In large construction and fabrication spaces, overhead/bridge cranes do the heavy lifting—literally. This practical guide takes you behind the scenes of a mega-project crane install. We’ll cover hoist and trolley setup—all explained in clear, real-world language.
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.
They’re the backbone of heavy shops and assembly lines, from beam handling to turbine assembly.
Why they matter:
Controlled moves for large, expensive equipment.
Huge efficiency gains.
Lower risk during rigging, lifting, and transport inside facilities.
Support for pipelines, structural steel, and big machinery installs.
System Components We’re Installing
Runways & rails: runway girders with crane rail and clips.
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: power supply, festoon or conductor bars.
Stops, bumpers & safety: end stops, buffers, travel limits.
Depending on capacity and span, the crane might be a single-girder 10-ton unit or a massive double-girder 100-ton system. The choreography is similar, but the scale, lift plans, and checks grow with the tonnage.
Pre-Install Prep
Good installs start on paper. Key steps:
Drawings & submittals: Freeze the GA and verify reactions with the structural team.
Permits/JSAs: Permit-to-work, hot work, working at height, rigging plans.
Runway verification: Check baseplates, grout pads, and anchor torque.
Power readiness: Confirm conductor bars or festoon supports, cable trays, and isolation points.
Staging & laydown: Lay out slings, shackles, spreader bars, and chokers per rigging plan.
People & roles: Brief everyone on radio calls and stop-work authority.
Tiny survey errors balloon into hours of rework. Spend time here.
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: Use feeler gauges on splice bars, torque rail clips.
End stops & buffers: Install and torque per spec.
Conductor system: Mount conductor bars or festoon track parallel to the rail.
Log final numbers on the ITP sheet. Misalignment shows up as crab angle and hot gearboxes—don’t accept it.
Lifting the Bridge
Rigging plan: Choose spreader bars to keep slings clear of electricals. Taglines for swing control.
Sequence:
Lift end trucks to runway level and set temporarily on blocks.
Rig the bridge girder(s) and make the main lift.
Land the bridge on the end trucks and pin/bolt per GA.
Verify camber and bridge square.
Prior to trolley install, bump-test long-travel motors with temporary power (under permit): confirm limit switch wiring. Re-apply LOTO once checks pass.
The Heart of the Lift
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.
Grinding noises mean something’s off—stop and inspect. Fix the mechanics first.
Power with Discipline
Power supply: Conductor pool construction near me bars with collectors or a festoon system.
Drive setup: Program VFDs for soft starts, decel ramps, and brake timing.
Interlocks & safety: E-stops, limit switches, anti-collision (if multiple cranes), horn, beacon.
Cable management: Secure junction boxes; label everything for maintenance.
Commissioning crews love clean labeling and clear folders. Photos of terminations help later troubleshooting.
ITP, Checklists, and Sign-Off
Inspection Test Plan (ITP): Hold/witness points for rail alignment, torque, electrical polarity, limit settings.
Torque logs: Record wrench serials and values.
Level & gauge reports: Attach survey prints.
Motor rotation & phasing: Document bump tests.
Functional tests: Anti-collisions and zone interlocks.
A tidy databook speeds client acceptance.
Load Testing & Commissioning
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: Limit switches trigger reliably; overload trips; horn/beacon function.
Training & handover: Operator basics, daily pre-use checks, rigging do’s & don’ts.
Only after these pass do you hand over the keys.
Everyday Heavy Lifting
Construction & steel erection: placing beams, trusses, and precast.
Oil & gas & power: generator and turbine assembly.
Steel mills & foundries: large part transfer.
Warehousing & logistics: bulk material moves with minimal floor traffic.
Floor stays clear, production keeps flowing, and precision goes up.
Do It Safe or Don’t Do It
Rigging discipline: rated slings & shackles, correct angles, spreader bars for load geometry.
Lockout/Tagout: clear isolation points for electrical work.
Fall protection & edges: scissor lifts and manlifts inspected.
Runway integrity: no cracked welds, correct bolt grades, proper grout.
Duty class selection: match crane class to cycles and loads.
A perfect lift is the one nobody notices because nothing went wrong.
Keep It Rolling
Crab angle/drift: verify end-truck wheel diameters and gearbox mounts.
Hot gearboxes: adjust brake air gap and reduce VFD decel.
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? Choose per site constraints.
Single vs. double girder? Singles are lighter and cheaper; doubles carry heavier loads and give more hook height.
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.
What You’ll Take Away
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.
Need a field bundle with JSA templates, rigging calculators, and commissioning sheets?
Download your pro bundle and cut hours from setup while boosting safety and QA/QC. Bookmark this guide and share it with your crew.
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