Emergency Overhead Crane Repair Restores Victorian facility Operations

Project Overview

During a critical maintenance shutdown at a major Victorian facility, a 70-year-old Johns and Waygood overhead crane experienced a catastrophic failure. The crane’s final upper limit malfunctioned, causing the hook to over-travel and strike the compensating sheaves, resulting in severe mechanical damage. This unexpected incident immediately halted essential maintenance on one of the facility’s two generators, creating significant downtime, safety risks, and production delays.

The Victorian facility urgently required a trusted and experienced crane service provider capable of delivering a fast, compliant, and technically precise repair. Crane Aid was engaged to lead the recovery effort, drawing on its in-house machining, engineering, and fabrication capabilities to restore full operational safety in record time.

The Challenge

The overhead crane, commissioned in 1951, had been a dependable workhorse for decades, but the age of the equipment presented a major challenge. With critical components damaged beyond repair and no readily available replacements, the client faced an extended outage if parts had to be sourced externally.

The failure of the final limit system also created a safety risk, as any repeat of the incident could have led to structural damage or personal injury. The project demanded not only rapid turnaround but full compliance with AS1418.1 (2025) Australian Standards, ensuring the crane could return to service safely and prevent future recurrence.

Crane Aid’s Solution

Crane Aid’s team acted immediately, mobilising its engineering, machining, and service divisions to deliver a comprehensive repair strategy. Using original technical drawings, Crane Aid reverse-engineered and manufactured new compensating sheaves from high-strength materials, enhancing durability beyond the original design.

The new sheaves were machined in-house at Crane Aid’s workshop, fitted with brass bushings for smoother operation and longer service life. While the original estimate allowed for a 3–4 week completion timeframe, Crane Aid compressed this into just two weeks — from materials procurement to full on-site installation.

All works were performed in accordance with AS1418.1 (2025) and under ISO9001-certified quality management systems. The repair team operated under a detailed Safe Work Method Statement (SWMS) and daily Job Safety Analysis (JSA), ensuring the project was completed with zero injuries, incidents, or equipment damage.

The Results

The repaired crane was returned to service 33% faster than initially projected, allowing the power station to complete its shutdown maintenance on schedule. The newly engineered sheaves not only restored full operational capability but also improved the longevity, safety, and performance of the crane.

By delivering precision-engineered components in-house, Crane Aid reduced downtime, eliminated supply chain delays, and provided a long-term, compliant solution for an aging but vital piece of infrastructure. The project concluded safely and efficiently, with no lost-time injuries (LTIs) and full AS1418.1 compliance documented.

Key Outcomes

• • ✅ Crane operation restored 33% faster than expected
  • ✅ Replacement sheaves engineered and machined in-house from stronger materials
  • ✅ AS1418.1 (2025) and ISO9001 standards fully adhered to
  • ✅ Zero injuries or incidents throughout project execution
  • ✅ Extended equipment life and enhanced operational reliability

About Crane Aid

Crane Aid Pty Ltd is a trusted Australian provider of overhead crane repairs, inspections, engineering, and component manufacturing. With full in-house machining and fabrication facilities, Crane Aid delivers rapid-response solutions that meet the highest standards of safety, compliance, and precision.

From emergency repairs to major modernisations, Crane Aid supports clients across manufacturing, construction, and logistics industries throughout Victoria and New South Wales — keeping Australia’s lifting equipment safe, reliable, and operational.