„How long will the crane last?” – this is one of the most common questions we ask when designing new equipment, but the answer can rarely be expressed as a single figure. This is because the service life of cranes is determined not by the calendar, but by standardised service classes. Those who understand this can plan and maintain their equipment much more effectively.
They plan in cycles, not in years
At international level, the basis for the design of cranes and lifting equipment is the ISO 4301 standard and the European FEM 1.001 series of standards; in Hungary, in accordance with these, the MSZ EN 13001-1:2015.
These do not simply specify a year, but combine two factors: the load spectrum (the size of the loads and the frequency with which the crane lifts them in relation to its rated load capacity) and the utilisation group (the number of operating cycle (to be completed during the planned period).
These two categories make up the crane classification system: internationally, they are designated from M1 to M8, whilst in Hungary and in previous practice they are designated from A1 to A8.
In essence, this indicates the level of stress that the structure and its main components can withstand without breaking.
What does this mean in practice?
According to the Hungarian Chamber of Engineers’ technical guide on the design of bridge cranes, the design is typically based on a 10-year reference period, assuming a given utilisation rate.
If the crane has indeed been operated in accordance with the specified working group, a so-called full overhaul of the lifting mechanism will be due around this time, in line with the manufacturer’s recommendations.
In theory, this refurbishment can be carried out an unlimited number of times; in other words, a crane with proper maintenance and, with periodic refurbishment, it can easily outlast its original design life.
Based on international experience, a well-maintained industrial crane operating under moderate loads typically provides reliable service for 20–30 years, and in light-duty applications for as long as 30–40 years, whilst one operating continuously in heavy industry (for example, port or in the steel industry), this figure typically falls to 15–20 years.
It is important to make a distinction: it is not the entire crane that „ages” all at once. The wear-and-tear parts – rope, brake pads, bearings – these require regular replacement, whilst the fatigue life of the steel structure and the main components is the real limiting factor.
Technical and economic service life – they are not the same thing
There is often a discrepancy between a crane’s theoretical, standard structural service life and the point at which its operation is no longer economically viable.
The technical service life lasts for as long as the structure can be operated safely, subject to appropriate inspections; the economic service life, on the other hand, comes to an end when the cost of repairs and component replacements exceeds the value that a new piece of equipment would provide. The decision between the two typically depends on the periodic inspections and can be made on a sound basis based on the renovation cost estimate.
In the next instalment of our series, we will show which factors, in day-to-day practice, have the greatest influence on whether a crane remains in service for a shorter or longer period than planned.
If you have any questions about the cranes, please call us: +36-27-360823
