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Cranes for Aerospace Manufacturing

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Granada Cranes

Aerospace manufacturing demands the highest levels of precision, cleanliness, and safety from every piece of equipment on the factory floor. The cranes that lift aircraft engines weighing 8 tonnes, position composite wing panels worth hundreds of thousands of pounds, and manoeuvre fuselage sections through assembly lines must meet standards that simply don’t apply in other industries. This guide covers the specialist crane requirements for aerospace and aircraft manufacturing facilities.

Aerospace Crane Quick Reference
Typical Capacity
2–20 tonnes
Positioning Accuracy
±2mm or better
Key Feature
Anti-sway control
Critical Factor
FOD prevention
Control Type
VFD with micro-speed

Why Aerospace Manufacturing Requires Specialist Cranes

An aircraft factory isn’t like a typical manufacturing facility. The components being handled represent enormous financial investments – a single jet engine can cost upwards of £10 million, while composite wing skins run into hundreds of thousands of pounds. Beyond the financial stakes, aerospace manufacturing operates under strict regulatory oversight where material handling incidents can ground entire production lines.

Standard industrial cranes simply cannot meet aerospace requirements. The sector demands:

  • Precision positioning – components must be placed with millimetre accuracy for assembly operations
  • Controlled motion – sudden movements or load sway can damage delicate composites or precision-machined surfaces
  • Contamination control – Foreign Object Debris (FOD) prevention is critical throughout production
  • Traceability – lifting operations often require documentation for quality records
  • Integration – cranes frequently form part of automated assembly systems
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Granada Cranes in Aerospace

We’re proud to be a trusted partner for leading aerospace manufacturers, providing bespoke industrial lifting solutions that meet the exacting standards of aircraft production. Our cranes support operations from component manufacturing through to final assembly.

What You’ll Be Lifting: Aircraft Component Weights

Understanding the weight range of aerospace components is the starting point for crane specification. Aircraft parts vary dramatically – from small avionics units to complete fuselage sections – but several key components drive capacity requirements.

Widebody Jet Engines

Rolls-Royce Trent XWB, GE90, CF6-80 series

5,600–8,700 kg

Narrowbody Jet Engines

CFM56, LEAP, V2500 series

2,000–4,000 kg

Wing Assemblies

Complete wing structures with control surfaces

Up to 30,000 kg

Fuselage Sections

Barrel sections for assembly joining

5,000–15,000 kg

Landing Gear Assemblies

Main and nose gear complete units

1,500–5,000 kg

Composite Panels

Wing skins, fairings, control surfaces

100–2,000 kg
Capacity Planning Note

While individual component weights determine minimum capacity, always factor in lifting attachments (spreader beams, cradles, vacuum systems) which can add 500–2,000 kg. Most aerospace facilities specify cranes at 1.5–2× the heaviest single component to accommodate tooling and provide headroom for future requirements.

Crane Types for Aerospace Facilities

Aerospace manufacturing typically employs a combination of crane types, each suited to different operations within the production workflow.

Most Common

Double Girder Overhead Crane

Primary lifting for major assemblies

The workhorse of aerospace assembly halls. Double girder configurations provide the stability, precision, and hook height required for handling large aircraft components. These cranes typically span 20–50+ metres across assembly bays and incorporate advanced motion control systems.

  • Capacity range: 5–50 tonnes (10–20 tonnes most common)
  • Spans up to 100+ metres available for aircraft final assembly
  • Often configured with dual hoists for tandem lifting
  • VFD control with micro-speed positioning standard

Single Girder Overhead Crane

Component manufacturing areas

Used in smaller production cells, machining areas, and parts storage zones where lighter loads and shorter spans are typical. Single girder cranes offer a cost-effective solution for facilities handling components rather than major assemblies.

  • Capacity range: 1–10 tonnes typical
  • Suitable for spans up to 25 metres
  • Lower headroom requirements than double girder
  • Good choice for tooling and fixture handling

Swing Jib Cranes

Workstation and assembly point lifting

Essential for providing operators with local lifting capability at specific work positions. Jib cranes handle smaller components, tooling, and lifting aids without requiring the main overhead crane. They’re particularly valuable at final assembly stations and in maintenance areas.

  • Capacity range: 125 kg–2 tonnes typical
  • 270° or 360° rotation options
  • Floor-mounted or column-mounted configurations
  • Ideal for cockpit instrument installation, fastener handling

Gantry & Semi-Goliath Cranes

Outdoor and flexible indoor applications

Used where building structure cannot support overhead runway loads, or in outdoor storage and delivery areas. Semi-goliath designs (one end on floor rails, one on elevated runway) offer flexibility for production layout changes.

  • Capacity range: 5–50+ tonnes
  • Independent of building structure
  • Can be designed for outdoor operation with weather protection
  • Good for raw material handling and delivery bays

Lightweight Crane Systems

Ergonomic handling and clean environments

Aluminium rail systems and enclosed track provide smooth, low-effort handling for lighter components. These systems are particularly suited to cleanroom environments where minimal contamination is essential, such as composite layup areas and avionics assembly.

  • Capacity range: up to 2 tonnes
  • Near-effortless manual or powered operation
  • Enclosed track designs prevent debris falling
  • Excellent for repetitive handling tasks

Critical Features for Aerospace Cranes

Beyond basic lifting capability, aerospace cranes require specific features that address the unique demands of aircraft manufacturing.

Precision Motion Control

Aircraft assembly requires positioning accuracy that standard industrial cranes cannot achieve. Modern aerospace cranes incorporate several technologies to deliver precision handling:

Variable Frequency Drives

VFDs provide stepless speed control for smooth acceleration and deceleration, eliminating the jerky motion of contactor-controlled drives

Micro-Speed Control

Ultra-low speeds (as low as 1% of full speed) for final positioning, allowing operators to make millimetre-level adjustments

Anti-Sway Systems

Electronic systems that predict and counteract load swing, reducing sway by up to 95% for safer, faster positioning

Load-Dependent Speed

Systems that automatically adjust lifting speed based on load weight, ensuring consistent handling regardless of component mass

Control Feature Purpose Typical Specification
Positioning accuracy Precise component placement ±2mm or better
Anti-sway reduction Load stability during movement 85–95% sway reduction
Micro-speed percentage Fine positioning control 1–5% of max speed
Speed range ratio Flexibility between rapid transit and slow positioning 100:1 typical

FOD Prevention and Cleanroom Compatibility

Foreign Object Debris (FOD) is one of aerospace manufacturing’s most serious concerns. A dropped bolt, a flake of paint, or debris from crane components can cause catastrophic damage to engines, create assembly defects, or compromise aircraft safety. Cranes must be designed to prevent contamination.

FOD Prevention is Non-Negotiable

Aerospace components and engines are highly susceptible to premature failure if contaminated during manufacture. FOD prevention isn’t just good practice – it’s a fundamental requirement that influences every aspect of crane specification, from materials to maintenance procedures.

FOD-prevention features for aerospace cranes include:

✓
Self-locking stainless steel fasteners – prevent bolts from vibrating loose and falling onto components
✓
Continuous kick plates on walkways – capture debris and prevent items falling from maintenance access areas
✓
Enclosed cable systems – cable festoon or energy chain prevents cable debris and lubricant drips
✓
Sealed gearboxes and motors – fully enclosed drive components eliminate oil leaks and wear particles
✓
Special coatings and finishes – powder coatings that don’t flake, materials that don’t degas
✓
Stainless steel construction – in cleanroom areas, stainless components prevent corrosion particles
✓
Non-shedding brake systems – brake materials selected to minimise particle generation

For composite manufacturing areas, cleanroom-rated cranes may be required. These are validated against ISO cleanroom classifications using laser particle counters to verify contamination levels during operation.

Safety Systems

Aerospace facilities require comprehensive safety features beyond standard industrial requirements:

  • Overload protection – prevents lifting beyond rated capacity (typically limits to 110% with alarm, cuts at 125%)
  • Collision avoidance – zone limiting and anti-collision systems where multiple cranes share runways
  • End-of-travel limits – prevent crane from overrunning runway ends or trolley limits
  • Emergency stop systems – accessible e-stops with fail-safe design
  • Redundant braking – dual brake systems on critical hoists for safety-critical lifts
  • Load monitoring – continuous display of load weight with recording capability

Lifting Attachments and Below-the-Hook Equipment

The crane itself is only part of the lifting system. Aerospace components require specialist attachments designed to protect high-value parts during handling.

Spreader Beams & Lifting Frames

  • Multi-point lifting for long or awkward components
  • Bespoke designs for specific aircraft parts
  • Adjustable designs for product families
  • Load distribution across fragile structures
  • Often designed with component cradles integrated

Vacuum Lifting Systems

  • Ideal for composite panels and skins
  • No surface marking or damage to finished parts
  • Quick attachment and release
  • Multiple pad configurations for different geometries
  • Battery backup for safety during power loss

Engine Stands & Cradles

  • Purpose-designed for specific engine types
  • Rotatable designs for maintenance access
  • Integration with transport dollies
  • Protection for sensitive engine surfaces
  • Typically supplied by engine OEMs

Soft Slings & Protective Straps

  • Textile slings for finished surface protection
  • Wide bearing surfaces to prevent marking
  • Colour-coded for capacity identification
  • Regular inspection requirements
  • Used with protective sleeving over sharp edges
Attachment Traceability

In aerospace, all lifting attachments must be traceable with documented inspection histories. Below-the-hook equipment requires its own thorough examination regime – typically every 6 months under LOLER. Many aerospace facilities maintain detailed logs of which attachments were used for each lift operation.

Automation and Integration

Modern aerospace manufacturing increasingly relies on automated systems, and cranes must integrate seamlessly into these workflows.

Automated Positioning

Cranes can be programmed with position memory for repetitive operations, moving automatically to preset coordinates. This is particularly valuable in production lines where components must be positioned at the same location repeatedly – for example, lowering fuselage sections onto assembly jigs.

System Integration

Aerospace cranes often connect to:

  • Production control systems – receiving instructions for component moves as part of manufacturing sequence
  • Automated assembly lines – coordinating with robotic systems, conveyors, and AGVs
  • Quality systems – logging lift data for component traceability
  • Maintenance systems – reporting operating hours and triggering service alerts

Remote and Centralised Control

Beyond standard radio remote controls, aerospace facilities may employ:

  • Control room operation for complex multi-crane moves
  • CCTV integration for blind spot monitoring
  • Tandem lift coordination for large assemblies
  • Condition monitoring with real-time performance data

Specification Considerations

When specifying cranes for aerospace manufacturing, these factors require particular attention:

1

Capacity & Configuration

Define maximum component weights plus attachments. Consider whether dual hoists for tandem lifting are needed. Account for future aircraft programmes that may require different capacities.

2

Speed & Precision Requirements

Balance throughput (rapid transit speeds) against positioning needs (micro-speeds). Specify anti-sway requirements based on load characteristics and operator skill levels.

3

Environment & Contamination Control

Identify cleanroom requirements and ISO classifications. Specify FOD prevention features appropriate to production area criticality.

4

Integration Requirements

Define interfaces with production systems, automation equipment, and existing cranes. Establish data requirements for quality and maintenance tracking.

5

Duty Cycle & Service Life

Aerospace production operates on long programme cycles. Specify FEM duty classifications (typically M5–M6) that support decades of reliable operation with appropriate maintenance intervals.

UK Compliance Requirements

Aerospace manufacturing facilities in the UK must meet the same lifting equipment regulations as other industries, though often with additional internal standards:

Regulatory Requirements
  • LOLER 1998 – Thorough examination every 12 months for the crane, every 6 months for lifting accessories
  • PUWER 1998 – Ongoing maintenance obligations and safe systems of work
  • BS 7121 – Code of practice for safe use of cranes
  • Additional aerospace-specific standards may apply depending on customer requirements and certification bodies

Many aerospace facilities impose requirements beyond statutory minimums, including more frequent inspections, enhanced documentation, and specific competency requirements for crane operators.

Frequently Asked Questions

What crane capacity do I need for jet engine handling?
Commercial jet engines typically weigh 2–9 tonnes depending on type. Narrowbody engines (CFM56, LEAP) are around 2–4 tonnes, while widebody engines (GE90, Trent XWB) reach 7.5–9 tonnes. You’ll need to add 500–1,500 kg for the engine stand/cradle, suggesting minimum crane capacities of 5 tonnes for narrowbody work and 12–15 tonnes for widebody engines.
How precise does positioning need to be for aircraft assembly?
This varies by application, but tolerances of ±2mm are common for major assembly operations. Anti-sway systems and micro-speed controls are essential to achieve this consistently. Some operations – particularly automated drilling and fastening – may require even tighter positioning.
Do aerospace cranes require cleanroom certification?
Not all aerospace cranes need full cleanroom certification, but FOD prevention is universal. Cleanroom certification (validated against ISO classifications) is typically required for composite manufacturing areas, fuel system assembly, and any area where components have exposed internal systems. Standard production areas may use FOD-prevention features without formal cleanroom rating.
What anti-sway reduction should I specify?
Modern anti-sway systems can reduce load swing by 85–95%. For aerospace applications, specify systems achieving at least 90% reduction. This dramatically improves productivity (no waiting for swing to settle) and safety (reduced risk of collision with jigs and structures).
Can cranes be retrofitted with precision controls?
Yes, existing cranes can often be upgraded with VFD controls, anti-sway systems, and enhanced safety features. This can be more cost-effective than full replacement if the crane structure and hoist are in good condition. A crane modernisation assessment will determine what’s feasible.
How do LOLER inspections work for aerospace cranes?
The crane requires thorough examination every 12 months (or more frequently if specified in the examination scheme). All lifting accessories – including specialist spreader beams, vacuum systems, and engine cradles – need examination every 6 months. Many aerospace facilities schedule these to align with production downtime periods.
What’s the typical lead time for an aerospace crane installation?
Lead times vary significantly based on specification complexity and building requirements. Standard cranes might be 12–16 weeks from order; highly specified systems with automation, custom FOD prevention, or special spans could be 20–30 weeks. Allow additional time for building structural assessment and any modifications needed to support the crane.

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