Inspection of structures supporting overhead cranes

An overhead crane is never more reliable than the structure that supports it. An inspection of an overhead crane according to CSA B167 does not cover its runway: beams, columns, rails, and anchorages are part of the building and fall under the Building Code and CSA S16. Premium Industrial Structures inspects this structure, documents each defect, and establishes intervention priorities.

Why inspect the structure of your overhead crane?

The crane runway (also called the crane track) absorbs the loads, braking, and impacts of the crane with each movement. If neglected, it can develop fatigue cracks, loose bolts, and misaligned rails, which ultimately compromise safety. Since the standard crane inspection does not cover this structure, it must be inspected separately.

CSA S16, CISC guide and CSA B167: which covers what?

None of these references provides detailed requirements for inspecting the structure in service. The industry therefore relies on Annex C of AIST Technical Report No. 13 and Chapter 6 of the CISC Crane-Supporting Steel Structures Design Guide (4th edition), which deal with existing structures. In addition, CSA S16 (assembly tolerances), CSA W59 and W178 (welding and weld inspection), and CMAA 70 and 74 (rail alignment) are also relevant.

What does the CSA B167:26 standard require for the structure?

• Documented evidence that the support structure was designed by an engineer for the maximum rated load of the overhead crane.
• The display, visible to the operator, of any capacity limit of the track or structure.
• For a new or modified overhead crane, confirmation by an engineer that the structure can support the test load.

An inspection describes the condition of the structure; it does not replace this confirmation. See the checks before adding or replacing an overhead crane ..

How often should a track be inspected?

The CSA B167 standard does not specify an inspection frequency for raceways. The AIST (Association for Iron & Steel Technology) recommends the following minimum frequencies in its Technical Report No. 13:

The actual frequency is determined by the environment (corrosion, heat), the duty cycle, the criticality of the equipment to your production, and the repair history. Do not wait until the next scheduled maintenance date in the following cases:

• addition or replacement of an overhead crane, or increase in capacity;
• impact, fire or purchase of a building;
• abnormal wear of the wheels or rails;
• overhead crane that moves at an angle or makes noise while moving;
• visible cracks in the beams or welds, or traces of rust around the bolts.

Who can inspect the structure of an overhead crane?

The AIST recommends that inspections be carried out by a qualified person experienced in overhead crane structures, under the supervision of an engineer. The engineer interprets the findings and determines the corrective actions. At Premium Industrial Structures, our inspectors have extensive field experience in the installation and repair of lifting equipment structures. We also provide training, are a member of the CISC, and participate in the revision of the CISC guide. Our network of engineers allows us to quickly assess the necessary corrective actions.

What do we check during the inspection?

• Column bases and anchor rods.
• Columns and bearing beams: supports, welds, stiffeners and fasteners.
• Lateral and longitudinal bracing.
• Rails, joints, rail fasteners and buffers.
• Modifications made over the years: welded fasteners, reinforcements, added or removed parts.
• According to the mandate, an alignment survey by laser scanning or surveying: rail spacing, level differences and plumb of columns.

When the survey reveals a geometric defect, the alignment of the overhead crane rails can be considered.

How does an inspection take place?

1. Review of the history, plans and operating conditions.
2. On-site visual inspection to identify anomalies, with non-destructive testing if a defect is detected. Depending on the mandate, additional measures may be taken (laser scanning, surveying).
3. Computerized inspection report : anomalies classified by type, with photos, location of each defect and intervention priorities.
4. Depending on the findings, the following actions will be taken : repair of steel structures , alignment of rails, or, if lifting requirements change, reinforcement of the structure, designed by an engineer with sealed plans, and then carried out. An inspection alone does not demonstrate that reinforcement is necessary.

A separate engineering analysis is required when anomalies are found, when fixes have already been made to the structure, or to confirm its capacity.

To be planned : safe access to the entire structure, with lifting equipment (e.g., a platform) or a lifeline, and the locking of the overhead crane during the inspection.

What influences the cost of an inspection?

The length of the runway, the number of overhead cranes, access at height, the availability of plans, the need for an alignment survey or non-destructive testing, and production constraints.

A single partner for your overhead crane and its structure

Together with its sister company, Groupe Industriel Premium, Structures Industrielles Premium handles everything: the overhead crane and its supporting structure. For the crane itself, see Groupe Industriel Premium's inspection of overhead cranes and lifting equipment .

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Here are some examples of defects detected during structural inspections: