Engineered Anti-Derailment System Installation for 55-Tonne Overhead Cranes

Enhancing Crane Safety and Compliance at a Victorian Maintenance Facility

Following a recent third-party inspection at a major Victorian maintenance facility, it was recommended that anti-derailment systems be installed on two 55-tonne overhead cranes. These systems are critical safety features designed to prevent wheel derailments, protect equipment, and safeguard personnel.

With the cranes essential to daily operations, the facility required a trusted partner capable of delivering a turnkey solution — from engineering and fabrication through to installation and testing — all without interrupting production. Crane Aid was selected for its proven expertise, precision manufacturing capabilities, and commitment to Australian Standards compliance.

The Challenge

This project presented several technical and logistical challenges. The cranes were positioned more than 10 metres above ground level, requiring precise jacking procedures to create safe access for installation. This operation demanded detailed planning, controlled lifting, and close coordination between engineering and service teams.

Additionally, the anti-derailment components needed to be manufactured to exact tolerances to integrate seamlessly with the existing crane structure. With no external supplier able to meet the specifications in time, Crane Aid’s in-house engineering and machining teams were tasked with producing the parts from scratch — ensuring dimensional accuracy, structural integrity, and full compliance.

Safety remained the highest priority throughout, with all works conducted under Safe Work Method Statements (SWMS), Job Safety Analyses (JSA), and approved lift plans, adhering strictly to ISO 9001 quality procedures.

Crane Aid’s Solution

Crane Aid’s engineering and machine shop manufactured all anti-derailment components in-house using advanced machining technology, guaranteeing perfect fit and functionality. Once complete, the site team implemented a carefully controlled jacking operation to safely elevate the cranes to the required height for access and installation.

The anti-derailment devices were precision-aligned, welded, and painted to match the existing crane structure and provide long-term protection against wear and corrosion. Every step — from fabrication to final inspection — was carried out with meticulous attention to safety and quality.

All installation activities were performed in strict accordance with AS1418 and AS2550 standards, ensuring compliance and long-term reliability.

The Results

The completed installation delivered a fully compliant, upgraded crane system with enhanced safety, stability, and operational reliability. Both 55-tonne cranes were fitted with precision-engineered anti-derailment systems, designed and installed exactly to the engineer’s specifications.

The project was completed without incident, delay, or lost-time injury (LTI) — a testament to Crane Aid’s strong safety culture and technical discipline. The facility’s cranes are now better protected against potential derailments, significantly reducing risk and improving overall operational resilience.

Key Outcomes

Precision-engineered anti-derailment devices manufactured in-house
Cranes safely jacked to 10 metres for installation access
Components welded, aligned, and painted to engineering specifications
All work completed under SWMS and JSA, aligned with ISO 9001 procedures
Zero LTIs or safety incidents
Improved crane safety, compliance, and reliability

About Crane Aid

Crane Aid Pty Ltd is a leading Australian provider of overhead crane repairs, inspections, engineering, and safety upgrades. With workshops in Dandenong South, South Albury, and Strathdale, Crane Aid supports clients across Victoria, New South Wales, and South Australia.

Our in-house machining, fabrication, and engineering teams allow us to deliver rapid, fully compliant solutions — from emergency repairs and preventative maintenance to custom-engineered safety modifications such as anti-derailment systems, load limiters, and structural enhancements.

Crane Aid — keeping Australia’s lifting equipment safe, compliant, and operational.