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What Size Crane Do I Need?
Answer 5 quick questions and we'll recommend the best crane type and capacity range for your application. No obligation — just expert guidance.
Crane Selector Tool
Answer each question to get your personalized recommendation.
Question 1 of 5
What is the primary purpose of your crane?
Question 2 of 5
What is the maximum weight you need to lift?
Question 3 of 5
How large is the area you need to cover?
Question 4 of 5
Do you have an existing building structure to attach to?
Question 5 of 5
How often will the crane be used?
Crane Selection Guide
How to Choose the Right Crane
Choosing the wrong crane type is one of the most common and costly mistakes in industrial facility planning. This guide walks you through every key decision factor so you get it right the first time.
Overhead Bridge Crane
Full-bay coverage · Maximum capacity
The workhorse of heavy industry. A bridge crane spans your entire bay and travels its full length, giving you complete overhead coverage. Ideal when you need to move heavy loads anywhere within a building.
Capacity¼ – 30+ Ton
Span10 – 100+ ft
CoverageFull Bay
StructureCeiling or Freestanding
Jib Crane
Workstation lifting · Space efficient
A single-arm crane that rotates around a fixed point, covering a circular area. Perfect for individual machine cells, welding stations, and loading docks where repetitive, localized lifting is needed.
Capacity¼ – 5 Ton
Reach8 – 20 ft
Rotation180° – 360°
MountWall or Floor
Gantry Crane
No runway needed · Portable
A self-supporting crane that stands on its own legs. No runway or building structure required. Available in portable wheeled versions that can be relocated anywhere on a flat surface.
Capacity500 lb – 20 Ton
Span6 – 30 ft
HeightAdjustable
MobilityPortable / Fixed
Hoist & Trolley
The lifting engine · Pairs with any crane
The hoist is the actual lifting mechanism — it attaches to the trolley which travels along your crane beam. Choosing the right hoist type (electric chain, wire rope, air, manual) is as important as the crane structure itself.
Capacity¼ – 25 Ton
TypesElectric, Air, Manual
TrolleysPush, Geared, Motorized
ControlPendant or Radio Remote
Key Factors to Evaluate Before You Buy
1. Load capacity: Always specify your maximum load with a safety margin. Standard industry practice is to add 15–25% above your heaviest expected lift. This accounts for rigging hardware weight and future production needs.
2. Hook height: The distance from the floor to the hook at its highest point. Measure your actual facility ceiling height, subtract the crane beam depth and hoist headroom, and you have your usable hook height. Many facilities are surprised how much headroom a crane system consumes.
3. Span and coverage area: For bridge cranes, the span is the distance between runway rails. For jib cranes, it's the boom reach. Map out exactly which area needs lifting coverage before specifying a system.
4. Duty cycle: How often the crane lifts, how much it lifts relative to its rated capacity, and how many hours per day it operates. This determines the CMAA duty class — see the Duty Class reference below. Under-rating your duty class is one of the most common mistakes and leads to premature equipment failure.
5. Environmental conditions: Outdoor use requires galvanized or corrosion-resistant finishes. High-temperature environments (foundries, steel mills) require heat shields and specialized hoist motors. Explosive atmospheres require air-powered or EX-rated electric equipment.
6. Building structure: Before specifying a ceiling-hung or top-running bridge crane, a structural engineer must verify that your roof or support columns can handle the combined dead load of the crane and live load of your maximum lift. If your building can't support it, a freestanding system solves this cleanly.
CMAA Reference
Crane Duty Classes Explained
The Crane Manufacturers Association of America (CMAA) defines six duty classifications — Class A through F — that determine the structural and mechanical requirements of your crane. Selecting the wrong class leads to premature wear, unexpected failures, and safety risks.
| Class | Service Level | Load Spectrum | Typical Use Cases |
|---|---|---|---|
| A | Standby / Infrequent | Very light loads, rarely at rated capacity. Long idle periods between lifts. | Powerhouses, public utilities, turbine rooms, transformer stations. Installed for emergency use. |
| B | Light | Light loads, no more than 50% of rated capacity two-thirds of the time. | Light assembly, service shops, light warehousing. Moderate lift frequency with long idle periods. |
| C | Moderate | Moderate loads averaging 50% of rated capacity. Regular lift cycles throughout the day. | Machine shops, paper mills, general manufacturing, intermittent production lines. The most common class for light industry. |
| D | Heavy | Heavy loads averaging 65% of rated capacity. High lift cycles throughout the workday. | Heavy machine shops, foundries, fabricating plants, steel warehouses, lumber mills, container yards. Steady production demand. |
| E | Severe | Very heavy loads at or near rated capacity consistently throughout the day. | Steel mills, scrap yards, cement plants, fertilizer plants, container handling. Multiple-shift, high-intensity operations. |
| F | Continuous | Maximum loads, highest possible lift cycles. Crane is essentially never idle. | Custom-engineered for continuous casting, automated steel production, and other extreme-duty applications. Must be engineered to specific application parameters. |
How to determine your duty class: Start with Class C for most manufacturing applications with regular daily use. Step up to Class D if your crane will be running multiple shifts or frequently lifting near its rated capacity. Class E and F are reserved for steel mill and continuous industrial operations. When in doubt, always step up — over-specifying duty class costs more upfront but prevents costly failures and downtime.
ASME standards also apply: In addition to CMAA classifications, crane systems must comply with ASME B30.2 (overhead and gantry cranes), ASME B30.16 (overhead underhung cranes), and OSHA 1910.179. All Crane Authority systems are supplied to meet applicable standards.
Before You Buy
Crane Buying Checklist
Use this checklist before contacting any crane supplier. The more of these you can answer, the faster and more accurate your quote will be — and the better the final system will fit your needs.
1
Maximum Load Weight
Know the weight of your heaviest lift including rigging hardware (hooks, slings, attachments). Add 15–25% safety margin. This determines your required crane capacity.
2
Bay Dimensions
Measure your building bay width, length, and height. For bridge cranes, bay width determines the required span. For jib cranes, identify the specific zone that needs coverage.
3
Usable Hook Height
Measure floor-to-ceiling height, then subtract any obstructions (lights, HVAC, existing structure). Account for crane beam depth and hoist headroom to determine your actual hook height.
4
Lift Frequency & Shift Schedule
Estimate lifts per hour and hours of operation per day. This determines the CMAA duty class and directly impacts component selection and long-term reliability.
5
Building Structure Assessment
For ceiling-hung or top-running systems, confirm that your roof framing or support columns have adequate capacity. Have a structural engineer review if uncertain — never assume.
6
Power Supply
Identify available voltage and phase at the installation location (115V/1ph, 230V/1ph, 230V/3ph, 460V/3ph). Air hoists require a compressed air supply. Confirm availability before specifying equipment.
7
Environmental Conditions
Note any special conditions: outdoor exposure, high temperatures, corrosive environments, explosive atmospheres, food-grade requirements. Each requires specific equipment ratings and finishes.
8
Control Preference
Decide between pushbutton pendant (tethered) and radio remote control. Consider operator positioning during lifts — if the operator needs to walk with the load, radio remote is strongly recommended.
9
Special Attachments
Identify below-the-hook requirements: hooks, magnets, vacuum lifters, C-hooks, spreader bars. These affect required capacity and hoist selection.
10
Budget & Timeline
Standard workstation systems typically deliver in 4–8 weeks. Custom-engineered systems may be 10–16 weeks. Knowing your required in-service date helps prioritize the right system configuration.
Frequently Asked Questions
Common Crane Questions
Answers to the questions we hear most often from facility managers, engineers, and purchasing teams across all industries.
What is the difference between a single girder and double girder bridge crane?
A single girder crane uses one bridge beam with an underhung hoist — ideal for lighter capacities (up to about 10 tons) and facilities with limited headroom. A double girder crane uses two bridge beams with a top-running hoist between them, allowing much higher capacities, longer spans, and better hook height utilization. Double girder is the standard for heavy industrial applications above 10 tons or where maximum hook height is critical.
How do I know if my building can support a bridge crane?
A qualified structural engineer must assess your building's roof framing, columns, and foundation to confirm they can handle the crane's dead load plus the live load of your maximum lift. If the structure is inadequate, a freestanding crane system — which anchors directly to a reinforced concrete floor — eliminates the need for structural building attachment entirely. We can advise on both options.
What is the difference between a hoist and a crane?
A hoist is the lifting mechanism — the motor, drum or chain, and hook that actually raises and lowers the load. A crane is the structural system (bridge, runway, jib arm, or gantry) that supports and moves the hoist horizontally. You need both: the crane positions the hoist over the load, and the hoist does the actual lifting.
What is the lead time to receive a crane?
Standard workstation jib cranes and smaller gantry systems typically ship in 2–6 weeks. Workstation bridge crane systems generally run 4–8 weeks. Larger custom-engineered bridge cranes with full runway systems can be 10–16 weeks depending on capacity and configuration. We provide accurate lead times at the time of quoting so you can plan your installation schedule.
Can I install a crane in a leased facility?
Yes — and this is where freestanding systems shine. A freestanding bridge crane or freestanding jib crane bolts to your concrete floor with anchor bolts and can be fully disassembled and relocated when your lease ends. Many companies invest in freestanding systems specifically for this reason. Verify that your lease allows floor anchor bolt installation, which is standard in most industrial leases.
What is a CMAA duty class and why does it matter?
The CMAA duty class (A through F) defines how hard the crane will work over its lifetime. It factors in the number of lifts per hour, the percentage of time the crane operates at or near full capacity, and hours of operation per day. Selecting a lower duty class than your actual usage requires results in accelerated wear, structural fatigue, and premature failure. Always verify your duty class with a qualified engineer before specifying a crane.
Do I need a permit to install a crane?
Permit requirements vary by municipality, crane capacity, and installation type. Most fixed crane installations above a certain capacity threshold require a building permit and may require an inspection. Portable gantry cranes typically do not require permits. We recommend consulting your local building department before installation. Crane Authority can supply engineering documentation to support your permit application.
What voltage do electric hoists require?
Electric hoists are available in 115V/1-phase, 230V/1-phase, 230V/3-phase, and 460V/3-phase configurations. Small chain hoists under 1 ton are commonly available in 115V for simple single-phase power. Larger wire rope hoists almost always require 3-phase power. Always confirm available voltage and phase at your installation point before ordering.
What is the difference between a wall-mount and freestanding jib crane?
A wall-mounted jib crane attaches to an existing wall or column and rotates up to 180°. It requires the wall or column to have adequate structural capacity to absorb the crane's moment load. A freestanding jib crane has its own floor-mounted column, rotates 360°, and requires only a reinforced concrete floor pad — no wall or structural attachment needed. Freestanding jibs are more flexible but require more floor space.
What maintenance does an overhead crane require?
OSHA and ASME standards require regular inspection and preventive maintenance. At minimum: daily operator visual inspections before use, monthly functional inspections by a designated person, and annual thorough inspections by a qualified inspector. Maintenance tasks include lubrication of wheels, bearings, and chain/rope; inspection of hooks, brakes, limit switches, and structural members; and periodic load testing. We can recommend a maintenance schedule appropriate for your duty class and usage.
Can an overhead crane be used outdoors?
Yes, but outdoor cranes require specific design considerations. All steel components should be hot-dip galvanized or given a marine-grade corrosion-resistant coating. Electrical components need NEMA 4 or higher enclosures to protect against rain and moisture. For marine environments with salt air exposure, stainless steel hardware is recommended at all critical points. Wind loading must also be accounted for in the structural design of outdoor runways.
What is a radio remote control and when should I use one?
A radio remote control replaces the standard pendant pushbutton with a handheld wireless transmitter, allowing the operator to walk with the load rather than being tethered to the crane. This significantly improves safety and precision, especially when spotting loads into tight positions. Radio remote is strongly recommended for any application where the operator needs to see around or under the load, or when working near machinery or press tooling.
Can I add a crane to an existing hoist or trolley system?
In many cases, yes. If you have an existing structural beam or monorail, you may be able to add a new or replacement hoist and trolley without changing the structure. The key factors are: beam size and capacity rating, available headroom, and power supply. We can evaluate your existing setup and recommend compatible equipment. If the structure needs upgrading, we can supply that as well.
What is the difference between a wire rope hoist and a chain hoist?
Electric chain hoists use a roller link chain and are compact, economical, and ideal for capacities up to about 3 tons with standard lift heights. Wire rope hoists use a steel cable wound on a drum and are designed for heavier capacities (1–25+ tons), longer lift heights, and higher duty cycles. For most production applications above 2 tons or with frequent use, a wire rope hoist is the better long-term investment due to its higher duty rating and lower operating cost per cycle.
Technical Reference
Crane Terms & Glossary
A quick-reference glossary of common overhead crane and hoist terminology used in specifications, quotes, and industry standards.
A
Anti-collision SystemSensors or controls that prevent two cranes on the same runway from colliding. Required when multiple bridge cranes share a common runway.
ASME B30American Society of Mechanical Engineers safety standards governing the design, installation, inspection, and operation of cranes, hoists, and rigging equipment.
B
BridgeThe horizontal structural beam(s) of an overhead crane that span the runway rails and carry the hoist and trolley. Can be single girder or double girder construction.
Bridge TravelThe movement of the bridge along the runway rails — the long-axis travel direction of the crane system.
Bumper / BufferEnergy-absorbing devices mounted at the end of crane bridges and runways to stop travel at the end of the rail and limit impact forces.
C
CMAACrane Manufacturers Association of America. Sets the industry standards (Spec #70 for top-running, Spec #74 for underhung) for overhead crane design and duty classification.
CapacityThe maximum rated load a crane or hoist is designed to lift safely. Always expressed as a defined working load limit — never exceed the rated capacity.
Chain HoistA hoist that lifts using a roller link steel chain. Available in electric or manual (hand chain) operation. Best for capacities up to 3 tons and standard lift heights.
Conductor BarElectrified rails mounted along the runway that deliver power to the bridge crane as it travels. An alternative to festoon cable systems.
D
Dead LoadThe weight of the crane structure itself — bridge, end trucks, hoist, trolley, and conductor system — that the runway and building structure must support at all times.
Double GirderA bridge crane configuration using two parallel bridge beams. The hoist runs on top of the beams (top-running trolley), allowing maximum hook height and higher capacity ratings than single girder systems.
Duty ClassCMAA classification (A–F) that defines how strenuously a crane is expected to operate over its lifetime, based on lift frequency and load spectrum. See the Duty Class table above.
E
End TruckThe wheel assemblies at each end of the bridge beam that ride on the runway rails and allow bridge travel. Available in powered (motorized) or non-powered configurations.
Enclosed TrackA hollow structural aluminum or steel track profile in which the trolley wheels ride inside the track. Common in workstation bridge cranes. Provides smooth, low-friction travel and protects the running surface.
F
Festoon SystemA cable carrier system that provides electrical power to a traveling crane bridge or hoist trolley using a series of cable hangers that accordion along the beam as the crane travels.
Freestanding CraneAny crane system that supports itself through floor-anchored columns rather than attaching to the building roof structure. Ideal for leased facilities or buildings with insufficient structural capacity.
G
Gantry CraneA crane similar to a bridge crane but supported on legs that travel on ground-level rails or casters instead of elevated runways. Can be portable or fixed.
GirderThe main horizontal structural member of a bridge crane. In single-girder cranes, one girder carries the hoist. In double-girder cranes, two parallel girders share the load.
H
HeadroomThe vertical distance from the bottom of the crane beam to the hook at its highest position (fully raised). Low-headroom hoists minimize this dimension to maximize usable hook height in facilities with limited ceiling clearance.
Hook HeightThe distance from the floor to the hook at its highest point. This is what determines how high you can actually lift a load — not ceiling height. Always verify hook height requirements before specifying a system.
HoistThe lifting mechanism — motor, drum or chain, gear train, brake, and hook — that raises and lowers the load. Attached to a trolley that travels along the crane beam.
I
Inverter DriveA variable frequency drive (VFD) that provides smooth, adjustable-speed control of crane motions. Reduces shock loads, improves positioning precision, and extends component life. Highly recommended for production applications.
J
Jib CraneA crane with a horizontal arm (boom) that rotates around a fixed vertical mast or wall bracket. Provides 180–360° coverage of a localized area. Ideal for individual workstations.
L
Limit SwitchA safety device that automatically stops crane motion (hoist travel, bridge travel, or trolley travel) when a physical limit is reached — such as the hook at maximum height or the bridge at the end of the runway.
Live LoadThe maximum rated capacity of the crane plus the weight of rigging hardware. This is the variable load that the crane structure, runway, and building must be designed to support.
O
OSHA 1910.179The Occupational Safety and Health Administration standard governing overhead and gantry crane installation, maintenance, operation, and inspection requirements in the United States.
Overload ProtectionA device that prevents the hoist from lifting loads that exceed its rated capacity. Can be mechanical (slip clutch) or electronic (load cell-based). Required by ASME and OSHA for many applications.
P
Pendant ControlA tethered pushbutton controller that hangs from the crane and is operated by hand. The operator must stay near the pendant while operating the crane. Standard on most electric hoists and cranes.
R
Radio Remote ControlA wireless handheld transmitter that controls all crane motions. Allows the operator to walk freely with the load. Significantly improves safety and positioning accuracy for production applications.
RunwayThe parallel rails and supporting structure along which the bridge crane end trucks travel. Can be ceiling-hung, wall-mounted, or supported on freestanding columns.
S
Single GirderA bridge crane configuration using one bridge beam with an underhung hoist. More economical than double girder, ideal for lighter capacities and tighter headroom situations.
SpanThe horizontal distance between the centerlines of the runway rails (for bridge cranes) or the reach of the boom (for jib cranes). Span is one of the most critical dimensions in crane specification.
T
Top-Running CraneA bridge crane where the end trucks ride on top of the runway rails. Allows higher capacities and longer spans than underhung designs and is the standard configuration for heavy-duty industrial cranes.
TrolleyThe wheeled assembly that carries the hoist and travels along the bridge beam, providing cross-travel (perpendicular to bridge travel). Available as push, geared, or motorized.
Trolley TravelThe movement of the hoist trolley across the width of the bridge beam — the short-axis direction of crane motion. Together with bridge travel, this gives the crane its full rectangular coverage area.
U
Underhung / Under-Running CraneA bridge crane where the end trucks and bridge beam hang from the bottom flange of the runway beam. Maximizes hook height in low-clearance facilities. The standard configuration for workstation bridge crane systems.
W
Wire Rope HoistA hoist that lifts using a steel wire rope wound on a drum. Suitable for heavier capacities (1–25+ tons), longer lifts, and higher duty cycles than electric chain hoists. The standard hoist type for production and heavy industrial applications.
Working Load Limit (WLL)The maximum load that equipment (crane, hoist, sling, or rigging hardware) is rated to handle in normal service. Never exceed the WLL of any component in the lifting system.
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