At Metreel, we know first-hand the tremendous boost to productivity and efficiency that cranes can bring to any workplace which undertakes repetitive lifting tasks.
However, like all types of machinery, cranes can be subject to downtime, which describes any period of time where the crane is unable to perform its intended function. The reasons for crane downtime could be due to mechanical failure or operator error. Additionally, there can be delays due to needing parts, certification or documentation.
Even short periods of downtime can have negative impacts on safety, productivity and ultimately the profitability of the business.
So that crane downtime can be avoided as much as is feasible, the crane experts here at Metreel have put together the following guide. Specifically, we’re here to uncover the main causes of crane downtime. This includes the hidden costs that all crane owners need to know about.
Crane Downtime – Why Does It Happen?
There is no single cause of crane downtime, since it can be due to mechanical reasons, or even legal reasons, as we’ve just touched upon above. This itself can be a huge challenge for businesses, since there are many facets which can impact the ability of the crane to operate and ultimately, the profitability of your operations.
That said, there are some common causes of crane downtime that we hear about often here at Metreel, based on the conversations we have with wider industry leaders.
These include the following categories.
Mechanical Failures
- Worn or frayed wire ropes
- Damaged gearboxes, bearings or shafts
- Hydraulic leaks or cylinder failures
- Brake and clutch wear on hoists or trolleys
- Overheating motors due to poor lubrication or overuse
Electrical And Control System Faults
- Control circuit failures
- Sensor malfunctions (i.e. load indicators and anti-collision systems)
- Corroded wiring or loose connections
- PLC or software errors on modern cranes
Operator Error or Misuse
- Overloading or side-loading the crane
- Incorrect rigging or sling selection
- Poor communication with signalers or lift supervisors
- Failure to perform pre-use checks
Maintenance Deficiencies
- Missed inspections or overdue servicing
- Use of non-genuine or incompatible parts
- Incomplete record keeping or poor documentation
- Reactive (breakdown) maintenance instead of planned
Environmental Conditions
- High winds or storms which halt operations
- Corrosion from saltwater or humidity
- Dust and debris clogging mechanical parts
- Extreme cold or heat affecting hydraulics and electrics
Compliance & Certification Delays
- Expired LOLER certificates preventing crane use
- Missing or incomplete lifting accessory inspection records
- Administrative delays in documentation or insurance approvals
Supply Chain Or Spare Parts Delays
- Waiting days or weeks for critical replacement parts
- Outdated or discontinued components for older cranes
Planning & Coordination Failures
- Poor lift planning leading to delays or unsafe setups
- Unclear scheduling between crane operators and site teams
- Conflicts between trades or equipment in shared zones
In short, that is a lot of potential crane downtime risk factors to consider! But, it’s all the more reason to get on top of what you can control through careful planning.
How Crane Downtime Can Be Costly For Your Business
Since cranes are capable of lifting loads at a far greater capacity (both in terms of weight and speed) than manual labour, their contribution cannot be overlooked. In fact, only when a crane is out of service does the true impact become clear, especially if lifting operations cannot go ahead and output slows as a result.
Initially, there can be direct costs such as repairs, replacement parts and service engineer callouts. Direct costs can also include additional labour to cover overtime and even temporary equipment hire.
There can also be indirect costs of crane downtime. This includes lost productivity, project delays and disrupted workflows.
Unfortunately, the costs associated with crane downtime don’t end there. That’s because there can be various financial penalties if cranes are rushed back into service without proper checks. Likewise, if the crane inspections or required maintenance tasks are missed. Ultimately, this can lead to further operational and reputational costs for the business, which can result in lost future contracts due to missed deadlines or safety incidents.
Preventing Crane Downtime
The big ‘truth’ about crane downtime that we alluded to in the title of this piece is that in the vast majority of cases, crane downtime is preventable.
Our top tips for preventing crane downtime include:
- Create a planned preventative maintenance program (PPM) based on manufacturer recommendations
- Use predictive data to spot wear and take action early
- Conduct regular inspections as per LOLER and PUWER requirements
- Train crane operators to the required standards and reassess them regularly
- Only use genuine parts to perform crane repairs
- Have backup plans in place to mitigate any potential disruption
- Ensure the proper storage of cranes when not in use
- Keep an eye on downtime and take steps to prevent the incident from recurring
- Be mindful of the crane’s lifespan and know when it’s time to replace or upgrade the crane
Is It Time To Replace Your Crane? Contact Us At Metreel
There comes a point for all machinery when sadly, the downtime becomes too frequent or even permanent. When your business relies on the crane to perform a specific job, downtime can have a huge impact on productivity.
At Metreel, we specialise in a variety of crane types, including overhead cranes, jib cranes, workstation cranes and monorail cranes. So, if it’s time to replace your existing cranes, or if you are looking to purchase a crane for the first time then you are in the right place!
So that we can direct you to the right product, please get in touch. You can also give us a call on 0115 932 7010.