Overhead cranes, like all equipment, have benefits as well as disadvantages.
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In the simplest terms possible, an overhead crane is a device, or piece of machinery, that enables you to lift and transfer heavy objects from one place to another.
Overhead cranes can be designed and built in a variety of configurations with various components swapped out or engineered to increase capacity and performance. Some of the most common reasons for using an overhead crane are as follows:
There are many different types of overhead cranes and each one is specifically constructed and engineered for a specific purpose or application to meet a company&#;s material handling demands.
In this article, we will be discussing the pros and cons of using an overhead crane on the worksite. We will also be discussing the different types of cranes that are available to you and their unique features and uses.
Now that we have discussed what exactly an overhead crane is, we will dive into the different disadvantages that are associated with them. We will also discuss why some companies or business owners choose to use different types of equipment instead of an overhead crane.
Compared to other types of heavy lifting equipment, cranes generally have a pretty high price. So when it comes to choosing between a crane and some other equipment, the upfront cost often creates some hesitation and concern.
The other disadvantage to using an overhead crane in your workplace is how much space they take up. Overhead cranes are typically much larger than other equipment options. If an overhead crane is initially built into the facility, it is typically supported by the building&#;s infrastructure. However, if the crane is freestanding, it will necessitate the installation of support columns throughout the facility, which can take up a significant amount of space.
Due to the large size of overhead cranes and the way they are built into the structure of a building, moving a crane from one facility to another is extremely difficult, if not impossible. In some cases, the overhead crane is even included in the lease agreement for a building.
Now that we know the few disadvantages to overhead cranes, let&#;s discuss the different ways that overhead cranes benefit you, the company, and the facilitated operation.
It is not unusual for an overhead crane to last up to 65 years. This is due to the fact that overhead cranes are generally built specifically for the operation at hand and are less prone to damage than other equipment.
Another advantage of using an overhead crane in a manufacturing, assembly, or warehousing facility is that cranes can handle corrosive or dangerous materials. Some of these materials could include hot metals, chemicals, and heavy loads. Overhead cranes can be used to lift and move these materials in extreme environments. Some cranes can be installed to assist workers in moving heavy objects in a controlled manner, reducing repetitive motion injuries and muscle strains.
Overhead cranes have significantly higher potential load capacity than other heavy lifting equipment. Overhead crane lifting capacities can exceed 400 tons. Going along with that, regardless of how high or low the load must be lifted, overhead cranes maintain the same capacity.
Overhead cranes can work up to 2-3 times faster than a group of workers or tow motors to lift and move material. Consider how an overhead crane can help a manufacturer, mill, or warehouse streamline processes and procedures by automating the lifting, maneuvering, and unloading of materials at their facility.
Performing maintenance on heavy machinery comes with the territory of working with heavy machinery. To some, it may be considered a disadvantage, and to others, it may be considered a benefit. Regardless of how you see it, maintenance is important.
Your overhead crane, like any other piece of equipment or machinery, will require regular maintenance to extend its life and keep it running efficiently. The following are some of the most common maintenance issues that come with overhead cranes.
Damage or degradation of wire rope is one of the most common problems with an overhead crane system. There are several common wire rope issues, including the following:
The life of wire rope can be influenced by a variety of operating conditions. Bending, stresses, loading conditions, load application speed, abrasion, corrosion, sling design, materials handled, environmental conditions, lubrication, and usage history will all influence how long wire rope can stay in service.
An overhead crane that is out of alignment can put significant strain on the crane system as a whole. The problem with a crane that isn&#;t tracking properly is that, over time, forces that weren&#;t accounted for in the overhead crane&#;s design and installation cause stresses to the runway beams themselves as well as the tie-backs or building support structures. These kinds of stresses can lead to:
A crane that isn&#;t tracking properly prematurely wears out the wheels, wheel bearings, and wheel flanges, as well as the motor drives and other equipment.
There are several issues with an overhead crane&#;s electric system that may necessitate service or future maintenance:
A hook is intended to hold a load in a specific and precise direction. When a load is not supported as intended by the hook, the weight compromises the hook&#;s internal integrity and increases the likelihood of bending, stretching, or cracking. If the load stretches out the hook&#;s throat opening, it may slip off the hook.
Regular inspections of hooks and other rigging hardware should be performed at the start of each shift to look for deformities or damage.
Overhead bridge cranes are the most common type of crane found on construction and work sites. They generally function while having two overhead bridge beams linked to the facility&#;s support system. They can either come in either a single or double configuration.
A monorail crane system is a stationary, overhead track on which trolleys travel to transport loads from one location in a facility to another. Because they improve production workflow and create a safe and secure work environment, monorail cranes are an ideal solution for linear, overhead material handling.
A mobile crane truck is a crane that is mounted on the chassis of a heavy, modified truck and can lift, lower, or move loaded materials horizontally and vertically. Truck cranes are commonly used in scrap yards and are outfitted with wire rope-suspended implements such as grapples, clamshells, crane hooks, and electric magnets.
Jib cranes resemble an upside-down letter &#;L.&#; They are typically floor mounted, either with their own dedicated support or to a building&#;s support beam. Jib cranes are typically equipped with an electric chain hoist and can be rotated manually. This allows them to perform numerous lifts over short distances with great efficiency.
These cranes are commonly found in production and assembly lines, factories, and mines.
Workstation cranes are similar to bridge cranes, but instead of relying on the building for support, they have their own floor-mounted supports. These cranes are extremely popular among garage mechanics and fabricators. They can be installed almost anywhere because they do not rely on the structural integrity of your building. They are also used in large manufacturing plants where a crane is not required to be accessible to the entire factory floor.
A gantry crane is a type of overhead crane with one or two girders supported by freestanding legs that move on wheels or along a track or rail system. When an overhead runway system is not feasible, gantry cranes are usually considered.
These are typically used outdoors or beneath an existing overhead bridge crane system. A gantry crane, unlike a bridge crane, does not need to be connected to a building&#;s support structure, eliminating the need for permanent runway beams and support columns. In some cases, this can result in significant material cost savings and a more cost-effective solution than a similarly specified bridge crane.
Larger gantry systems may run on an embedded rail or track in the ground, usually in a straight line in a dedicated work area. Smaller portable gantry systems are moved around a facility on castors or wheels for maintenance or light fabrication work.
Gantry cranes are classified into several types based on the type of supporting structure and application. The following are some of the most common types of gantry cranes.
One of the most common types of gantry cranes is the full-gantry overhead crane. It is made up of two supporting legs that move across fixed rails. The crane is usually used in a specific working area where vehicles can pass beneath it. This crane&#;s trolley moves within the main span, and the main beam has no overhang.
Typically, one leg of a semi-gantry crane runs along a surface rail, while the other runs along a runway system attached to a wall or other vertical structure. Depending on your construction site or requirements, you can establish the height difference between the two legs.
This type of gantry crane is portable and can be transported and assembled at various locations as needed. As a result, it offers more flexibility. However, because it is small, it can only handle light loads.
An adjustable gantry crane can be portable or stationary. It also has a variable height and span design. Depending on your load requirements, you can adjust the base width, height, and horizontal beam length.
This crane is made up of only one girder and rail. The trolley and hoist are usually under-hung. They run on the bridge&#;s underside. It is frequently a light- or medium-duty crane that is appropriate for areas with limited floor space and low headroom. It also offers low-cost lifting solutions.
This crane, on the other hand, is made up of two girder beams that form the bridge. It is typically made up of a top-running trolley and a hoist. Under-running designs, on the other hand, are quite common. It is intended for heavy-duty use.
Have you noticed that accidents or near misses in your facility often involve the use of a forklift? This could include damage to nearby structures, to the forklift itself, or even a failed lift.
Or maybe you are looking to upgrade your facility, expand your facility, or move into a new facility and you&#;re wondering if adding an overhead crane could improve your production processes?
When it comes to material handling there are two standard options for lifting and moving loads&#;overhead cranes and forklifts. While these two types of machines can move material through your facility, there are distinct differences between the two&#;especially when it comes to safety and efficiency.
Our goal with this article is to help you establish a base-level understanding of forklifts and overhead cranes and how they differ from one another. In this article, you&#;ll learn more about:
A forklift is a piece of material handling equipment driven and controlled by an operator from the ground level. It consists of a truck carriage&#;in which the operator sits&#;accompanied by two extending forks meant for sliding underneath and lifting pallets.
A standard straight mast forklift utilizes the extended forks to lift and lower palletized loads throughout a facility. In extension forklifts, the forks also extend to lift the load inwards and outwards.
Forklifts are most commonly found in warehouse and manufacturing environments where they can be used for lifting and stacking pallets on shelving. They are also commonly used for:
Forklifts, in comparison to most types of overhead cranes, are much smaller. In addition, since forklifts are mobile rather than stationary, they are much more maneuverable than overhead cranes. Forklifts can be driven between narrow aisles, adjust to changes in elevation, and carry materials between buildings.
The initial price of purchasing a forklift is significantly less in comparison to most overhead crane options. Because forklifts are more susceptible to damage and often require more maintenance than an overhead crane, it is very possible that the long-term cost of a forklift outweighs the initial cost of an overhead crane.
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The life expectancy of a forklift is only about 10-15 years in comparison to overhead cranes which can remain in service upwards of 65 years. Because forklifts have a significantly shorter life expectancy, it is more common for a business to lease a forklift as opposed to buying them outright.
The forks on a typical forklift extends upwards anywhere from 15-18 feet. As the forks extend upwards&#;or outwards in cases where you are using an extension forklift&#;the capacity decreases. The higher the lift takes the load, the less weight the forks can safely lift.
In addition, the higher you need to lift items in your facility, the bigger&#;and more expensive&#;the forklift will need to be in order to support the load weight.
Because forklifts are mobile machines&#;compared to overhead cranes that are stationary on a rail&#;it is much more common for them to get damaged, and cause damage, from driving around the facility and bumping into racking, walls, dock doors, or other items.
It&#;s not uncommon for forklift operators to mistakenly damage both the forklift and surrounding racking systems, especially in warehouse environments where there is high employee turnover and fast-paced operations.
Frequent damage to the forklifts&#;and racking systems&#;can lead to a significant monthly cost in repairs.
Forklift operation usually requires two people. One employee has to drive / operate the machine while the other helps rig the load and spot for the operator. In some cases, the operation of a forklift requires three employees.
Not only does this require more time and labor, but when an extra person is needed to operate the forklift, you have to pull an employee from somewhere else in the shop, resulting in downtime elsewhere.
On an overhead crane, a horizontal beam called the bridge travels up and down a runway on a track or rail. A trolley and hoist move side to side along the bridge to lift and lower loads throughout a rectangular bay. These types of cranes are used to increase safety and efficiency within a warehouse or other facility and have varying load limits ranging anywhere from .25 to 400 tons.
The basic way to identify an overhead crane is that it&#;s exactly what it sounds like, overhead&#;the beam moves horizontally up and down a runway above a facility or construction site along a fixed path.
Overhead cranes are usually permanent structures in facilities or construction sites where they are installed for repetitive workflow use.
It&#;s not uncommon for an overhead crane to last upwards of 65 years as opposed to the expected life of a forklift of about 10-15 years. This is because overhead cranes are custom built for the application at hand and less susceptible to damage.
Due to their mobility on the ground, it&#;s not uncommon for a forklift operator to mistakenly collide with other objects or storage racking. Overhead cranes, on the other hand, remain a stationary part of the building structure and simply maneuver over any structures / racking below&#;making it much less likely to be involved in any accidents.
A crane bay design that is free of obstacles, obstructions, and employees will help to maximize safety and prevent accidents.
A standard forklift requires 12-foot aisles to navigate through rows of storage to place and remove loads from racking, whereas overhead cranes can maneuver directly over the contents of a facility. Whether or not these aisles will be needed is something to consider when designing a warehouse pallet racking system.
Overhead cranes have a much higher potential lift capacity. Overhead crane capacities can run upwards of 400 tons whereas some of the largest forklifts will max out around 70 tons.
Unlike a forklift, an overhead crane maintains the same capacity regardless of how high or low the load is lifted.
In most cases, an overhead crane is built specifically for the facility and task at hand. Meaning, that many of the components and functions of the crane are custom designed to withstand rigors of repetitive lifts and the specific products and product flow in your facility. These specialized components support a longer service life, less breakdowns, and help keep production running.
A big part of custom designing an overhead crane is choosing which CMAA service class is best for your business. Crane service classifications allow you to select and build an overhead crane that is the most economical and safest design for your lifting application. Selecting the right duty cycle or service classification of an overhead crane helps ensure that the components of the overhead crane are durable enough to withstand the load and usage requirements.
The high initial price can often be the biggest hesitation in a customer&#;s decision to purchase an overhead crane. Compared to a forklift, there will be a larger upfront cost when buying an overhead crane.
However, using an overhead crane in place of forklifts in your facility typically leads to savings in the long run related to maintenance, safety, and repairs.
Overhead cranes&#;unless they are a smaller jib crane or workstation crane&#;are typically going to be much larger than a forklift. If an overhead crane is initially built into the facility, they are typically supported by the infrastructure of the building. However, if the crane is freestanding, it will require support columns to be placed throughout the facility which can take up a significant amount of space.
Since cranes are typically built into the structure of a facility&#;whether it be part of the initial design or a retrofit&#;it is a near permanent structure of the building. Because of the large size of overhead cranes and the way they are built into a building&#;s structure, it is very difficult and sometimes impossible to move a crane from one facility to another. In some cases, the overhead crane is even part of a building&#;s lease agreement.
The height of storage racking or other structures present within the crane bay will need to be shorter than in other parts of the facility, as the crane must be able to maneuver over anything present within the bay. This leads to slightly less storage capacity in your facility.
In rarer cases, an overhead crane can be incorporated into the racking system. It is more common, however, for the crane to be an entirely separate entity.
We asked our Crane Technical Specialists what some of the most common reasons are for a customer to upgrade from a forklift to an overhead crane.
The most common reason for switching from forklifts to an overhead crane is an accident, near miss, or injury. As mentioned above, overhead cranes tend to be safer than forklifts and yield fewer accidents.
It&#;s critical to maintain a safe environment for your employees. It&#;s also important to note that one claim to a workman&#;s compensation can completely outweigh the cost of any crane purchase&#;making it a worthwhile investment.
Something has changed in your manufacturing or production processes. That change can be related to a number of different things, including:
Any of these changes can create additional wear and tear on forklifts. Making more frequent or heavier lifts can put a strain on your equipment if the demands of the new process exceed the capabilities that they were originally intended for.
Over time, this can lead to premature wear or even failure of your forklift equipment. Costs related to service calls to repair or replace individual components can add up and eventually exceed the cost of a new piece of equipment, or an initial investment into a crane system.
Overhead cranes can be completely customized to fit any facility and, unlike a forklift, are designed for the specific application at hand. This leads to more efficient workflows and longer-lasting material handling equipment.
Overhead cranes have a longer life expectancy than forklifts and, in some cases, a single overhead crane could replace multiple forklifts.
Forklifts are also associated with frequent repairs, maintenance, and damage to other objects in the facility. In comparison to overhead cranes, forklifts have extra costs associated with:
So, while an overhead crane may be a larger investment upfront, if utilized correctly, it can save a business money in the long run.
Depending on the set-up of your facility, it may make more sense to install an overhead crane instead of using a forklift. For example, in a facility where loads of over 200 tons need to be regularly lifted, an overhead crane will be necessary.
However, in cases where the material handling equipment is being retrofitted to the facility, it may be easier and quicker to purchase a forklift and begin using it right away. It all depends on the immediate needs of your facility.
Of course, there are also many situations where both overhead cranes and forklifts are successfully used together. In order for any sales staff to determine a recommendation for your facility, it&#;s important that they thoroughly understand your facility&#;s workflow and processes.
A short article cannot completely inform a decision on whether to invest in a forklifts or an overhead crane. However, we hope that this article helped you to form a base-level understanding of what forklifts and overhead cranes are and the differences between the two.
Forklifts have a lower initial price and their size and mobility makes it much easier for them to quickly maneuver throughout a facility and between facilities. They also have a short life expectancy, require more labor, are susceptible to damage, and diminish in capacity as the lift height increases.
Overhead cranes have a much longer life expectancy, are effective in minimizing accidents, save aisle space, and have a much higher potential capacity. On the flip side, they have a much higher initial price, are very large and semi-permanent, and must be able to maneuver over anything present in the crane bay.
Some of the most common reasons our crane specialists recommend a switch from forklifts to an overhead crane are:
If you are interested in determining what the best fit for your facility is or want to schedule a consultation, contact us to speak with a specialist.
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