A well-built crane can serve for decades. Over time, parts wear and controls age, but the steel structure is often still sound. Modernizing the crane can then cost far less than replacing it.
This guide lists what can be upgraded on an existing crane and what to send for a quotation.
When modernization makes sense
- The structure and runway are in good condition, but the controls or drives are old.
- Spare parts for the original equipment are hard to find.
- Downtime and repairs are becoming frequent.
- You need smoother, safer or more accurate handling.
- The load or the duty has changed and the crane must be checked against it.
What can be upgraded
- Drives: inverter (VFD) control for smooth starts, accurate positioning and less wear.
- Control: radio remote control or a new pendant.
- Safety devices: overload protection, limit switches and emergency stops.
- Hoist and trolley: a new hoist unit or trolley matched to the structure.
- Brakes, gearboxes and motors.
- Electrification: conductor bar or cable festoon.
- Hooks, hook block and rope.
Inspect first
Before deciding, have the crane inspected: structure, welds, wheels, rails, gearboxes, brakes, ropes and electrics. The inspection tells you which parts to replace and whether the structure can carry the planned duty.
Modernize or replace
If the structure is sound and the capacity is still right, modernization is usually the better value. If the structure is damaged, the capacity is no longer enough or the duty has changed a lot, a new crane may be the better choice.
What to send for a quotation
- The nameplate data: manufacturer, capacity, span and year.
- Photos and drawings, if you have them.
- A description of the problems or the goals.
- Duty: lifts per hour and hours per day.
- Power supply and control method.
After the work
After modernization the crane should be inspected and load-tested before it returns to service, and the records should be kept.
Electrification: festoon systems and conductor rails
When a crane is modernized, the power supply along the runway and the bridge is often worth renewing too. Two common choices are cable festoon systems and insulated conductor rails.
- Cable festoon system. Flat cables hang from small carriers that run in a track. The carriers are made of galvanized steel or plastic, and the catalogue gives a maximum cable load per carrier, for example 10 kg for plastic carriers and 35 kg for steel carriers. Towing arms, support brackets and pendant station trolleys complete the system. Plug and socket connections speed up fitting and later service.
- Insulated conductor rail. An enclosed PVC conductor line with up to five conductors. It is protected against accidental contact, the earth conductor is marked on the housing, and the parts resist corrosion. It suits straight runs and curves, indoors and outdoors, installs quickly and needs little maintenance. Current collector trolleys are available for 35 A and 70 A, singly or in pairs, with feeder boxes, expansion joints, inspection points and sectionalizing joints as accessories.
Wheels, rails and end carriages
The end carriage wheels carry the whole crane, and they are either driven or free-running. Worn wheels and rails cause noise, skewing and uneven wear. When you modernize, check the wheel diameter and wear, the rail type (flat rail or A-type rail), the permitted wheel load and the tolerances. Anti-jump and rail-locking devices, storm brakes, rail sweeps and hydraulic buffers can be added where the crane needs them.
A typical modernization project
- Inspect the crane and its runway.
- Agree the goals: safety, accuracy, availability or a new duty.
- Receive a quotation with the parts and the scope.
- Plan the stoppage with your production team.
- Fit the new parts, then inspect and load-test the crane before it returns to service.
How CESAN can help
CESAN supplies spare parts and modernizes existing cranes. Send us the data above and our engineers will recommend what to replace.
Why choose CESAN
- Turkish manufacturer since 1976. CESAN designs and builds overhead, gantry and jib cranes and hoists in its own factory in Turkey, with engineering, sales and after-sales in one country.
- Projects in more than 52 countries. Experience with different standards, climates and site conditions.
- A full range. Single girder cranes up to 32 t, double girder cranes up to 250 t and gantry cranes up to 500 t, plus jib cranes, hoists, transfer carts and attachments.
- Recognized standards. Design to FEM 1.001, EN 13001 and ISO 4301, CE marking, and ISO 9001 and TSE certificates for the company.
- Installation and commissioning on site. CESAN handles installation, commissioning and the load test in any country.
- Factory acceptance test (FAT). The complete crane system is tested before delivery, and customers or third parties can witness the tests.
- 24-month warranty, with the terms stated in each quotation.
- An office in Dubai for Gulf customers.
Send us your requirements
Send the nameplate data, photos and a short description of what you want to improve. Send them through the enquiry form and our engineers will reply with a technical and budgetary assessment.
See our overhead cranes and the guide overhead crane price guide.