Overhead Crane Overhauls
We extend the service life of your overhead cranes through our expert structural, mechanical, and electrical expertise.
Why Choose Us
Up to 70%
Savings compared to replacement costs
$6M+
Federal awards over the past 5 years for modernization projects
VENDORS
WHAT MAKES US UNIQUE
Mission-Ready Designs
Extensive experience designing cranes that meet strict DOD and Navy standards and requirements.
Smart Integrations
Ability to integrate commercial off-the-shelf components into compliant systems.
Cybersecurity Safeguards
Unique expertise in cybersecurity controls for crane systems.
Our Overhead Crane Modernization Services
We specialize in bringing aging crane systems back to peak performance through targeted upgrades and cost-effective modernizations. Our overhaul services address both mechanical and electrical systems, ensuring your equipment meets the highest standards of safety and compliance.
Control System Upgrades
- Replacement of outdated or unsupported controllers
- Drive replacements
- Conversion of DC to AC systems (due to limited availability of DC motors)
- New operator control stations, wiring, festoon systems, drives, and motors
- Major control system replacements, including large-scale rewiring, festoon system installation, operator cab rewiring, and installation of new control panels
Mechanical Overhauls
- Full hoist and trolley replacement
- Gear replacements
- Bearing replacements
- Other major mechanical system refurbishments
Load Testing
- After overhauls to ensure compliance with Navy, Army, OSHA, and OEM requirements
Measurements
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Load Testing
- Periodic testing on Navy cranes, which are required every 1–4 years
- Annually load testing for Army cranes
- Compliance with NIST-certified test weights for precise load verification.
Case Study: Naval Research Lab (Washington, D.C.)
Equipment: Bridge crane with a 15-ton hoist and 15-ton auxiliary hoist.
Work Performed
- Overhaul focused on upgrading the control system
- Replacement of the entire hoist and trolley system
- Installed new operator controller, wiring, festoon system, drives, and motors
Outcome: Delivered a modernized hoist system with improved reliability and reduced long-term maintenance costs.
OUR TEAM
Meet Terry Leach
Vice President of Operations, Overhead Crane Division
Mr. Terry Leach joined Craneworks in 2010 as a Project Manager for Large Projects, where he successfully led numerous electrical modernization initiatives for cranes ranging in capacity from 10 to 550 tons.
During his tenure, he managed several high-profile programs, including an 18-month, three-crane modernization project for the U.S. Army Corps of Engineers in South Dakota.
With over 28 years of experience across multiple industries—including Defense, Nuclear, Mining, Aviation, Pulp and Paper, Coal, and Hydropower Generation—Mr. Leach brings extensive technical and operational expertise to every project.
His proficiency in overhead lifting systems spans from integrated patented track monorails to 600-ton bridge cranes.
In 2020, he was promoted to Vice President of Operations for the Mid-Atlantic and Carolina Regions, where he oversees Navy Weight Handling Equipment (WHE) programs supporting multiple military installations.
Throughout his career, Mr. Leach has designed and installed more than 160 overhead bridge cranes and hoists, demonstrating a proven track record of engineering excellence and leadership in complex lifting applications.
De’Angelo Jackson
Senior Contract Coordinator
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Debbie Janette
Senior Project Manager
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Josh Dixon
Project Manager
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David Brown
Principal Structural Engineer
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Curtis Newsome
Crane Technician
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Jeff O’Rourke
Mechanical Engineer
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FAQ
What’s the difference between modernization and routine maintenance?
Maintenance covers smaller, regular tasks (fluid changes, brake adjustments, inspections). A modernization or overhaul is a larger project that replaces or modernizes entire systems to extend the crane’s life, like replacing a hoist, control panel, or entire trolley assembly.
How long can an overhead crane last after an overhaul?
With proper care, an overhauled crane can continue to operate for 20–30 years or more, often performing like new while avoiding the cost of full replacement.
Is it cheaper to modernize or replace a crane?
In most cases involving 15-ton cranes or higher, or complex control implementations, a modernization is far more cost-effective than replacement. By updating only the systems that need it—such as controls or hoists—you extend the crane’s lifespan without paying for an entirely new structure.
Do overhauls affect crane certification?
Yes. After every overhaul, we conduct rigorous load testing and provide certification to ensure your crane meets OSHA, OEM, Army/Navy, and ASME standards.
Can you modernize cranes from any brand?
Yes. We work with all major overhead crane brands, and our technicians are trained to handle a wide range of OEM systems.
