Step 1: Define the Work (Not Just the Weight)

• Capacity & load profile: What’s the heaviest and most frequent lift? Don’t spec the entire system only for a rare peak load.

• Lift height & hook approach: Confirm clearances, building obstructions, mezzanines, and required hook coverage.

• Cycle frequency: How often will the crane move? Duty and heat build‑up matter in production.

Pro tip: Create a short “top 10 lifts” table (weight, pick point, path, frequency). This aligns engineering, safety, and operations.

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Step 2: Match Duty Class to Reality

Duty class influences frame strength, motor sizing, brakes, gearboxes, and the crane’s overall life. Typical classes range from light/intermittent use up to continuous/severe service. If your line runs multiple shifts or has frequent starts/stops, do not underspec. Choosing the correct duty class reduces unplanned downtime and long‑term maintenance.

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Step 3: Choose the Right Configuration

• Single‑girder vs. double‑girder: Single is lighter and cost‑effective; double can offer higher capacity, better hook height, and more options for walkways and lights.

• Top‑running vs. under‑running: Top‑running maximizes capacity and hook height; under‑running can be a good fit for lighter loads and tighter spaces.

• Hoist type:

  • Wire rope hoists: higher capacities, smoother high‑duty cycles.

  • Chain hoists: economical for lower capacities and workcells.

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Step 4: Controls, Speed, and Precision

• VFDs (variable frequency drives) provide soft starts/stops, better positioning, and reduced wear.

• Radio remote controls enhance operator mobility and line‑of‑sight safety.

• Anti‑sway & creep speed features improve precision placement for assembly and fixtures.

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Step 5: Safety & Operator Experience

• Overload protection, end‑stop limits, and collision avoidance reduce risk.

• Zone control (no‑go areas) helps protect equipment and people.

• Lighting on the bridge, audible/visual alarms, and load displays build operator confidence.

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Step 6: Building Interface & Runway

• Verify runway beam sizing, column spacing, and wheel loads with your building engineer.

• Confirm power delivery (conductor bar or festoon), grounding, and panel locations.

• Consider future expansion: spare panel capacity, longer runways, or a second bridge down the road.

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Step 7: Lifecycle Cost (Beyond the Bid)

• Energy use: VFDs and efficient motors can reduce consumption and heat.

• Wear items & parts availability: Standardize hoists and controls across bays when possible.

• Service access: Platforms and walkways can lower service time, improving uptime.

• Training & inspections: Budget for operator training and periodic inspections to maintain safety and compliance.

Quick Spec Worksheet

1. Max/frequent load & dimensions

2. Required hook coverage (X/Y/Z)

3. Duty profile (hours/day, starts/hour)

4. Environment (heat, dust, moisture, washdown)

5. Required placement precision

6. Preferred controls (pendant/radio)

7. Power & building constraints

8. Future expansion needs