Like any complex equipment, overhead cranes require routine maintenance to function safely and effectively for the long term. Neglecting maintenance can lead to costly repairs, operational downtime, and, most importantly, serious safety hazards.
Regular maintenance ensures compliance with safety regulations, prolongs the crane’s lifespan, and improves overall workplace efficiency. Businesses can keep their lifting equipment running smoothly by investing in quality maintenance, following routine servicing schedules, adhering to LOLER (Lifting Operations and Lifting Equipment Regulations 1998), and addressing minor faults before they become major failures.
The Importance of Regular Maintenance for Overhead Cranes
Extending The Lifespan Of An Overhead Crane
An overhead crane is a long-term investment, but without proper care, its lifespan can be reduced. Routine maintenance prevents excessive wear and tear, ensuring that the crane remains operational for years to come. Addressing minor issues before they develop into major failures is a must to save money on costly replacements.
Minimising Downtime and Operational Disruptions
When an overhead crane breaks down, it disrupts workflow and can cause delays that affect overall productivity and put projects on pause. This Operational downtime and the cost of emergency repairs can have significant financial repercussions.
Proactive maintenance prevents unexpected failures, allowing businesses to plan for necessary repairs and replacements rather than dealing with sudden interruptions.
Bramley Engineering will repair or replace any parts that will not last the year until the next inspection to save your business costs of expensive emergency call-outs, and operational downtime. We won’t replace anything that doesn’t need replacing within the year but will highlight any parts to keep an eye on.
Crane Safety and Compliance
Overhead cranes are designed to handle significant loads, but without regular maintenance, parts and components can wear out, increasing the risk of failure. A crane malfunction is serious and could result in severe injuries or even fatalities. Routine maintenance enables engineers to identify potential hazards and address them before they become a serious problem, protecting businesses, staff, and the public.
Overhead cranes in the UK, and all other lifting equipment and accessories, must comply with LOLER. These regulations require that cranes undergo routine inspections to ensure they remain safe for operation by meeting the required inspection standards.
Proper maintenance will help these inspections run smoothly with a higher likelihood of passing. Failure to comply with LOLER can result in legal consequences, including fines or even imprisonment, and put workers in danger. See our guide to LOLER inspections to find out more about the regulations and requirements.
Understanding LOLER Inspections and Regulations
LOLER places the responsibility on employers to ensure that lifting equipment is maintained in a safe condition. Under LOLER, overhead cranes must undergo periodic thorough examinations carried out by a competent person. These inspections must take place:
- Every 12 months for lifting equipment (including cranes and loading equipment).
- Every 6 months for lifting accessories.
- More frequently if the equipment is used in extreme conditions or heavy-duty operations or where equipment is designed for lifting people.
During a LOLER inspection, engineers assess:
- The structural integrity of the crane.
- The condition of lifting components, such as hooks and chains.
- The operation of safety mechanisms.
- The functionality of brakes and limit switches.
- Any signs of excessive wear, corrosion, or fatigue.
After the inspection, a report is generated highlighting any defects, with recommendations for necessary repairs or part replacements. Our LOLER inspections are so thorough in identifying parts that won’t last 12 months that we shouldn’t hear from you again until the inspection is due. We ensure that overhead cranes remain safe, fully functional, and LOLER-compliant year-round.
Learn more about common LOLER inspection failures and how to avoid them.
What is the Life Expectancy of an Overhead Crane?
The lifespan of an overhead crane depends on usage, environmental conditions, and maintenance frequency. Cranes operating in harsh environments, such as steel mills or chemical plants, may have a shorter lifespan due to exposure to extreme temperatures and corrosive substances. Regular maintenance plays a big role in extending the life of an overhead crane and ensuring optimal performance throughout its service years.
On average, a well-maintained overhead crane can last between 20 to 30 years. However, some cranes exceed this lifespan when manufactured with a bespoke crane design and properly cared for with frequent upgrades of modern components.
Common Issues and Repairs in Overhead Cranes
Even with routine maintenance, certain components in overhead cranes are more susceptible to wear and tear. Some of the most common faults include:
- Wire Rope Degradation – Over time, wire ropes can fray, corrode, or develop kinks, reducing their load-bearing capacity.
- Electrical System Failures – Faulty wiring, damaged circuit boards, or failing contactors can lead to operational failures and crane malfunctions.
- Alignment Issues – Misaligned runways or bridge components cause uneven wear and affect the crane’s efficiency.
- Brake System Wear – Worn-out brake pads or failing brake mechanisms compromise the crane’s ability to stop safely.
- Hoist Malfunctions – Excessive use can cause hoist motors, gears, and bearings to wear out.
- Overloading Damage – Exceeding the crane’s weight capacity puts stress on its structural components and can lead to cracks or deformities.
Addressing these issues early during routine maintenance and repair can prevent major failures, removing the need for more costly emergency repairs and project disruption.
How Do You Inspect an Overhead Crane?
Overhead crane inspections are divided into two main categories:
- Frequent Inspections – Conducted daily, weekly, or monthly, focusing on high-wear components like hooks, chains, and safety devices.
- Periodic Inspections – Performed every few months or annually (including annual LOLER inspections), involving an in-depth examination of the entire crane system by a competent person, such as a Lifting Engineer from Bramley Engineering.
The key inspection steps usually include:
- Operational Testing – The crane is run through its standard functions to detect abnormal movements or sounds.
- Component Examination – All mechanical and electrical components are checked for damage or wear.
- Structural Inspection – The crane’s frame, runway, and supports are assessed for signs of stress or fatigue.
- Load Chain and Hook Analysis – Deformation, cracks, and excessive wear are identified.
- Brake Check – Brakes are tested for responsiveness and holding power.
How Do You Service an Overhead Crane?
Servicing an overhead crane is a process that ensures all parts function optimally. Service or repair will usually be required after an inspection, annual or frequent, where issues have been identified. The key steps include:
- Visual Inspection – Engineers assess structural components, cables, and load-bearing parts for visible damage, corrosion, or wear.
- Lubrication – Proper lubrication of moving parts reduces friction, preventing excessive wear and overheating.
- Electrical System Check – Wiring, control panels, and limit switches are inspected for signs of damage or malfunction.
- Load Testing – Periodic load tests verify that the crane can safely lift its maximum rated load.
- Alignment Verification – Ensuring proper alignment of the bridge and runway prevents uneven wear and operational inefficiencies.
- Brake System Examination – The braking system is tested to ensure it can hold and stop loads safely.
- Safety Device Checks – Emergency stop functions, limit switches, and warning signals are tested for reliability.
- Report and Recommendations – A detailed report is generated, highlighting necessary repairs and improvements. We have a secure online system that stores all records so compliant record-keeping is also made easy for you.
What Does an Overhead Crane Technician Do?
An overhead crane technician ensures the safe and efficient operation of overhead crane systems. This includes installation, maintenance, repair, and maintaining compliance with safety regulations.
When installing new crane systems, components should be correctly assembled, aligned, and tested for functionality. Once a crane is operational, routine maintenance then becomes key to protecting and prolonging the lifespan of the crane. This involves conducting regular inspections, servicing, and making necessary adjustments to prevent unexpected failures.
How Can Bramley Engineering Help?
At Bramley Engineering, our lifting engineers and LOLER inspectors are highly qualified and accredited crane technicians who ensure your lifting equipment operates safely, efficiently, and in full compliance with LOLER and other industry standards.
Our team is trained to diagnose and repair all types of electrical and mechanical faults, whether it’s a motor malfunction, worn-out components, or an unexpected electrical failure. As designers, manufacturers, and inspectors of overhead cranes, we’ve seen it all. We don’t just fix problems – we prevent them.
Find out more about our crane maintenance and repair services or request your free crane servicing or repair quote. If you’ve got any questions, get in touch or give us a call on 01525 375225 and we’ll be happy to have a chat and see how we can help keep your cranes running smoothly.