Determine the maximum load to be lifted. If the load falls between standard rated capacities, always go with the higher capacity.

A manual hand chain hoist is much less expensive than an electric hoist. Manual hoists should be considered when speed is not important and when lifts are very infrequent.  When lifting heavier loads you should consider the fact that in order to lift a 5 ton load by hand, you must pull over 200 feet of chain at 80 pounds of force to lift 1 foot. Manual hand chain hoist can be used for vertical lifting and where accurate positioning of the load is required. For example, installing and removing tools and dies from machinery.

Manual lever hoist can be used in different positions, such as horizontal pulling and where accurate positioning of the load is required.  Lever hoist provide excellent spotting capability. Thus they can be used in small tight areas. Lever hoists are versatile. Electric chain hoists are not made for side pulls much less a true pulling application but ratchet lever hoists can be used at any angle.

The main difference between Electric chain hoist and wire rope hoists is in the design of the lifting mechanism. When a wire rope hoist lifts, it wraps the rope around a grooved drum. A chain hoist lifts by pulling the chain through sprockets and depositing the chain into a chain container. Both types use similar motor, brakes, and controls.

Reeving refers to the configuration of the wire rope, blocks and drum of the hoist. Reeving affects the headroom, lifting speed and capacity by increasing the hoist's mechanical advantage. Reeving also determines if the hoist has lateral hook movement or true vertical lift. The three terms used in reeving are: single, double, and part. Single or double refers to the number of ropes coming from the drum. Part deals with the mechanical advantage gained by multiple reeving. For example, with a two part single reeving (2PS) the load is distributed over the two parts, and the mechanical advantage doubles the capacity of one part reeving but reduces by one half the lifting or lowering speed of the hook.

Some applications require that the load not move right or left of the hoist centerline while being lifted. This is called true vertical lift and requires that the hoist be double reeved. Double reeving also requires less headroom than single reeving.

Both chain and wire rope hoists are rated H-4 (heavy duty). Duty ratings are a better indicator of hoist durability than hoist type (chain or wire rope). Both types use similar motors, brakes and controls.

• Chain Container: Used on most electric chain hoist to store the extra chain.
• Dual hoist brake: Many hoists are designed with a second mechanical load brake. This brake assists in the braking process and helps control the decent rate. Although a single brake system is safe, many people like having a second brake as an added security.
• Variable Frequency Drive: Add multistep infinitely variable speed control.  With variable speed control the speed ramps up and down at a programmed rate reducing load swing.  Variable drives also allow very slow speeds when positioning loads, medium speeds when traveling with large loads or fast speeds when traveling empty.
• Faster trolley: There typically is little of no added cost for the faster speed on the trolley but we recommend the variable drive when using faster speeds to reduce swing and allow easy positioning of the load.
• Limit switches: Although all manufacturers still do not add upper and lower limit switches as standard, OSHA has stated that upper limit switches are mandatory (several manufactures have tried to skirt this by using an overload device as the limit which OSHA has clarified as not adequate.)  Lower limits are required in some instances and we recommend them in all applications.
• Explosion proof: when installing a hoist in an explosive environment, class group and division must be specified. Explosion proof hoists are very expensive. One less costly way of achieving explosion proof is with an air operated hoist.
• Spark resistant: this is completely different from explosion proof. Typically this includes stainless bronze wheels, chain, and hooks.
• Space heaters: Space heaters keep motors or controls warm and dry. These are typically used in environments where motors will not run very frequently and there is a lot of moisture around.
• Fusing: Branch fusing is required when on a crane. This means one set of fuses for the hoist and one for the trolley.

Adverse environments, Corrosive, explosive, high temperature, etc., should be considered in the purchase of your hoist.  We recommend you contact one of our sales representatives if you have any concerns.  Options such as epoxy paint, stainless or zinc chain and hooks, rain covers should be considered in harsh environments.

Some manufacturers have recommended using top running end trucks without rail.  This is a VERY BAD idea.  Not only is there a potential safety hazard with this standard rolling tolerance for beams, makes it very difficult to install this properly. The safety issue is due to wheel loading on the outside flange of the beam. If the beam is not sized for wheel loading, the flange can bend down due to this load. You will typically spend more to size a beam properly for wheel loading than the rail would have cost.

Double girder cranes typically have the hoist and trolley riding on top of the cross girders. It is a wire rope hoist that is placed on top of the crane kit and has a H4 duty class. Double girder cranes can provide more lift, because the hoist is placed between the cross girders rather than under them. Therefore, the depth of the cross girder is gained in switching to double girders.

A crane kit is a package that can come with many options to suit your lifting needs. A basic crane kit comes with top and under running end trucks with options to add different features on them. Equipment that can come with a crane kit includes end trucks, hoists, festoon systems, remote control, bridge crane, and many more options.

The best crane type for your individual needs is ascertained based on application and building dimensions (if the crane is to be fitted to an existing building rather than a new building). The most effective way to determine if a top running or under running crane kit is right for you is to consult with your crane manufacturer and installer before making the final decision about the appropriate equipment to purchase.

ACI’s crane kits are a money saving concept for the build-it-yourself customer who has basic fabrication skills.

Typical single speed bridges travel at 60 or 70 FPM.  Even with a short, 60 foot long, building it will take 1 minute to travel this distance.   We strongly recommend higher speeds used with variable drives.  The variable drive allows slow and fast motions along with ramped acceleration and deceleration.  140 FPM is a medium to medium slow walking pace and we have found is a safe and comfortable pace for a crane.  Even if you find that it is faster than you want the variable drive allows the top speed to be reduced to as low as you wish.

Variable drives are typically added to the bridge and trolley motions on all but the lowest cost cranes.  A variable drive improves efficiency and safety.  By allowing infinite speed control and ramping the speed up and down, the operator can move loads faster with no dangerous load swing.  The very slow speeds available allow accurate positioning; where the faster speeds allow moving cranes with no load or small loads to move more quickly.  A variable drive bridge and trolley can save over 50% of the movement time over a single or 2 speed crane.  When programmed properly variable drives reduce brake wear. Variable drives lifts are becoming cost effective and improve reliability.

Remotes are used in situations where being tethered to the crane is inconvenient.  In applications where the operator must walk around an object to assure proper positioning, such as truck repair facilities, remotes allow one operator to do the work of two people. In facilities that move long items the remote allows the operator to balance the end of the load eliminating the need for an extra person.   With improved reliability, added safety features, and lower cost remotes are an option we are seeing on increasing numbers of cranes.

With Independent festooned pendants, remote controls are becoming more reliable and less costly, therefore independent festoons are not used very often.  An independent festoon for the pendant allows the operator to stand anywhere along the length of the crane when operating, not just next to the hoist.  The pendant cable runs on a second separate festoon track.  This is important when rotating long items or if the operator must lift from a pit or truck or walk in a crowded area.

Advantage of D.C. brakes over A.C. brakes is that they are compact in size. D.C. brakes are ideal when the number of operations is high but inching is not required. A.C. brakes are not suitable when the number of operations is very high but they can withstand if inching operations are made for small time or intermittently.

ACI’s crane kits are a money saving concept for the build-it-yourself customer who has basic fabrication skills. The following options that can be added to the crane kits include:

• Dual hoist brake:  Many hoists are designed with a second mechanical load brake. This brake assists in the braking process and helps control the decent rate. Although a single brake system is safe, many people like having a second brake as an added security.
• Chain Container:  Used on most electric chain hoist to store the extra chain.
• End truck wheels:  Some manufacturers use cast wheels.  Although less costly they typically have a much lower life span than hardened steel wheels.  The purchaser typically will not see this as they will still last many years.  Due to the high cost to replace wheels we recommend only hardened steel wheels be used.
• Larger wheels and motors: In applications where cranes are used continuously the owner should consider larger, hardened steel, wheels and larger motors to extend the life of the crane.  A 12 inch wheel turns half as fast as a 6 inch wheel for the same crane speed.  This greatly increases the life of the bearings, gears, as well as wheel surface.  A larger motor puts forth less effort to move the crane and has more surface area for cooling.  This reduces the temperature of the motor increasing its life. Replacing one set of wheels due to wear will typically cost more than upgrading to larger wheels.
• Faster bridge:  Typical single speed bridges travel at 60 or 70 FPM. Even with a short, 60 foot long, building it will take 1 minute to travel this distance. We strongly recommend higher speeds used with variable drives. The variable drive allows slow and fast motions along with ramped acceleration and deceleration. 140 FPM is a medium to medium slow walking pace and we have found is a safe and comfortable pace for a crane.  Even if you find that it is faster than you want the variable drive allows the top speed to be reduced to as low as you wish.  
• Faster trolley:  There typically is little of no added cost for the faster speed on the trolley but we recommend the variable drive when using faster speeds to reduce swing and allow easy positioning of the load.
• Trolley and bridge brakes:  Cranes are required to have a non-coasting mechanism on the bridge and trolley.  This can be done with a worm gear or a brake.  Many manufacturers do not include this even though it is a requirement.
• Trolley bumpers and rail sweeps: These are required on hoists used on crane systems (there are some exceptions to this rule but they are required in most applications)  Some crane manufacturers assume that because many hoist manufacturers only offer this as an option that it is not required and do not include it.
• Horn:  Safety should always be a prime consideration when lifting and moving loads.  A horn is used to warn others of approaching load.  We have found that a horn activated by motion does not work well with cranes, especially when more than one crane is in a building.  The constant beeping tends to be ignored over time.  MHS uses a horn activated by a button on the pendant.  This allows the operator to warn others when necessary without having the continuous beeping.  We use a very loud, 110db at 1 meter, horn to assure the horn is heard over shop noise.
• Strobe light: A strobe light is added for safety also.  Unlike a horn that looses effectiveness if activated on motion the light is very effective on motion and does not require operator interface.  A light also works well in very noisy environments.
• Dual collectors: Conductor bar for power along runways comes standard with a single collector shoe for each phase.  As the system ages, conductor bar will get rust and other contaminates which will cause the single collector shoe to lose contact in spots.  This single phasing damages motors and brakes and electrical equipment.  In order to minimize, this dual collectors can be used.  Unless there is a very long section of bad bar, the dual collectors assure power is not lost. Dual collectors are required with variable drives.
• 4th conductor bar for ground:  Although the National Electric Code (NEC) previously allowed the crane wheels to be used as the ground, this changed in 2005.  A ground bar is now required. We have found in many instances, over time, the runway rail either gets painted or contaminated with dirt causing loss of ground and a shock hazard.
• Explosion proof: when installing a hoist in an explosive environment, class group and division must be specified. Explosion proof hoists are very expensive. One less costly way of achieving explosion proof is with an air operated hoist.
• Spark resistant – this is completely different from explosion proof. Typically this includes stainless bronze wheels, chain, and hooks.
• Upgraded Electrical:
  • CONDUIT INSTEAD OF SO CABLE: Many crane builders have begun using SO cable or tray cable across the bridge instead of conduit.  Although much less costly, this DOES NOT meet National Electric Code requirements (610-11).  Wiring, with the exception of festooning and very short pieces to the collectors, must be armored or be in conduit.  All ACI cranes use conduit. NOTE:  Everyone will say their crane meets code.  You should ask if they use conduit, but the best way to make certain is to specify that the wiring be in conduit.  (It is confusing when you are getting two different stories.  If you are not sure which is correct, please ask our sales person.  He will show you the code.)
  • FESTOON WIRING IN PROTECTIVE COVER: Although this seems like a good way to protect wires from being cut, and cuts the cost of a crane, we know of no cover that is UL approved or that meets National Electric Code.  Wiring used in these covers is designed to be used in conduit and does not have the protective covering around it that a flat or SO cable have.  Flat cable is specifically designed for festooning and is what ACI uses on all of its cranes. Individual wires in a cover DOES NOT meet the National Electric Code.
  • RELAYS: We have found the best way to increase the life of a relay is to assure continuous clean power.  This can be done by electrical analysis to verify voltage drop throughout the entire system is not too high (MHS engineers verify voltage drop with each system we sell) and by using dual collectors to reduce the possibility of phase loss. We can offer higher amperage relays which will also increase the relay life if you wish.
  • CIRCUIT BREAKERS: Cranes require branch fusing (one set of fuses for each direction).  Circuit breakers can be used in the place of fuses although we do not recommend this.  A crane blowing a fuse is a sign that there is a problem that needs to be fixed.  Where circuit breakers are used we have found that people tend to reset the breaker, and if it holds do not find out why it blew. This is a safety issue, putting faulty equipment into service should never be done and it is extremely rare that a fuse will fail for no reason.
  • HEAVIER FESTOONING: There are many different styles of festooning.  Everything from a stretched wire with metal rings sliding across to heavy duty trolleys designed to travel on steel beams.  For very small job cranes, we do not recommend stretched wire festooning.  ACI uses a C track festooning and trolleys with roller bearings as a standard on its cranes.  The C track system will work well for all but the heaviest or fastest use. ACI will offer upgraded festooning if we believe it would be cost effective.  If you need more information please ask.
  • SPECIAL CONDUCTOR BAR: There are several reasons to consider special conductor bars.  Voltage drop – long runs and high current will cause low voltage to electrical components if proper conductor bar and wire is not used (ACI analyzes every system to assure this does not occur).  Corrosion – Chemicals or high moisture can cause premature corrosion on conductor bar.  In environments where this may occur we recommend a stainless or copper clad bar.  Sun exposure.  There are special UV covers for some conductor bars which may be considered.  In many instances it the bar will need to be replaced due to corrosion at the about the same time the cover breaks down due to UV.
  • NEMA 4 ELECTRICAL: In high dust or outside locations weather tight NEMA 4 electrical boxes and NEMA 4 wire grommets should be used.
  • SPACE HEATERS: Space heaters keep motors or controls warm and dry. These are typically used in environments where motors will not run very frequently and there is a lot of moisture around.

What am I actually doing with the system? For example, will it be used to move expensive tools into/out of a molding machine or to load/unload steel from trucks?

How can a crane increase the safety of the loads being lifted?

How can a crane improve my workers' safety in handling the loads?

How frequently will it be used each shift?

How will the load need to be moved and located?

How easy is it to move the system to a new location in my factory?

Do I really need three axes of hook movement (e.g., up/down, left/right, and forward/back) or will only two be sufficient?

How heavy are the loads to be lifted? sole

How much money should I invest in a system?

To help determine which pendant you are looking, here are some questions that need to be answered:

1. Determine the number of switches (button holes) required.
2. Select switches (include light inserts if required).
3. Calculate the number of conductors required.
4. Determine outer diameter of cable.
5. Select appropriate bushing to fit over cable. Cable bushing consists of waterproof packing to prevent the entry of water or dust, while the bushing part protects the electric cable.
6. Select options, i.e. buzzers, blind rubber, key switch, etc.

Remotes are used in situations where being tethered to the crane is inconvenient.  In applications where the operator must walk around an object to assure proper positioning, such as truck repair facilities, remotes allow one operator to do the work of two people. In facilities that move long items the remote allows the operator to balance the end of the load eliminating the need for an extra person.   With improved reliability, added safety features, and lower cost remotes are an option we are seeing on increasing numbers of cranes. We sell many brands of remotes.  All work well but there is a tremendous difference in the durability of the hand held unit (transmitter).  The least costly will work well in environments where they will take little abuse.  The most costly are designed to work in harsh environment.  When pricing this option, be certain you are being quoted the same brand and model.

With Independent festooned pendants, remote controls are becoming more reliable and less costly, therefore independent festoons are not used very often.  An independent festoon for the pendant allows the operator to stand anywhere along the length of the crane when operating, not just next to the hoist.  The pendant cable runs on a second separate festoon track.  This is important when rotating long items or if the operator must lift from a pit or truck or walk in a crowded area.

Maintained pushbutton pendant - This type of pendant is often used in conditions that require long distance and where accurate positioning is a concern. Once pressing the button, the current continues to provide power to your equipment until it is pressed again causing it to stop.

Momentary pushbutton pendant - This type of pendant is often used in conditions that require accurate positioning within a short distance. A person must continue to press and hold the button to provide power to the equipment. Once the button is released, the power will stop.

A jib crane has one fixed leg, a cantilevered boom that rotates around the fixed leg, and a hoist/trolley unit that traverses the boom and lifts loads for placement somewhere else. A jib crane is helpful in a high-repetition lift process where an overhead crane would be otherwise tied up. Jib cranes are typically one to two tons, but sometimes reach five ton capacity. The reach or span of the boom does not typically exceed ten feet. When calculating a jib crane reach, it’s important to consider “end-approach”, or how close the hoist/trolley unit can approach the ends of the boom – space for the hoist/trolley machinery, which is typically 12”, must be accommodated at each end of the boom.

The most common applications for jibs are individual workstations; e.g., machine tools, welding/fabrication stations, and some small assembly stations. They are also often used in simple loading / unloading operations where it is not necessary to spot a load precisely.

Jib cranes most often handle lighter loads at lower duty cycles than their bridge and gantry crane counterparts. A "classic" application for jibs is to outfit an assembly floor with a series of jibs at individual workstations, which are then supported by an overhead crane to lift / carry full assemblies. The hook coverage is limited to the boom length. The hook operates along a boom which rotates about a fixed point.

Jib cranes are designed and manufactured in four styles:

• Free standing or portable jib cranes – The freestanding jib crane, or Pillar jib crane as it is sometimes called, is available with 360-degree jib rotation. Freestanding jib cranes require no additional support aside from an adequately sized permanent foundation. For this jib crane, standard spans and under boom heights are available up to 20 feet. The top bearing assembly on a free standing jib crane utilizes a Timken tapered roller bearing provided with grease fitting for proper lubrication. Free standing jib crane is available in three styles: Base plate mounted freestanding jib crane, foundation mounted free standing jib crane, and sleeve insert mounted jib crane.
• Wall cantilever jib cranes – Wall cantilever jib cranes offer greatest potential clearance under the boom. They are the ideal substitute for traditional, heavy I-Beam Jib Cranes. These jibs are designed to service circular areas and support tool balancers, air balancers, vacuum lifters, and hoists. When column or wall mounted, they can handle up to a 200° rotation. Standard wall mounted jib cranes are available up to spans of 30 feet.
• Wall bracket tie rod supported jib cranes – Tie rod supported jib cranes offer a lower cost design with no supporting components used under boom. This jib has 2 brackets that mount to a wall or building beam.  The bottom bracket has a boom that is perpendicular to the wall with a bracket toward the end that a tie rod is attached to.  This is the least expensive jib, but it takes up the most head room and it exerts the most force on whatever it's mounted to.
• Mast style jib cranes (top and bottom supported) – Mast Type Jib Cranes offer a low cost alternative to achieve 360˚ rotation without a large mounting foundation as is required by free standing models.  The mast is supported top and bottom by the overhead building steel and floor.  Mast Type Jib Cranes are available in 2 designs, full cantilever and drop cantilever.

The standard capacity rating of a jib crane represents the net rated load of the hook at the hook of a hoist of the same rated capacity as the crane. The design factor for the stresses in the crane is based on the capacity plus 25% of the rated load for impact and 15% of the rated load for the weight of the hoist and trolley. This was utilized along with the average yield stress of the material to determine the type of the design. This design provides a margin to allow for variations in material properties, operating conditions, and design assumptions.

The maximum weight of the application should match, NOT exceed, and design weight. The capacity rating is based on a design load. The ACI jib crane design criteria allows the least amount of deflection so as not to hamper the performance of the jib crane.

Two important options that must be added on the jib crane are the speed and the pendant that controls the speed and movement of the attached hoists. The speed of the jib can come with single speed but you can have the option to add variable drive which eliminates the need for reversing contactors, and allows for multi-speed operation of jib cranes. Variable frequency drive provides infinitely variable speed options for maximum control and load positioning from micro speed to full speed, both in acceleration and deceleration phases.

The control panel can also be added as an option and it includes mainline contactor, reversing magnetic contactors, thermal overload, 110V fused control transformer, branch circuit fusing to crane motor and solid state adjustable “soft start” control adjustable for time and torque in a NEMA 3R enclosure.

Stainless steel wear rings for corrosive or spark resistant applications, air drives for spark resistant applications, gear and pinion drive components for accurate positioning or high duty cycles, special control enclosures and wiring for hazardous locations, multi-speed units for delicate handling situations, and protective coatings

A gantry crane is similar to a bridge crane, but typically has legs at either end of the bridge girders, which are then mounted with end trucks at the bottom of the legs to move the gantry along ground-level tracks. Gantry cranes are more frequently found outdoors where no raised runway is present. Also, small non-powered gantry cranes are used in light duty applications such as small machine shops or automobile garages. These gantry cranes typically do not have a fixed path, but rather have rubber tires.

Not all Gantry Cranes cost less than their bridge crane counterparts. A gantry crane is a more cost-effective alternative if:

• You are currently in a leased facility and do not want to make a major investment in a bridge crane runway structure.
• You may be planning to move the crane in the near future and want to take your entire investment with you.
• You require a crane system that moves loads between the interior and exterior of your building.
• You need long runway structures of over 150 feet where the runway steel and foundation costs are very high.

Permanent magnets are basically permanently magnetized material. The magnet can hold on to certain weight depending upon its capacity. Electromagnets depend on electricity to charge the magnet and to firmly hold the material to be lifted. These magnets need a permanent power source to work, which means that a power failure could lead to major problems.

A positive feature of these magnets, compared to conventional cranes and hooks, is that the magnet does not do any damage to the material that is being handled.

Each unit is equipped with a handle assembly for easy separation from the ferrous object. To use, simply attach the magnet to the desired ferrous object, that is wide enough to incorporate the handle assembly, and begin lifting.

To determine which beam clamp is right for your lifting needs, you must have the approximate weight and flange width of your objects. The flange width is simple, you must measure how wide the object is so that the clamp could adjust tightly for lift. Once you collect the weight, choose the closest clamp which is listed as metric ton (Note: 1 ton = 2,200 lbs).

Shackles are recommended for permanent or long term installations and where the load may slide on the shackle pin causing the pin to rotate. Screw pin shackles can be used in any application where a round pin shackle is used. In addition, screw pin shackles can be used for applications involving side-loading circumstances.

Both varieties of shackles are for towing and/or hoisting situations. The galvanized forged steel shackles are ideal for industrial applications. The stainless steel shackles are more corrosive-resistant and, are therefore ideal for marine applications.

Both are thermoplastic polymers, they can be used in similar applications and both contain aromatic chemicals in their plastic structure. Nylon is totally synthetic, but polyester can be made from plants. Polyester slings have become very valuable especially in applications that subject the sling to acid conditions. Whereas, nylon slings is highly resistant to alkalies, but should not be used in acid conditions. Also, polyester slings are excellent where headroom is limited because of the webbing’s low stretch characteristics. Polyester can be used in temperatures up to 200° F.