Installing an overhead crane is already a monumental task, but it becomes exponentially more complex when integrating it into an existing facility. Unlike new constructions that allow for a blank canvas approach, existing buildings come with their own unique set of challenges—obstacles that demand thorough planning and customized solutions. This blog serves as your guide to the various considerations and best practices for implementing overhead cranes in existing structures without disrupting ongoing operations.
Production Constraints: Timing is Everything
When asking any crane manufacturer about the most crucial factor in installing an crane in an existing building, the unanimous response would be "production timelines." Aligning your production schedules with the installation window is imperative. The optimum scenario is to carry out the installation during a pre-planned production downtime, ensuring zero hindrance to ongoing operations and safety for both the installation team and employees.
Site Accessibility: Laying the Groundwork
Prior to starting any installation, experts will conduct a comprehensive job site overview. They will evaluate critical aspects like roofing load capacities, structural support beams, existing runway structures, and foundational aspects.
Moreover, accessibility for heavy equipment and trucks carrying the crane components must be carefully planned. It's not just about where the crane will go; it's also about how it gets there without causing disruptions.
Structural Surveys: The Unsung Hero
Before any heavy lifting begins, structural or third-party civil engineers often conduct road surveys. These experts evaluate the suitability and safety of your existing structures, enabling smoother installations and future operations.
Delivery Timeframes: Meeting Deadlines
One often-overlooked factor is the delivery timing of the crane components. Sourcing elements like end trucks and trolleys must align with your installation schedules. While expedited deliveries are sometimes possible, they can incur additional costs that will be billed to the client.
Equipment Needs: Every Job is Unique
Although installers usually come with their machinery, installations in existing buildings may require specialized equipment, including customers' welding gear for cost-saving. It's not just the machinery used for the installation that's important; it's also where these machines will be stored when not in use. Make sure to allocate sufficient staging areas for equipment, such as empty parking lots or open spaces within the facility.
Safety Protocols: A Non-Negotiable Requirement
Safety is paramount in any installation process. Contractors and vendors should undergo site-specific safety training, which can include drug tests, background checks, and certifications for operating specialized equipment like manlifts or forklifts.
The Load Test: Verifying Operational Safety
Once the crane is up and installed, it must undergo load testing to confirm its operational efficacy. Various materials—ranging from water weight bags to steel—are used to test the crane's highest operation levels and trip settings, ensuring complete safety and compliance with regulations.
In Conclusion: It Takes a Village
Successfully installing an overhead crane in an existing structure requires a concerted effort from multiple parties: from operational departments and production teams to project managers, equipment suppliers, third-party engineers, and installation technicians. Experience and reputation are crucial here; make sure you're working with partners who have a track record of successful installations in complex, existing structures.
Incorporate these considerations and steps into your installation strategy for a smoother, more efficient, and safer implementation of your overhead crane system. Armed with this knowledge, you can make informed decisions that will impact not just the installation phase but the long-term productivity and safety of your facility.
