When loads get too big for forklifts and too precise for rough handling, teams turn to overhead cranes. This practical guide takes you behind the scenes of a mega-project crane install. You’ll see 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, with a trolley that travels left-right along the bridge and a hoist that lifts the load. The system delivers three axes of motion: long-travel along the runway.
You’ll find them in fabrication bays, hensel phelps construction steel plants, power stations, oil & gas shops, precast yards, and logistics hubs.
Why they matter:
Safe handling of very heavy, unwieldy loads.
Less manual handling, fewer delays.
Lower risk during rigging, lifting, and transport inside facilities.
High throughput with fewer ground obstructions.
System Components We’re Installing
Runways & rails: continuous beams and rail caps.
End trucks: wheel assemblies that ride the rail.
Bridge girder(s): single- or double-girder configuration.
Trolley & hoist: cross-travel carriage with lifting unit.
Electrics & controls: VFDs, radio remote, pendant.
Stops, bumpers & safety: end stops, buffers, travel limits.
Based on design loads and bay geometry, you may be dealing with modest shop lifts or major industrial picks. The installation flow stays similar, with heavier rigs demanding extra controls and sign-offs.
Before the First Bolt
Good installs start on paper. 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: Mark crane components with ID tags.
People & roles: Appoint a lift director, rigger, signaler, and electrical lead.
Tiny survey errors balloon into hours of rework. Measure twice, lift once.
Getting the Path Right
If rails are off, nothing else will run true. 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.
Lifting the Bridge
Rigging plan: Softeners protect painted flanges. Dedicated signaler on radio.
Sequence:
Install end trucks at staging height to simplify bridge pick.
Rig the bridge girder(s) and make the main lift.
Use drift pins to align flange holes; torque to spec.
Measure diagonal distances to confirm squareness.
Before anyone celebrates, 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: Check overload/SLI and emergency stop.
Cross-travel adjustment: Align trolley rails on a double-girder.
Pendant/remote: Install pendant festoon or pair radio receiver; function-test deadman and two-step speed controls.
A smooth trolley with a quiet hoist is a sign of good alignment. Don’t mask issues with higher VFD ramps.
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: Secure junction boxes; label everything for maintenance.
Future you will too. Photos of terminations help later troubleshooting.
QA/QC & Documentation
Inspection Test Plan (ITP): Hold/witness points for rail alignment, torque, electrical polarity, limit settings.
Torque logs: Re-check after 24 hours if required.
Level & gauge reports: Attach survey prints.
Motor rotation & phasing: Confirm brake lift timing.
Functional tests: Anti-collisions and zone interlocks.
QA/QC is not paperwork—it’s your warranty in a binder.
Ready for Work
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: Maintenance intervals for rope, brakes, and gearboxes.
When the logbook is clean, the crane is officially in service.
Everyday Heavy Lifting
Construction & steel erection: handling long members safely.
Oil & gas & power: moving heavy pumps, skids, and pipe spools.
Steel mills & foundries: large part transfer.
Warehousing & logistics: high throughput lanes.
Floor stays clear, production keeps flowing, and precision goes up.
Controls that Matter
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: regular runway inspection plan.
Duty class selection: match crane class to cycles and loads.
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: misalignment or over-tight brakes.
Rope drum spooling: dress rope and reset lower limit.
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.
Quick Answers
Overhead vs. gantry? Bridge cranes ride fixed runways; gantries walk on the floor.
Single vs. double girder? Span and duty class usually decide.
How long does install take? Scope, bay readiness, and tonnage rule the schedule.
What’s the duty class? FEM/ISO or CMAA classes define cycles and service—don’t guess; size it right.
Why Watch/Read This
Students and pros alike get a front-row seat to precision rigging, structural alignment, and commissioning. You’ll see how small alignment wins become big reliability wins.
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. Save it to your site tablet for quick reference.
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