Overhead cranes—often called bridge cranes—are the quiet workhorses that keep heavy industry moving. This practical guide follows the journey from bare runways to a commissioned crane ready for service. We’ll cover final load testing and handover—with the same checklists pro installers use.
Bridge Crane Basics
At heart, a bridge crane is a bridge beam that spans between two runway beams, carrying a trolley-mounted hoist for precise, vertical picks. The system delivers three axes of motion: long-travel along the runway.
You’ll find them in fabrication bays, steel plants, power stations, oil & gas shops, precast yards, and logistics hubs.
Why they matter:
Safe handling of very heavy, unwieldy loads.
Huge efficiency gains.
Lower risk during rigging, lifting, and transport inside facilities.
Support for pipelines, structural steel, and big machinery installs.
System Components We’re Installing
Runways & rails: runway girders with crane rail and clips.
End trucks: motorized gearboxes for long-travel.
Bridge girder(s): cambered and pre-wired.
Trolley & hoist: reeving, hook block, upper limit switches.
Electrics & controls: power supply, festoon or conductor bars.
Stops, bumpers & safety: end stops, buffers, travel limits.
Based on design loads and bay geometry, the crane might be a single-girder 10-ton unit or a massive double-girder 100-ton system. The choreography is similar, with heavier rigs demanding extra controls and sign-offs.
Make-Ready & Surveys
A clean install is mostly planning. Key steps:
Drawings & submittals: Approve general arrangement (GA), electrical schematics, and loads to the structure.
Permits/JSAs: Job Safety Analysis (JSA) for each lift step.
Runway verification: Survey columns and runway beams for straightness, elevation, and span.
Power readiness: Lockout/tagout plan for energization.
Staging & laydown: Lay out slings, shackles, spreader bars, and chokers per rigging plan.
People & roles: Brief everyone on radio calls and stop-work authority.
Millimeters at the runway become centimeters at full span. Measure twice, lift once.
Alignment That Saves Your Wheels
Runway alignment is the foundation. Targets and checks:
Straightness & elevation: shim packs under clips to meet tolerance.
Gauge (span) & squareness: Check centerlines at intervals; confirm end squareness and expansion joints.
End stops & buffers: Verify clearances for bumpers at both ends.
Conductor system: Keep dropper spacing uniform; ensure collector shoe reach.
Log final numbers on the ITP sheet. Correct now or pay later in wheel wear and motor overloads.
Girder Erection & End Trucks
Rigging plan: Softeners protect painted flanges. Taglines for swing control.
Sequence:
Lift end trucks to bloomberg building runway level and set temporarily on blocks.
Rig the bridge girder(s) and make the main lift.
Land the bridge on the end trucks and pin/bolt per GA.
Verify camber and bridge square.
Prior to trolley install, bump-test long-travel motors with temporary power (under permit): confirm limit switch wiring. Re-apply LOTO once checks pass.
Hoist & Trolley
Trolley installation: Mount wheels, align wheel flanges, set side-clearances.
Hoist reeving: Lubricate wire rope; verify dead-end terminations.
Limits & load devices: Set upper/lower limit switches.
Cross-travel adjustment: Verify end stops and bumpers.
Pendant/remote: Install pendant festoon or pair radio receiver; function-test deadman and two-step speed controls.
Grinding noises mean something’s off—stop and inspect. Fix the mechanics first.
Electrics & Controls
Power supply: Drop leads tagged and strain-relieved.
Drive setup: Program VFDs for soft starts, decel ramps, and brake timing.
Interlocks & safety: Zone limits near doors or mezzanines.
Cable management: Keep loops short, add drip loops where needed.
Future you will too. If it isn’t documented, it didn’t happen—put it in the databook.
Trust but Verify
Inspection Test Plan (ITP): Third-party witness for critical steps.
Torque logs: Re-check after 24 hours if required.
Level & gauge reports: Note any corrective shims.
Motor rotation & phasing: Document bump tests.
Functional tests: Jog commands, inching speeds, limits, overloads, pendant/remote range.
A tidy databook speeds client acceptance.
Proving the System
Static load test: Hold at mid-span and near end stops; monitor deflection and brake performance.
Dynamic load test: Travel long-run, cross-travel, and hoist at rated speed with test load.
Operational checks: Emergency stop shuts down all motions.
Training & handover: Operator basics, daily pre-use checks, rigging do’s & don’ts.
When the logbook is clean, the crane is officially in service.
Applications & Use Cases
Construction & steel erection: placing beams, trusses, and precast.
Oil & gas & power: moving heavy pumps, skids, and pipe spools.
Steel mills & foundries: large part transfer.
Warehousing & logistics: high throughput lanes.
Once teams learn the motions, cycle times drop and safety improves.
Safety & Engineering Considerations
Rigging discipline: dedicated signaler and stop-work authority.
Lockout/Tagout: test before touch every time.
Fall protection & edges: approved anchor points, guardrails on platforms, toe boards.
Runway integrity: no cracked welds, correct bolt grades, proper grout.
Duty class selection: overspec when uncertainty exists.
A perfect lift is the one nobody notices because nothing went wrong.
Troubleshooting & Pro Tips
Crab angle/drift: re-check runway gauge and wheel alignment.
Hot gearboxes: adjust brake air gap and reduce VFD decel.
Rope drum spooling: check fleet angle and sheave alignment.
Pendant lag or dropout: antenna placement for radio; inspect festoon collectors.
Wheel wear & rail pitting: lubrication and alignment issues.
A 10-minute weekly check saves days of downtime later.
FAQ Snippets
Overhead vs. gantry? Choose per site constraints.
Single vs. double girder? Singles are lighter and cheaper; doubles carry heavier loads and give more hook height.
How long does install take? Anything from a couple weeks to a few months.
What’s the duty class? FEM/ISO or CMAA classes define cycles and service—don’t guess; size it right.
Who Gets the Most Value
Students and pros alike get a front-row seat to precision rigging, structural alignment, and commissioning. You’ll gain a checklist mindset that keeps cranes safe and productive.
Looking for a clean handover databook index you can reuse on every project?
Grab the installer pack so your next crane goes in cleaner, faster, and right the first time. Bookmark this guide and share it with your crew.
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