By Marc-André Martineau
Manager and partner at Premium Industrial Group
In short…
No, an overhead crane cannot be operated above its rated capacity under normal circumstances. However, there is a provision in the standards that allows such lifting to be carried out occasionally and under very strict conditions.
You need to lift a machine or part that is heavier than the capacity of your overhead cranes, once a year for maintenance, for example. Can you still do it? And if you are planning a new overhead crane, is it better to buy a larger one just for that one lift, or to choose equipment suited to your day-to-day operations?
A poorly controlled overload lift can cause major damage or serious injuries. Fortunately, the standard provides a clear framework. In this article, we look at what CSA B167-26 allows, the 8 conditions for a planned engineered lift, and how to choose the right capacity when an exceptional lift is added to your regular needs.
Let’s start by checking the main question: is it permitted to lift more than the rated capacity of the lifting device?
Is it permitted to lift a load above an overhead crane's rated capacity?
Under normal circumstances, it is not permitted to lift a load with an overhead crane if its weight exceeds the crane's rated capacity. However, CSA B167-26 includes a provision known as a planned engineered lift, which allows this type of operation in certain situations.
CSA B167-26 refers to ASME B30, which sets out the conditions for this type of lift. These are always special operations that must follow specific rules. Let's take a closer look.
What conditions apply to a planned engineered lift?
First, this type of operation must be treated as occasional and special, since it involves additional risks compared to a regular lift. When a planned engineered lift is required, the following conditions must be met:
| Condition | Requirement |
|---|---|
| 1. Maximum capacity | No more than 125% of rated capacity (e.g., 6,250 kg on a 5,000 kg overhead crane) |
| 2. Frequency | No more than 2 planned engineered lifts in any 12-month period |
| 3. Lift plan | Prepared by a qualified person and approved by an engineer, in collaboration with the manufacturer. The plan includes notifying everyone present in the area. |
| 4. Crane history | Written summary of previous planned engineered lifts, structural repairs and major modifications |
| 5. Equipment inspection | By a qualified person before the lift, then again after. Any deficiency must be corrected before the lift and before the crane is returned to service. |
| 6. Supporting structure | Runway examined, inspected and approved by a qualified person. Calculations account for any deterioration or damage. |
| 7. Brake test | Short-distance test to confirm that the brake holds the load |
| 8. Record | Calculations, inspections and distances travelled entered in the crane logbook for each planned engineered lift |
Beyond 125% or 2 lifts in 12 months, the design of the crane's structural, mechanical and electrical components must be verified by appropriate calculations for the load to be lifted.
Most of these conditions must be met before the load even leaves the ground, which requires significant planning.
Is it better to buy a higher-capacity overhead crane?
Not necessarily. A higher-capacity overhead crane costs more, but more importantly, it may be poorly suited to your day-to-day operations: its hoisting and travel speeds may not match your production needs. It is also heavier, which increases the loads on the runway and the building structure.
On the other hand, if your heavy lifts are more frequent than expected, other options are available: a second piece of equipment, a rigging or machinery moving contractor, or a crane rental.
To find the right solution, ask yourself these questions:
- What are my day-to-day lifting needs? To define them, read Need an overhead crane? Where to start
- What is the maximum weight of my occasional lifts? Does it stay below 125% of the capacity being considered?
- How often do I need to make these lifts? More than 2 times in 12 months?
- Can my organization apply the 8 conditions for a planned engineered lift every time one is needed?
Let's look at two concrete examples.
Scenario 1: An exceptional lift within the limits
Day to day, you handle parts weighing up to 5 tonnes. Once a year, you need to lift a 6-tonne machine for maintenance. With a 5-tonne overhead crane, this lift represents 120% of rated capacity, once in 12 months: both limits are met. If your organization can apply the other 6 conditions, a 5-tonne overhead crane may be a smart choice. However, if these conditions affect your productivity too much, the options in Scenario 2 are worth considering.
Scenario 2: An exceptional lift beyond the limits
Same situation, but the machine weighs 7.5 tonnes and must be lifted every quarter. That is 150% of rated capacity, 4 times a year: both limits are exceeded. A planned engineered lift no longer applies, and the crane's design must be verified by calculations for this load. Instead, compare the cost of a 7.5-tonne overhead crane, including the effect of its speeds on your production, with the cost of an outside service such as a crane rental.
The same analysis applies to existing installations.
So, what's the best decision?
Under normal circumstances, an overhead crane's rated capacity must never be exceeded. The standard does, however, allow a planned engineered lift, provided it does not exceed 125% of rated capacity, is limited to 2 lifts in any 12-month period, and meets all 8 required conditions.
The real decision is made upfront: an overhead crane suited to your daily operations, with occasional planned engineered lifts, or a solution that can handle the heavy load without restrictions. It all depends on the weight to be lifted, how often, and your organization's ability to apply the procedure.
Our specialists can assess your needs, whether for a new project or for your existing installations. For an overhead crane already in place, we can also perform the inspections required before and after a planned engineered lift.
