🛠️In the overhead crane service industry, ensuring safety and efficiency requires understanding engineering principles and deep, hands-on experience with the machinery itself. Recently, I encountered a case with a client highlighting the difference between theoretical engineering and practical, qualified crane maintenance.
👷♂️The Situation: A client had been experiencing recurring issues with a Demag hoist, resulting in four rope replacements over four years. Concerned about the underlying cause, the client hired an engineering firm, which reported that the incorrect rope lay (left lay instead of right lay) was being used on the hoist. They questioned why this issue was not identified earlier and expressed frustration about the repeated repairs.
Before this, we had offered a solution of adding a time delay between slow and fast speeds, a successful industry solution to mitigate shock loading and reduce wear on the hoist rope. However, the client had yet to implement this recommendation, contributing to continued rope damage.
📋Our Response: After reviewing the manufacturer's specifications again, we determined that the rope used was the manufacturer-specified left-hand (LH) lay rope, per Demag's recommendations for this specific hoist model (EZDH 1050 H24KN5 4/1). The rope was sourced and installed according to the manufacturer's documentation and relevant industry standards (CSA B167-16)¹, requiring replacement parts to meet or exceed the original manufacturer's specifications.
In Canada, an 📐engineer generally has no authority to supersede a hoist manufacturer's specifications. These specifications are based on rigorous testing, safety standards, and regulations established by organizations like the ✅Canadian Standards Association (CSA), ✅Occupational Health and Safety (OHS) regulations, and ✅other governing bodies. The ✅manufacturer's specifications are legally binding, and overriding them could result in unsafe conditions, liability issues, and potential violations of provincial or federal safety regulations².
However, 📐engineers may assess and make recommendations or modifications if they align with safety codes, standards, and regulations. If a deviation from the specifications is needed, it typically requires comprehensive analysis, documentation, and approval from both the manufacturer and regulatory authorities.
It's important to note that, according to✅Engineers Canada’s Code of Ethics, engineers must prioritize public safety and adhere to industry standards. The Code of Ethics emphasizes that professional engineers must only undertake work they are competent in and must respect all safety regulations and manufacturers’ specifications unless formal processes are followed for modifications³.
In today’s industry, we see more and more companies entering the overhead crane service space with staff and often owners who have never worked for an overhead crane company or received proper training under qualified and experienced crane technicians. This lack of hands-on technical experience and specialized training raises significant safety concerns, as these companies often do not understand the varying requirements of hoist manufacturers, so they generalize requirements, usually leading to unsafe practices. Properly trained technicians are essential for maintaining compliance with industry standards like CSA B167-16 and the manufacturer's specifications; this prevents accidents and equipment failure and reduces unplanned maintenance costs.
🏢Our company, as qualified crane technicians, took several steps to ensure compliance:
🔍Consulted the Manufacturer: We contacted Demag directly to verify the specifications and confirmed that the left-hand lay rope was correct for this model.
🔍Reviewed Other Installations: We service many other Demag hoists with similar configurations in the same area. All use left-hand lay ropes without issues; some have been in service for many years without needing a replacement.
🔍Recommended Upgrades: In addition to rope replacements, we had recommended an electrical upgrade over the past few years to mitigate the shock loading contributing to the rope damage—something the client had not yet implemented.
🏗️Additional Manufacturer Insight: To further support our decision to stick with the LH lay rope, a blog post from Demag explains, "In most cases, Demag designs their wire rope hoists in violation of this best practice, but for a major engineering reason that benefits the user and for additional safety." The blog continues, "Due to wear on the drum and sheaves, we will never recommend changing the lay of the rope used on a hoist when the wire rope needs changing." The article concludes with, "This knowledge will allow you to be a more effective technician for your customers, but you can also promote safety in the industry."⁴
🤝At Venter Cranes, this is precisely our goal: to offer our clients the best service while promoting industry safety.
⚠️The Core Issue: This situation raises an important question for the industry: What qualifies a crane technician? Is it an engineer who may have theoretical knowledge but lacks hands-on experience or a qualified technician who works daily with cranes, is familiar with manufacturer specifications, and is trained according to applicable standards?
While engineers provide valuable insight, particularly in identifying systemic issues, they are not necessarily qualified to service, repair, or maintain overhead cranes.
👷♂️A qualified crane technician: Serves Time Under Competent Technicians: Technicians learn from hands-on experience, working under the guidance of experienced crane professionals, not just through classroom or theoretical study.
✅Follows Applicable Standards: Crane technicians are trained and certified according to industry standards such as CSA B167-16 and ASME B30⁵, ensuring they understand both the safety requirements and the manufacturer's specifications.
📋Understands Manufacturer Guidelines: Technicians regularly work with specific manufacturers, like Demag, and are intimately familiar with their equipment, knowing when exceptions (such as using LH lay ropes) apply.
🤝Collaboration Between Overhead Crane Companies and Engineering Firms:
In the crane service industry, overhead crane companies and engineering firms must work together to ensure safety and the best client outcomes. This relationship, however, only works when each party respects what the other brings to the table. Engineers provide valuable analytical expertise, often identifying underlying issues with equipment. On the other hand, Crane service companies offer practical, on-the-ground experience in maintenance and repairs, ensuring that standards are met and equipment operates safely and efficiently.
⚠️The Increasing Issue with “Engineering” Companies in Crane Services:
As more engineering firms enter the crane servicing space, clients must differentiate between theoretical knowledge and practical competency. While capable in other areas, many of these firms must gain experience working with cranes daily. A certificate in engineering doesn’t automatically deem them competent to service or maintain cranes safely and effectively, however many are caught up in a misconception.
Conclusion: The key takeaway from this case is that qualified crane technicians who have hands-on experience and follow industry standards and manufacturer specifications are essential to ensuring that cranes operate safely and efficiently. While engineering firms may offer insights into underlying issues, only technicians trained in real-world applications can provide the comprehensive service required to maintain these complex machines.
According to the Canadian Standards Association (CSA), a qualified crane inspector in Canada has served practical time under a competent technician, is trained in compliance with safety standards like CSA B167-16, and has hands-on experience with cranes in daily operation. This practical training, combined with knowledge of manufacturer specifications and safety codes, ensures that technicians are equipped to maintain, repair, and service cranes effectively and safely.
It is critical to reiterate that safety in the overhead crane industry requires regulating and clearly defining what constitutes a qualified crane technician and the role of the manufacturer's specifications in an investigation. These regulations must ensure that technicians meet educational and experiential requirements and adhere to safety standards set by governing bodies such as the CSA and OHS. These regulations are necessary for safe practices to arise, potentially leading to hazardous working conditions, equipment failure, liability issues, or, in the case of this case study, advising a client to install an incorrect rope on a crane.
In our case, we stood by our commitment to safety and industry standards, offering to replace the rope free of labour costs if the engineering firm could provide an official engineering report instructing a deviation from the manufacturer’s specifications approved by the manufacturer. Ultimately, our goal is to ensure a safe industry, maintain strong client relationships, and continue to feed our families through honest, competent work.
💻Footnotes:
Canadian Standards Association (CSA) B167-16: Safety Standard for Maintenance and Operation of Overhead Cranes.
Canadian Standards Association (CSA) and Occupational Health and Safety (OHS) regulations provide binding safety requirements for cranes and lifting equipment.
Engineers Canada Code of Ethics: Engineers must prioritize public safety and only undertake tasks they are competent to perform. See: Engineers Canada Code of Ethics.
Demag Cranes blog, "In most cases, Demag designs their wire rope hoists in violation of this best practice, but for a major engineering reason that benefits the user and for additional safety," blog.demagcranes.com.
ASME B30: Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings.
About the Author:
Bradley Sliedrecht has over 30 years of experience as an overhead crane technician. He is a Certified OHC Trainer, Qualified Electrician, Millwright, CWB Welding Supervisor, and Rigging Inspector. Bradley holds both a Bachelor's and a Master's degree. He brings a wealth of knowledge and hands-on expertise to the industry. His commitment to safety and high standards in crane maintenance has made him a trusted professional in his field.
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