Returning to Work After Shutdown: Safe Crane Operations

The Christmas and New Year shutdown period is an important time for rest and reset, but it also introduces unique safety risks when operations resume.

Overhead cranes, hoists, and lifting equipment that have been idle for several weeks require extra attention before returning to full production. Whether you operate an overhead crane, jib crane, gantry crane, or workstation system, taking the right steps early can prevent breakdowns, costly downtime, and serious safety incidents.

Below is a practical guide to help ensure your crane operations restart safely and smoothly.

Why post-shutdown crane checks matter

After extended shutdowns:

  • Lubricants can settle or degrade

  • Electrical components may be affected by moisture or temperature changes

  • Wire ropes and chains can develop corrosion

  • Brakes and limit switches may not operate as expected

  • Operators may be out of routine

A proactive approach protects your people, your equipment, and your production schedule.

1. Conduct a visual crane inspection before use

Before lifting any load, complete a basic visual inspection of your crane and hoist system:

  • Check wire ropes or load chains for wear, corrosion, or damage

  • Inspect hooks, latches, and lifting attachments

  • Look for oil leaks, loose bolts, or structural damage

  • Confirm end stops and buffers are intact

  • Ensure pendant controls or radio remotes are functioning correctly

If anything appears unusual, stop and contact a qualified crane service provider before operating.

2. Test crane functions with no load

Always perform a no-load functional test:

  • Hoist up and down

  • Long travel and cross travel

  • Emergency stop

  • Upper and lower limit switches

  • Braking performance

This ensures the crane is responding correctly before handling suspended loads.

3. Review operator competency and refresh training

Even experienced operators can become rusty after extended breaks.

Consider:

  • Toolbox talks focused on crane safety

  • Reviewing safe lifting procedures

  • Reinforcing exclusion zones

  • Reminding operators of load limits and duty classifications

Competent operators are one of the most critical safety controls in overhead crane operations.

4. Check service and inspection compliance

Australian Standards require regular crane inspections and maintenance.

Confirm that:

  • Your crane inspections are up to date

  • Logbooks are current

  • Any defects identified before shutdown were repaired

  • Major inspections or annual services are scheduled if due

If you are unsure, arranging a professional crane inspection can provide peace of mind and compliance assurance.

5. Be mindful of fatigue and reduced alertness

The first weeks back at work often involve:

  • Early starts

  • Heat exposure

  • Reduced sleep routines

  • Mental fatigue

These factors increase the risk of incidents involving lifting equipment. Encourage slower ramp-ups and maintain strong supervision during the return-to-work period.

6. Plan lifts carefully during early production

Avoid rushing critical lifts:

  • Use lift plans where required

  • Confirm load weights

  • Use appropriate lifting beams, spreader beams, and rigging gear

  • Communicate clearly between dogmen, riggers, and crane operators

A controlled restart is always safer than recovering from an accident.

When to call a professional crane service provider

You should arrange professional support if:

  • Your crane has been idle for several months

  • You notice unusual noises, jerky movement, or faults

  • Your crane is overdue for inspection

  • You are commissioning new equipment

  • Your site is increasing production capacity

A preventative service is far more cost-effective than unplanned downtime.

Supporting safe crane operations all year round

At West Crane Services, we support customers across Victoria and Australia with:

  • Overhead crane servicing and inspections

  • Breakdown response

  • Preventative maintenance programs

  • Load testing

  • Crane repairs and upgrades

  • New overhead crane and hoist installations

  • Australian-made crane manufacturing

If you would like assistance inspecting or servicing your crane after the shutdown period, our team is ready to help.

Stay safe. Start smart. Lift with confidence.

If you would like to discuss your crane servicing requirements or book a post-shutdown inspection, contact West Crane Services today.

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