Lifting equipment has a finite operational lifespan, and the decision to replace or modernise a crane depends largely on its mechanical, structural and foundational condition. Where the fundamental condition of the equipment remains sound, modernisation can often provide a more economical and practical alternative to complete replacement.

The Konecranes Crane Reliability Study (CRS) provides a comprehensive assessment of lifting equipment, evaluating its current condition and providing a theoretical assessment of its remaining design life. The study also delivers detailed recommendations for component upgrades and modernisation.

“The average lifespan of a crane is between 20 and 25 years. A CRS modernisation analysis assesses the crane’s current safety, productivity, reliability, usability and design-life status, as well as the electrical and mechanical functions of the crane system” says Ian Grobler, Sales Manager for Konecranes South Africa.

He added that as lifting equipment becomes older and potentially less productive, replacement can become an unnecessary expense when modernisation may achieve the desired outcome at a lower cost.

An ageing crane is not necessarily an unsafe crane. However, equipment that is inadequately inspected, maintained and assessed presents an increasing risk of mechanical failure, accidents, production losses, financial costs and potential legal liability

Keeping pace with technological advances

The technology incorporated into an overhead crane at the time of its original installation may have since been superseded by more advanced solutions. Continuous research and development has resulted in improvements that make modern cranes safer, more efficient, productive and cost-effective.

“Safety regulations may also have changed or become more stringent since the original lifting equipment was purchased” explains Grobler. “A Konecranes CRS analysis can identify components and systems that 

can be upgraded to meet current regulatory requirements, potentially eliminating the need for a costly complete replacement.”

The CRS process

A Crane Reliability Study involves a team of Konecranes specialists assessing the lifting equipment in its production and operating environment. The process includes a detailed evaluation of the crane structure and components, interviews with operators and maintenance personnel and a review of relevant technical and maintenance documentation.

Following the assessment, Konecranes provides a detailed report outlining the condition of the equipment, identified risks and recommended actions. Further consultation can then assist the customer in planning maintenance, modernisation and future investment requirements.

CRS performance indicators

A CRS can be particularly valuable when a crane, its components or the lifting process is approaching a point where the probability of failure, remaining service life or consequences of failure can no longer be adequately managed through routine inspection and maintenance.

A number of indicators may point towards the need for a CRS, including:

- An increase in equipment breakdowns

- More frequent emergency repairs

- Repetitive component failures

- Deterioration of safety-critical components

- Increasing maintenance requirements and costs

- The age of the equipment

- Accumulated operating hours or service data

- Changes in production requirements or operating conditions

The information gathered through the CRS provides the data required to make informed decisions about how best to restore the equipment to its expected level of performance, reliability and safety.

Modernisation versus replacement

Modernisation does not necessarily mean replacing the entire crane. Depending on the assessment, upgrades can be targeted at specific components or systems to address changing operational requirements.

Common modernisation solutions can include the replacement or upgrading of hoists, trolleys, operator cabins and control systems. These upgrades can be used to improve lifting capacity, operating speed, duty classification, ergonomics, load control, safety and overall productivity.

Importantly, the age of a crane alone does not determine whether a CRS is required. Grobler said “A relatively new crane operating intensively in a high-consequence application may warrant a CRS, while an older crane with very low utilisation and an excellent documented maintenance and inspection history may not. An old crane is not necessarily unsafe, but an old crane that is inadequately inspected and assessed presents a progressively greater risk of mechanical failure, accidents, financial loss and legal liability.”

Rather than automatically replacing existing equipment, a detailed assessment can determine whether the crane can be modernised and upgraded to meet new productivity, application and safety requirements.

Making an informed investment decision

Several factors can trigger the need to reconsider the future of lifting equipment. These include the need to extend the crane’s economic service life, increased production demands, changes in application, more frequent maintenance and rising maintenance costs.

The key question is therefore not simply whether a crane is old, but whether it remains fit for purpose and whether modernisation can economically restore or improve its performance.

“Our Konecranes CRS provides the information and data required to make an informed decision about whether to replace or modernise” says Grobler. “Modernisation can be one of the most cost-efficient ways of returning cranes and their components to an optimised level of performance” he concluded.

With the expertise, technology and resources to modernise virtually any make or model of overhead crane, Konecranes can help customers extend the productive life of existing lifting equipment while addressing changing safety, reliability and productivity requirements.