Whether to overhaul, retrofit or replace a large crane depends on its age, the cost of repair compared with a new crane, and the cost of unplanned downtime. As a rule of thumb, if a crane has passed 15–20 years of service or its structure is heavily damaged, a retrofit or replacement usually gives a lower total cost of ownership, better energy efficiency and better safety than repeated repairs.
3 Criteria for Deciding
1. The 50% Rule
A common engineering and accounting rule of thumb: if a major repair (parts and labour) costs more than about 50–60% of a new crane of the same grade, buying new is usually better value. A new crane comes with a fresh warranty and removes the risk of other, unreplaced parts wearing out.
2. Unplanned Downtime and Lost Opportunity
In continuous production, time is money. If a large crane breaks down repeatedly and stops logistics or production, the accumulated cost of a few days of downtime can exceed the price of a new hoist or crane. Replacing it buys stability for the business.
3. The Safety and Technology Gap
Cranes in service for more than 15 years often use older single- or two-speed motor control that jerks when lifting, increasing load sway and structural fatigue. Newer cranes with inverter (VFD) speed control and modern electronic safety systems reduce this risk.
Retrofit: The Strategic Middle Option
If an assessment shows that the main girder and runway beams are still structurally sound, the plant does not need to buy a whole new crane. A retrofit replaces only the hoist, the drive motors and the electrical control panel, giving performance and safety close to a new crane for less capital spend.
Comparison of the Options
| Factor | Overhaul | Retrofit | Full replacement |
|---|---|---|---|
| Initial investment | Lowest | Medium (high value) | Highest |
| Service life after the work | Short; other parts may fail | Medium; core systems renewed | Longest |
| Safety and technology | Same as before | High; new sensors can be added | Highest; current standards |
| Production downtime | Medium (dismantling and repair) | Medium (can be planned) | Longest (structure removed) |
How ONVALLA Helps You Decide
ONVALLA acts as an engineering advisor: we inspect the crane in depth, analyse the structure and metal condition, and prepare a report comparing repair, retrofit and replacement, so every baht invested delivers the most for production and safety. For hoists specifically, see hoist overhaul vs. a new hoist.
Frequently Asked Questions
Can a retrofit use a different hoist brand from the original?
Yes. ONVALLA’s engineers can design adaptor parts and adjust the electrical system so a new, high-quality hoist fits and works safely with the existing crane structure.
How long does an industrial crane last before replacement should be considered?
Typically around 15–20 years of economic and engineering life, depending on duty class and maintenance history. Beyond this, older spare parts get harder to find and repair costs stop being worthwhile.
Ask for a crane condition assessment through our after-sale service or contact ONVALLA.
