This question comes up with every older crane: repair and modernize, or buy new? There is no general answer — there is only an assessment of three things: the condition of the steel structure, the costs, and what the crane is supposed to do over the next 15 years.
The scope of work we do in modernizations is summarised in crane modernization and refurbishment.
When modernization makes sense
The steel structure of an old crane is often in better shape than everything else. Bridges built in Czechoslovakia even in the 1980s have a reserve that today’s serial production often lacks. If the structure is sound, modernization pays off almost every time:
- Hoist replacement with a new SWF — better brakes, more precise positioning, parts available for the next 30 years.
- New electrical installation and control panel — no more chasing faults through 40-year-old wiring.
- Frequency inverters on the travel and hoist drives — smooth starts, no jerking, easier on the mechanics and the load.
- Radio remote control — the operator stands next to the load, not under it.
- Retrofitting safety devices — load limiter, anti-collision systems, signalling. The crane passes inspection without objections.
Modernization typically costs 30–50 % of a new crane’s price and the device is back in operation in days, not months.
When a new crane is the better choice
We do not recommend modernization if at least one of the following applies:
- The structure is damaged or fatigued over time — cracks in the main welds, bridge deformation. Repair is not worth it and safety cannot be “modernized in”.
- You need higher capacity or span — a bridge cannot be re-rated to a higher capacity. Changing a parameter means a new bridge and runway.
- The crane no longer fits the process — if production has changed so much that you need a different lifting height, tandem operation or automation, a new crane comes out cheaper than a set of compromises.
How to compare costs honestly
The purchase price is not the whole price. Compare like this:
| Modernization | New crane | |
|---|---|---|
| Initial investment | 30–50 % of the new price | 100 % |
| Production downtime | days to 2 weeks | weeks (manufacturing + installation) |
| Service life after the work | 15–20 years | 25–30 years |
| Spare parts | available (SWF, new electrics) | available |
| Building modifications | none | possibly a runway and hall assessment |
Watch out for a hidden item with a new crane: if the old crane is heavier or has a different wheel gauge, the runway and its anchoring may need modification. That can change the bill significantly — which is why we assess the runway first and only then quote the crane.
How we approach the decision
With every older crane we do the same thing: inspect the structure and electrical installation, assess the runway, and budget both the modernization and the new solution. You get both prices side by side with a service-life estimate — and you decide with numbers in hand, not on a salesperson’s promise.
Most customers with a sound bridge modernize today. Where it makes no sense, we say so straight — and then we design the new crane for you, runway included.
More about the scope of work is on the crane modernization and refurbishment page, or send us the crane type and year of manufacture — we will give you an indicative verdict free of charge.