Exploring Factors Influencing Overhead Crane Inspection Cost

Overhead cranes play an indispensable role in many industries. However, the breakdown or failure of this equipment could lead to expensive repairs as well as downtime in production.

Prioritizing safety inspections and maintenance can save businesses a considerable sum by enabling prior detection of potential dangers and allowing for the proactive implementation of preventive maintenance measures. They help minimize downtime, thus cutting production expenses. 

Hence, understanding why overhead crane inspections are necessary, how frequently they should occur, and determining the associated costs is crucial. In this blog post, we will delve into these topics and explore the various factors that impact the cost involved in overhead crane inspections.

Why is There a Need for Overhead Crane Inspection?

Inspection is critical as crane accidents can result in serious personal injuries or even deaths due to the proximity to people while moving loads. Frequent inspections help avoid these tragedies by making sure all essential components are working as intended, including hoist, trolley, bridge, runway, end trucks, etc.

An effective crane inspection program begins with trained inspectors taking ample time to thoroughly examine all components that could contribute to an unplanned breakdown or compromise safety in the future. Furthermore, OSHA mandates frequent and periodic inspections designed to catch problems before they become an immediate safety or production issue.

How Often a Crane Should Get Inspected?

Crane inspections are essential for safety and vary depending on how often the equipment is used. The common types of inspections are as follows. 

• First, a new or altered crane undergoes an initial inspection, which includes a documented visual check and a load test to confirm it meets safety standards
• Next, come functional test inspections. These are quick, daily checks performed before every shift to verify the crane functions properly and that all components operate as expected
• The frequency of frequent inspections depends on crane usage. They range from daily for cranes in severe service to monthly for normal service. These inspections encompass checking for broken or deformed components and general wear and tear, with a particular focus on operating mechanisms and hoists
• Lastly, periodic inspections are the most comprehensive. They cover the entire crane, checking for structural integrity, functionality, and compliance with safety standards. The frequency of periodic inspections again depends on usage, ranging from quarterly for severe service to annually for normal and heavy service.  These inspections specifically target faulty electrical components, the control system, and wear and tear in the brake system. It further focuses on intricate parts that might be missed during frequent inspections

The timing of crane inspections relies on the wear, deterioration, or malfunction risks associated with critical components, which are further influenced by the crane’s duty cycle or service classification.

Check out this blog to learn about the benefits of regular overhead crane inspections.

Factors That Affect the Cost of Overhead Crane Inspection

Now that you have understood what’s checked during overhead crane inspections and how often they occur, let’s understand the factors that influence the cost of these inspections.

1. The Type of Crane

Various types of overhead cranes cater to specific needs, including double-girder configurations, gantry cranes, and explosion-proof models. Inspection costs are influenced by crane design, application, and components; for instance, inspection for a top-running single-girder EOT crane differs from an under-running single-girder EOT crane due to their vertical alignment.

2. Total Number of Cranes Used

Expanding on the concept of crane quantity, the presence of numerous overhead cranes on your premises not only extends the duration of inspections but also amplifies the associated costs. As the number of cranes multiplies, so does the complexity of ensuring each one meets safety standards and operational requirements during inspections. Consequently, businesses must factor in both time and financial resources to accommodate the comprehensive evaluation of multiple cranes. 

3. The Age of the Crane

The age of the crane has a significant impact on inspection costs. Older cranes require more detailed and extensive assessments because they are worn out and may deteriorate. The testing of older equipment is often required to comply with the latest safety regulations. To accurately estimate inspection costs and ensure thorough maintenance of equipment safety and functionality, it is important to factor in the age.

4. Components

Inspection times vary based on the crane components; typically taking anywhere from an hour to several hours in total for complex models like double-girder EOT cranes with multiple moving parts that will need inspection. On the other hand, a basic jib crane typically takes less time. Special consideration is needed for components like radio remote controls and electric systems, particularly those with variable speed controls.

5. The Crane’s Installed Height

It becomes more difficult to inspect certain components the higher up the crane is placed. It may be necessary to use specialized equipment or take additional safety measures to conduct a thorough inspection without endangering worker safety. Cranes at higher heights, for example, pose a greater risk of falling items, requiring stricter safety protocol and possibly more frequent inspections.

6. Your Operating Environment

Your facility’s operating environment can also influence the cost of an overhead crane inspection. For instance, if your company operates in hazardous environments (e.g. chemical baths or hot metal), an inspector may need to wear protective equipment, which adds significantly to the overall costs associated with inspections.

Additional inspection costs could increase if your facility contains obstructions, equipment or overhead impediments that impact the safety or structural failure of cranes. To effectively assess these potential concerns an inspector must walk the facility and evaluate its operating environment to detect any problems that could impact safety or lead to structural failure of your cranes.

learn about the top 9 causes of crane accidents and safety tips to avoid them.

Conclusion

In the end, it’s important to take into consideration a variety of factors in evaluating the cost of overhead crane inspections. Although some companies might offer inspections at a reduced cost it is essential to be cautious about the motives behind such deals since they might be focused on offering repair services over precise assessments. 

Ensuring regular inspections and preventive maintenance can extend the life of cranes, however, the eventual replacement could be inevitable and could lead to expensive repair expenses. Talking to both manufacturers as well as qualified experts in inspection is a good idea to figure out the most appropriate maintenance schedule for your particular business’s needs. With our industry-leading knowledge and a commitment to minimize downtime, our staff of experts at Bajaj Indef stands ready to offer a full range of overhead crane and hoist services.  Reach out to us at [+91 (22) 489-33303] or drop us an email at [ enquire@indef.com ] to get quotes for a customized solution that meets your individual needs.