Overview
This bridge crane replacement project involved replacing two aging 7.5-ton bridge cranes used for handling coiled steel at a Midwest manufacturing facility. The existing cranes had become increasingly difficult to support because the original manufacturer was no longer in business. The customer needed a reliable replacement that would fit the existing runway, maintain the same lifting coverage, and improve operator safety with modern features.
AFE Crane designed, manufactured, and installed two new bridge crane systems that met the facility’s production requirements while improving reliability, safety, and long-term serviceability.
Project Challenges
The existing bridge cranes had supported the facility’s coil handling operation for many years. Over time, replacement parts and technical support became increasingly difficult to obtain. Rather than continue investing in aging equipment, the customer decided to move forward with a bridge crane replacement before reliability affected production.
The project involved more than replacing two cranes. The new systems had to operate on the existing runway while maintaining the hook coverage needed to handle coiled steel throughout the work area. The customer also wanted to add modern safety features that were not available on the original cranes.
AFE Crane needed to engineer a replacement system that fit the existing facility while minimizing disruption to production. The project also included engineering, manufacturing, installation, startup, and load testing.
The AFE Crane Solution
AFE Crane supplied two 7.5-ton top running double girder bridge cranes designed specifically for the application. The cranes featured large spans and operated on the existing runway system. This approach eliminated major building modifications while preserving the facility’s existing workflow.
To maximize hook height and hook coverage, AFE Crane selected top running hoist-trolleys. This configuration maintained the lifting capability required for handling coiled steel while improving overall crane performance.
The new crane systems also incorporated several safety upgrades. Radio controls improved operator visibility and flexibility during lifting operations. Crane-to-crane anti-collision systems helped prevent contact between the two bridge cranes operating on the same runway. End-of-travel slowdown and stop functions reduced impact loading during bridge and trolley travel. Travel horns and warning lights also alerted personnel whenever the cranes were moving.
These improvements modernized the lifting system while increasing operator safety and protecting the equipment.
Executing the Bridge Crane Replacement
AFE Crane managed the project from engineering through final installation. The engineering team developed drawings that integrated the new cranes with the existing runway while meeting the customer’s production requirements.
The installation team removed the existing cranes and installed the new systems. They completed startup activities and load testing before placing the cranes into service.
By using the existing runway structure and coordinating the installation carefully, AFE Crane completed the bridge crane replacement with minimal disruption to the customer’s manufacturing operation.
Results
Replacing the unsupported crane systems improved reliability while allowing the customer to modernize a critical part of its material handling process. The new bridge cranes maintained the required hook coverage, maximized available hook height, and introduced several safety features that were not available on the previous equipment.
The completed project also extended the expected service life of the facility’s lifting equipment while reducing the challenges associated with maintaining obsolete crane systems.
Conclusion
A successful bridge crane replacement does more than replace aging equipment. It improves safety, increases reliability, and gives manufacturers an opportunity to incorporate modern technology without changing their production process.
AFE Crane delivered a complete turnkey solution that replaced unsupported bridge cranes with modern systems designed to fit the existing facility and support reliable coil handling for years to come.
Before beginning a replacement project, many facilities also evaluate whether modernization is a practical option. Read our article on Overhead Crane Modernization vs. Replacement to compare both approaches.
Contact AFE Crane
If your facility operates aging bridge cranes that have become difficult to maintain or support, AFE Crane can help. Our engineering team can evaluate your existing equipment and recommend the most practical solution for your operation.
Whether you are considering modernization or a complete replacement, AFE Crane provides engineering, manufacturing, installation, startup, and long-term service support.
Contact AFE Crane to discuss your next bridge crane project.