – Dust can cause mechanical wear over time.
Our Solution:
Aside from using high-quality, durable materials, we include bespoke features to enhance safety and efficiency, ensuring your crane design is fit for purpose. These could include:
- Use of food-grade oils for clean environments like food manufacturing and utility work.
- Integrated brushes on moving parts enable self-cleaning by dusting the crane as it operates.
- Wind-lock mechanisms to prevent jibs from uncontrolled slewing in windy conditions, minimising damage.
- Parking brakes on overhead travelling cranes to prevent beams from shifting due to wind, to avoid collisions with end stops.
3. Delivery and Installation Challenges
Transporting and installing large cranes like gantry cranes and bridge cranes can be complex. The size and weight of cranes make delivery and installation particularly challenging, especially when access to the installation site is restricted. In some cases, cranes need to be transported in smaller pieces and assembled on-site, which can affect load capacity.
Our Solution: We design modular cranes that can be broken down into smaller parts without compromising their safe working load (SWL). If modifications do impact load capacity, we’ll conduct redesigns to ensure the crane meets SWL requirements while providing an easier installation.
4. Compliance with Safety Regulations
From EOT crane manufacturing to ceiling cranes, we know all lifting equipment must completely comply with LOLER (Lifting Operations and Lifting Equipment Regulations) and in some cases PUWER (Provision and Use of Work Equipment Regulations 1998) guidelines. Non-compliance can lead to severe fines, staff injuries and operational shutdowns.
Our Solution: Our designers are highly trained to provide fully compliant designs that exceed industry safety standards. We can integrate advanced control systems and features such as limit switches, electronic sensors to enforce no-go zones, automated stop functions, and protective enclosures to safeguard both personnel and equipment.
And it doesn’t stop there. We can also conduct ongoing LOLER inspection services with our own qualified LOLER inspectors to keep your cranes fully operational and legally compliant.
5. Cost-Effective, Sustainable Design
Balancing affordability with performance and durability is a key challenge for crane manufacturing companies. Cheaper materials may lower upfront costs but can dramatically compromise safety and longevity, often costing more in the long run through repairs and replacements.
Our Solution: We design with strategy, making careful choices on features like wind-resistant gantry columns and modular components to maintain affordability without sacrificing quality. Our approach reduces steel costs while enhancing structural resilience, offering you the best value crane for your needs.
Why Choose Bramley Engineering to Design and Build Your Crane?
With over 40 years of expertise in overhead crane manufacturing, we solve complex design, build and installation challenges that other companies struggle with. We offer more than just a crane design and build, with Bramley Engineering you’ll receive:
- Bespoke Crane Solutions: Every project is custom-engineered to meet your specific operational requirements.
- Expert Compliance & Safety Assurance: Our cranes are designed to meet LOLER and all industry safety standards.
- End-to-End Service: From initial design to installation and ongoing maintenance, we provide a seamless, hassle-free experience.
Get a Free Crane Design Consultation Today!
Looking for a reliable, bespoke overhead crane? Contact Bramley Engineering for a free design and quote. Let’s build a more efficient lifting solution for your business.
For more information, get in touch! Email us at enquiries@bramleyengineering.co.uk or give us a call on 01525 375225 and we’ll be happy to help.
