Remote Control Safety Requirements for overhead cranes and Hoists

Remote controls installed on overhead cranes and monorail hoists are a great productivity tool as well as offering the operator additional safety by allowing them to handle loads away from the traveling crane. But the remote operation of cranes introduces some new safety challenges, as well as safety warning devise requirements.

It’s what you can’t see that will hurt you with remote operating cranes and hoists. Operators of remotely operated equipment must be properly trained in the safe operation of the crane as well as the proper operation and potential hazards of remote-operated cranes. Operators are able to potentially operate the crane in areas where they do not have a line of sight of the moving equipment or load. This can definitely pose a safety issue for other workers, equipment and the load itself. Therefore, operators of remotely controlled cranes must be properly trained to have 100% visual contact with both the equipment and the load. It is also imperative that the operator has 100% visual on where the load is placed in order to not lower the load onto an unseen object or fellow worker. Where there is not a clear line of sight, the operator must reposition themselves to always have 100% visual sight on the equipment and load. In many cases, the travel of the bridge or hoist trolley must be paused while the operator visually catches up to where the load will be transported. While travel is paused it is important that the suspended load is not parked over pedestrian walkways or over work positions and equipment.

All remote control operated cranes and hoists must be furnished with a warning devise that operates during the travel motion of the hoist, crane, and trolley motions. This requirement applies to cranes, jibs, monorail hoists, and stationary hoists. The warning device can be a visible strobe or audible device such as a buzzer or siren. Intermittent horns to warn pedestrians can also be employed, however, they are not a substitute for the continuous audible or visual warning device. The main thing to consider is that the warning device must properly get the attention to the moving load.

Having a warning device is not enough, as workers operating the crane as well as those exposed to the remote-controlled crane must be trained in safe practices regarding working around remotely operated crane systems.

If you would like to learn more about remote-operated cranes or hoists, contact us

A good crane inspection program using a trained and qualified inspector will identify problems on the crane that relate to safety as well as those that require repairs that will lead to costly unplanned downtime.
Beyond ensuring the safety of your employees that operate the crane and work in the vicinity, the primary objective of routine crane inspections is to lower your cost of unplanned breakdowns. When you defer or eliminate crane and hoist inspections; the equipment will continue to wear, and parts or components that will cause downtime will not be identified. One unplanned breakdown could easily cost many years of rigorous inspections on all your equipment.
For example: If you defer proper and routine crane inspections and the hoist wire rope fails during a shift you not only have the potential for a catastrophic personnel accident but that crane is put out of service until a new wire rope can be delivered and then installed. The part will need to be express shipped and the labor to install done on overtime to get your equipment running sooner. What if the part is days or weeks off due to supply issues? What was the real cost of the downtime and the loss of production as well as the impact on your own customer that may now receive a late delivery? And this example is just a very common hoist failure point since a wire rope typically has a life of around two years. The inspection likely would have identified the rope wear, allowing you to order the part for efficient replacement without impact on safety, production, and minimizing cost impacts.
In a much more severe case, you might have a very custom or special crane parts such as a hoist motor, crane wheel, or gearbox that could shut you down for 10 weeks or more. The average cost of a crane inspection for a standard crane is a couple of hundred dollars.
As can be easily understood, this minor expense done four or more times a year on your production equipment could easily be the best investment you make since an unplanned outage could cost many tens or hundreds of thousands.

1. Site introduction to your appointed contact and equipment operators as applicable
2. A site safety check and securing the work area as required
3. Operational check to determine that the hoist and crane controls and limits are operating properly
4. Safety lock-out of electrical systems to the crane during portions of the inspection
5. Using a personnel lift to allow hands-on inspection of the mechanical, structural and electrical systems of the crane and hoist
6. Lubrication and adjustment services depending on the inspection program
7. Inspection of the runway structure and electrification system to identify observable problems
8. Full written inspection report using our proprietary software and inspection system which includes images of found deficiencies
9. Post-inspection review with our site contact to communicate areas of concern.
   Yuantai Group members are experts in crane and hoist inspection and repair. Give your local branch a call and we will develop a program that reduces the risk of production loss and improves the safety of your people.

The choice of girder type in an overhead crane should be based upon application and building envelope considerations rather than price. Even though single girder cranes are generally less expensive than double girder cranes, each is the best tool for their designed application.

SINGLE GIRDER CRANES
Single girder cranes are great for light to moderate duty applications for normal production or maintenance applications. Single Girder Cranes have one girder attached to end trucks of the crane with the end trucks running on runway rail that runs the desired length of the building. With single girder cranes, the hoist is under running with the cross travel trolley generally running on the lower flange of the bridge girder. Single girder cranes are generally limited to 20 ton capacity with the bridge girder construction of wide flange beams under 65’ span and fabricated single box girder over 65’ span. The overall span is limited to about 130’.
Single girder cranes typically require less space over the top of the runway beam to the lowest obstruction of the building since the hoist in below the girder. In many existing buildings, the runways have been installed at a high position within the building limiting available clearance for use of only single girder cranes.
A single girder crane should suffice if the duty requirement is light to heavy and the application is simple production or maintenance.

DOUBLE GIRDER CRANE
Double Girder Cranes are great for larger capacities, higher duty cycles, and longer bridge spans. Double girder cranes have two girders attached to end trucks of the crane with the end trucks running on runway rail that runs the desired length of the building. With double girder cranes, the hoist is top running on rails installed on the tops of the girders with the hoist spanning the gage of the two girders. Double girder cranes are generally used for heavier loads, longer bridge spans, and for improved hook height since the hoisting machinery is on top of the girders rather than below. The capacity of double girder crane can be over 100 tons and with spans reaching well over 150’.
Double girder cranes typically require more space over the top of the runway beam to the lowest obstruction of the building since the hoisting machinery runs above the bridge girder. Therefore, where a double girder crane is desired there must be 4’ or more of clearance over the runway to the lowest obstruction. This over the runway clearance requirement increases with the capacity of the crane unless the hoist is dropped in between the girders, which is generally costly.
Many special applications such as heavy production, coil handling, and turning of loads with dual hoists are best served through the use of double girder cranes.

Yuantai Crane has application professionals in each of our offices that can assist you in determining the correct crane and hoist type for your application. We design, fabricate, and install single and double girder cranes out of our regional fabrication facilities that ensure efficient delivery and high-quality control. When ready to specify your next crane, please contact us!

About crane accidents will happen every year.
It’s no secret that working with big machinery can be dangerous. That’s why safety is always a priority.
Preventive methods should be taken to ensure safety while using an overhead. Here’s an overhead crane maintenance checklist to follow:

When To maintenance Overhead Crane ?
While designated personnel should perform required maintenance and repairs, the crane operator should conduct daily inspections before and after each use.
According to Yuantai, a safety check should be done at the beginning of each shift.
A well-trained and qualified crane operator should ensure all equipment is ready for use.
A daily inspection chart should be signed off each day by the operator to ensure the safety inspection is complete.
What The Checklist Includes
An overhead crane maintenance checklist includes three different checkouts:

Area Check
This check is to ensure the area around the crane is clear. Some of these activities include:
Know the location of the crane disconnect switch.
Make sure there are no warning signs present
Check to make sure workers are not working near the area
Look ahead to verify there is nothing around the area where the load will be moved.
Check to make sure the below-the-hook devices are designed for the crane in use and will safely be able to lift the load.
Make sure that the load capacity is equal to or less than the capacity of the crane.

Preliminary Check
Once the area check has been performed, the operator can begin the preliminary check of the equipment. This should be done before he or she touches any controls.
Check the electric systems, bridge, runway, trolley, and hoist to make sure there are no loose, broken, or damaged parts.
Make sure the wire rope is seated in the drums grooves properly.
Ensure that the open power source is secure and there is nothing close.
Check the strain reliefs or brushings to make sure that no wires are pulled.
Make sure there is no damage to the pushbutton pendant.

Equipment Safety Check
After the preliminary check is complete, the crane operator must perform a safety check of the crane itself to make sure it is in working order. This is to ensure there is no potential for malfunction.
Several different categories need to be signed off when checking the equipment.
Check all powered systems. Including, making sure the power button is not sticky, the hoist hook rises, and the upper limit switch is functioning properly.
Make sure all hooks are in working condition. There should be no more than 10% wear on any part of the hook.Ensure there is no damage or cracks on the bottom block assembly. The sheaves should be able to rotate freely and smoothly.
Make sure there are no broken wires on the wire rope and load chain. There should be no kinks, cuts, or thermal damage to any ropes or chains.

Safety Comes First
Taking the time to make sure the crane is in safe operating status will prevent accidents on the job site.
Remember, this is not a comprehensive safety checklist. For any questions or needs, you may have, feel free to contact us.
We’re here to make sure any project you have will be successful.

MOBILE CRANES
Knowing how mobile cranes work can help you determine if one of these machines is the right fit for your specific job requirements. At Yuantai Crane, we understand how important it is to have the right equipment for the job. That is why we offer a wide range of mobile crane rentals for a selection of different industries.

What is a Mobile Crane?
Mobile cranes are designed to use a collection of simple machines in order to both raise and lower objects, as well as to move them horizontally. This type of crane can be easily moved from one location to the next, making it a cost-effective rental option for many construction companies. Mobile cranes can be used to lift heavy objects and move them short distances, as well as to help construct larger tower cranes.
How Mobile Cranes Work?
Through a combination of simple machines, mobile cranes are able to gain a mechanical advantage to lift heavy objects. The mast (the tall vertical part of a crane) is supported by a large, heavy base, which helps offset the weight the crane holds at higher heights. At the top of the mast, there is a slewing unit, consisting of a gear and motor, which allows the crane to rotate. The slewing unit also contains the jib (a long horizontal working arm) that uses a trolley to help carry the load, as well as a shorter machinery arm that contains the crane’s motor, along with large concrete counter weights to help balance the load. In addition to these simple machines, mobile cranes also utilize a pulley system, which helps the crane lift heavier loads with minimal force.
If you would like to learn more about how mobile cranes work, please contact Yuantai Crane at the location nearest you or by filling out a contact form on our website.

As we know, an overhead crane, at a certain time, will wear down. Instead of buying a new crane, there is the option to repair your old one. A lot of this can be related to an automobile experience. We will repair your dings, replace your wheels, and put in new wiring.

The components of an overhead crane are very small. You have two end trucks that have a motor on both of them, then you have a beam that goes across and you have wiring systems that runs it to a host and a control panel. As part of our crane refurbishing process at Yuantai Group, we bring the crane to our facility, strip it down, sand blast, repaint, rewire, repair the wheels, and reassemble on site.

The biggest expense to an overhead crane is its beam. If the beam is salvageable, all you may have to replace are the wheels and wires. You could be investing $3,000 versus a $12,000 investment for a new crane. With crane refurbishing, you are repairing the pieces and parts that are worn down. For example, we refurbished cranes for a galvanizing plant. The galvanizing plant uses chemicals that eats away steel, so we sand blasted, repainted and performed repairs to their existing cranes and we saved them about $40,000 because they didn’t have to purchase six new cranes.