By Marc-André Martineau
Manager and partner at Premium Industrial Group
When demands increase and production has to keep pace, it sometimes becomes necessary to replace or add new equipment to meet requirements. This includes overhead cranes. Premium Industrial Group has helped a number of companies safely add overhead cranes ot existing structures.
In this context, a question frequently comes up: ”Is it safe to add an overhead crane of the same capacity to my runway track? “ For example, a customer might think :”I have a track equipped with a ten-ton overhead crane; surely I can add a second ten-ton overhead crane? But is it really that simple? Are there any risks involved in increasing the number of lifting equipment on the same track? For growing companies, these questions are crucial.
In this article, we will outline the three essential checks to ensure the safe addition of an overhead crane. It is important to note that these same checks also apply when replacing an overhead crane. By following these steps, you can move forward with confidence in your project and select the right experts to support you.
But to start, let’s talk about the capacity of the structure.
Why check the structure’s capacity before adding an overhead crane?
If the new overhead crane has a higher capacity than the existing one, the structure must be able to support this additional load. Unless this was planned from the design stage, only an engineer can confirm that the structure is strong enough, or determine the reinforcements required.
What if the capacity is equal or lower? Verification by an engineer is still necessary, because the owner must be able to demonstrate that the structure is compliant. Most structures can accommodate another overhead crane, but some require a minimum distance between the two to avoid concentrating the load in one spot. If such a restriction applies, there are 3 solutions for dealing with a capacity restriction on a crane runway.
Some may think: "The two cranes will never work side by side; each one will stay at its own end." But accidents often result from an unexpected event that could have been anticipated. "Never" can quickly become "once," with serious consequences for people and equipment.
Let's now look at the 3 elements to verify before adding an overhead crane, starting with capacity.
1 – How to check structural capacity before adding an overhead crane
Step 1 : Consult plans or perform an engineering analysis
First, check the engineering drawings, which show the structure’s capacity. If these documents cannot be found, you may need to contact the company that carried out the work. Where no plans are available, an engineering analysis will determine the capacity and criteria required for the addition.
Step 2 : Analyse technical specifications
Example of a table showing overhead crane specifications on an engineering drawing
If the capacity of the new equipment is equal to or inferior to the structure’s, it does not guarantee it can be added without restrictions. Check the overhead crane’s specifications: sometimes, a table indicates whether the structure can accommodate another piece of equipment, while specifying the spacing to be respected between the overhead cranes (see the following table). This distance must be ensured by installing devices to maintain a safe distance, such as mechanical or electronic systems.
2 – How to check the conductor bars system before adding an overhead crane
The electrical system for the runway tracks is designed for the current installation. Adding another overhead crane could exceed this electrical capacity. This could lead to problems such as motor overheating. It is therefore important to check that the conductor bars have the necessary capacity.
Will voltage losses still be acceptable with the addition of an overhead crane?
Any power supply can lose a little power when feeding equipment. But by adding another crane, this may no longer be acceptable. You could then add a new power point, or even install a parallel system.
3 – How to check the disconnect switch before adding an overhead crane
Each overhead crane is fitted with a circuit breaker to cut off power in the event of a problem. However, it was designed for a single unit. If another is added, the circuit breaker may no longer be adequate. You may need to adjust the fuse and cable ratings, which only a master electrician is authorized to do.
To make a success of your overhead crane addition project
Adding lifting equipment to the same track is not as simple as it sounds. That’s why we recommend calling in the professionals.
Who can help you?
Here is a table of experts who can help you check the different elements to consider :
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Verification element
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Professional |
Overhead crane supplier assistance
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|
Capacity
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Contractor, engineer or outside firm
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Provide capacity data and modification costs if necessary.
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|
Conductor bar ratings
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Overhead crane supplier
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Check and evaluate for adequate electrical capacity and voltage losses. Provide modification cost.
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|
Disconnect switch
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Master electrician
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Provide an electrical load estimate for the power supply isolator.
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Do you have an overhead crane project in mind?
Adding another crane can be complex, but you’re not alone! If you have a project of this type, Premium Industrial Group is here to serve you to ensure the safety of your installation. Contact us for a free consultation by filling out the quote form at the bottom of the page.
If you would like to know more about runway track reinforcement, please visit the following page of our partner Premium Industrial Structures : https://structuresindustriellespremium.com/en/services/crane-runway-reinforcement// .
Frequently asked questions about adding an overhead crane
Can I add an overhead crane of the same capacity as the existing one without any verification?
No. Even at equal or lower capacity, the structure may have been designed for a single crane, or for several cranes with a minimum spacing between them. You also need to confirm that the conductor bars and the mainline disconnect can power an additional crane. Only an engineer can confirm the structure's capacity.
Who is responsible for having the structure verified before adding an overhead crane?
The owner. CSA B167 considers the crane runway an integral part of the building, subject to the building code. The owner must therefore obtain the necessary approvals. Section 51 of Quebec's Act respecting occupational health and safety also requires employers to protect workers from risks related to equipment and buildings.
What if I no longer have the structural drawings?
Start by contacting the company that built the structure or installed the crane, as it may have kept the drawings. Otherwise, an engineering analysis of the existing structure will determine its capacity and the conditions required to add an overhead crane.
What if the engineer requires a minimum distance between overhead cranes?
A spacing restriction does not necessarily stop the project. Options include an electrical or mechanical anti-collision system, a shared load management system, or structural reinforcement. Each solution has its own costs and limitations depending on your operations. Learn more about the 3 solutions for dealing with a capacity restriction on a crane runway.
Is an RBQ licence required to reinforce a crane runway?
Yes. Reinforcing a crane runway is a modification to the building structure. The work must follow an engineer's requirements and be performed by a company holding the appropriate RBQ licence. For more details, read "Do you need an RBQ licence to install an overhead crane in Quebec?".
Do the same verifications apply when replacing an overhead crane?
Yes. A new crane does not necessarily have the same weight, wheel loads or power consumption as the old one. The structural capacity, the conductor bar rating and the mainline disconnect must all be validated, exactly as for an addition.
