Client: Confidential industrial operator – UAE
Sector: General Industry
Execution period: 3 weeks (incl. dismantling, refurbishment, commissioning)
Background
The client, a UAE-based industrial facility operating in a coastal outdoor environment, was using a 5-ton gantry crane that had been in continuous service for over a decade. Despite basic operational functionality, the crane showed clear signs of ageing:
- Advanced corrosion on structural elements
- Worn-out electrical and mechanical components
- Safety systems no longer compliant with current regulations
- Decreased lifting precision and reliability
Replacing the crane with a new system would have required long lead times, civil modifications, and a significant investment. Lootah Lemmens was approached to assess whether the existing crane could be technically and economically restored to safe, certifiable condition.
Technical Scope of Work
Following an in-depth site survey and structural assessment, our engineering team developed a full refurbishment scope covering both mechanical and structural elements. The work was executed in the following phases:
1. Disassembly and Decommissioning
- Controlled dismantling of the hoisting unit using mobile crane assistance
- Lock-out/tag-out procedures implemented for electrical isolation
- Protective measures to safeguard the main structure during hoist removal
2. Hoist Replacement
- Installation of a Verlinde electric wire rope hoist, rated 5,000 kg SWL
- New trolley system configured to fit existing rail and structural clearances
- Commissioned with overload protection, limit switches, and new festoon cabling
3. Structural Rehabilitation
- Local repair of corroded weld seams and stiffener plates
- Reinforcement of main beam and end carriage connections
- Sandblasting, anti-corrosion coating, and full repainting (RAL 1004 yellow)
- Dimensional and deflection checks to confirm load-bearing compliance
4. Electrical and Control Modernization
- Replacement of main control panel with IP65 industrial-grade enclosure
- Integration of a Tele Radio Panther remote control system for safe operation
- New wiring, overload protection relays, and emergency stop circuit
5. Testing and Certification
- Load test at 125% of SWL in accordance with EN 15011
- Final inspection and third-party certification issued on-site
Project Results
Thanks to the successful execution of this refurbishment project, the client achieved:
- Extended crane lifecycle without the need for full replacement
- Full compliance with current safety standards and local authority regulations
- Minimized downtime (less than 3 weeks total execution time)
- Significant cost savings compared to new equipment procurement
Engineering Note
This project demonstrates the feasibility of refurbishing ageing lifting equipment when the primary structure remains dimensionally sound. With proper analysis and professional execution, restoring such cranes is a cost-effective and sustainable alternative to replacement — especially in time-critical industrial environments.
Looking to restore or upgrade your crane?
Lootah Lemmens offers structural assessments, engineering consultancy, and full refurbishment solutions for overhead, gantry, and jib cranes throughout the GCC.
Contact us to schedule a site visit or discuss a tailored solution.
