How to Choose the Right Overhead Crane for Your Business

Choosing the right overhead crane is a significant investment decision. Get it right and you’ll have a lifting solution that improves productivity, safety, and efficiency for decades. Get it wrong and you’ll face costly modifications, premature wear, or a crane that simply doesn’t meet your needs. This guide walks you through the key factors to consider.

The Six Key Decision Factors

Before you speak to any crane supplier, you need to understand six fundamental specifications. These will determine everything from the crane type to the price.

1. Capacity: What Weight Do You Need to Lift?

Capacity is usually the starting point. You need to know the maximum weight you’ll be lifting – not the average, but the absolute heaviest load the crane will ever need to handle.

Consider both your current requirements and potential future needs. Upgrading a crane’s capacity after installation is expensive and sometimes impossible – it’s much more cost-effective to specify slightly higher capacity from the start.

View our overhead crane range by capacity to see what’s available from 1 tonne to 60+ tonnes.

2. Span: How Wide Does the Crane Need to Reach?

The span is the distance between the runway rails – essentially, how wide an area the crane can cover. This is usually determined by your building width or the width of the area you need to service.

Key considerations for span:

• Building columns – the crane runway is typically mounted on or adjacent to the building’s structural columns
• Coverage area – ensure the hook can reach all areas where you need to lift and place loads
• End approaches – how close to the runway ends does the hook need to travel?
• Obstructions – account for any columns, machinery, or other obstacles

3. Lifting Height: How High Do You Need to Go?

Lifting height – also called hook height or height of lift – is the distance from the floor to the hook at its highest position. This depends on:

• Building height – your available headroom sets the upper limit
• Stacking requirements – how high do you need to stack materials or load onto vehicles?
• Machinery clearance – do loads need to pass over equipment at height?
• Below-hook equipment – spreader beams, grabs, and lifting accessories reduce effective hook height

If headroom is limited, consider a low-headroom hoist design which maximises lifting height in constrained spaces. Single girder cranes with underslung hoists typically offer better hook height than double girder cranes in the same building.

4. Duty Cycle: How Hard Will the Crane Work?

Duty cycle (or duty classification) describes how intensively the crane will be used. This affects component selection, design life, and ultimately cost. A crane used occasionally for maintenance tasks needs different engineering than one running continuously on a production line.

Be honest about your duty requirements. Under-specifying duty classification to save money leads to premature wear, frequent breakdowns, and ultimately higher lifetime costs.

5. Single Girder vs Double Girder

One of the most fundamental choices is whether to go for a single girder or double girder crane. Each has advantages depending on your application.

In many applications, single girder cranes offer the best value. But for heavy lifting, long spans, or demanding duty cycles, double girder is the right choice. A good supplier will advise on which type suits your specific requirements.

6. Controls: How Will Operators Control the Crane?

Crane controls affect safety, productivity, and operator comfort. The main options are:

Radio remote controls have become increasingly popular as they allow the operator to stand in the safest position with the best view of the load. They also eliminate trailing pendant cables which can be a trip hazard or snag on loads.

Building and Installation Considerations

Your building has a major impact on crane selection. Before specifying a crane, you need to understand:

For Existing Buildings

• Structural capacity – can the columns and foundations support the crane loads?
• Available headroom – what’s the clearance under roof trusses and services?
• Access for installation – how will the crane be brought in and erected?
• Runway mounting – can runways be fixed to existing steelwork?
• Power supply – is adequate electrical supply available?

For New Buildings

If you’re building a new facility, involve the crane supplier early. The building can be designed around the crane requirements, which often results in a more efficient and cost-effective solution than retrofitting a crane to an existing structure.

Hoist Selection: Wire Rope or Chain?

The hoist is the component that does the actual lifting. Two main types are used on overhead cranes:

For most industrial overhead crane applications, wire rope hoists are the preferred choice due to their greater capacity, height, and duty capabilities. Electric chain hoists work well for lighter applications and workstation cranes.

Questions to Ask Your Crane Supplier

The Buying Process: What to Expect

Information to Gather Before Contacting Suppliers

The more information you can provide upfront, the more accurate and useful the supplier’s proposal will be.

Summary

An overhead crane is a long-term investment that should serve your business for 20-30 years or more. Take time to specify it correctly, choose a reputable supplier who will support you throughout the crane’s life, and don’t make decisions based solely on initial price. The right crane, properly installed and maintained, will pay for itself many times over in improved productivity and safety.

Explore our full range of overhead gantry cranes, or contact us to discuss your requirements with our team.