UNDERSTANDING OVERHEAD CRANE DEFLECTION

AND CRITERIA
Overall, deflection is literally defined as “deviation from an allotted course”. It can mean that
something is deviated by turning aside or by coming off course. For overhead cranes, this
definition translates to the relative vertical or horizontal displacement of a member or part of an
overhead crane. So how does that impact the design of the crane, and how is the vertical and
horizontal deflection calculated? And, how do organizational specifications differ from crane to
crane and from association to association? Let us explain.

VERTICAL DEFLECTION CRITERIA

Vertical Deflection Criteria is the maximum (vertical) deflection ratio allowed for a lifting device.
Vertical deflection differs from horizontal deflection, but both are taken into account for enclosed
track bridge cranes. Vertical deflection impacts any part of the crane that stands vertically,
including the mast, columns, wall, etc.
Most systems are manufactured to an approximate deflection, because manufacturers have no
control over installation, foundation rigidity, or the standard variation in thickness tolerances for
the piping, tubing, steel plate, and sheet metal. That means, some variation above or below
deflections defined by manufacturers should be considered normal. That being said, when
overhead cranes are installed according to the standard installation manual and maintained
according to the manufacturers installation maintenance manual, you can be assured of the
safety of lift products and their ability to handle chosen rated capacities and performance
standards.
When measuring deflection for safety standards, the deflection is measured at 100 percent
capacity, rather than 125 percent capacity. According to ANSI Standards (ANSI/ASME B30.2) for
Overhead Travelling Cranes Operational and Running Tests: “Standard deflection must be
measured with a load of 100 percent of the rated capacity and must not exceed the allowable
deflection specified by the applicable design standard.” For each type of crane the deflection
value differs, depending on the crane’s overall length, span, or reach.
For workstation (enclosed track) bridge cranes, the vertical deflection value is less than for
heavier bridge cranes. Enclosed track workstation bridge cranes have a deflection limit of L/450.
The letter “L” literally stands for the length of the crane, or span. In other words, to determine the
deflection of your workstation bridge crane, you must first know its span or length. This equation
is always measured in inches. That’s because if your deflection is higher than a value measured
in inches, you’re in big trouble. Deflection should be very minor. To measure your deflection, use
the deflection limit defined for that type of crane and divide that number by the length (or span) of
your specific system. If your bridge length is 34 feet, you will divide the deflection limit defined by
your manufacturer (L/450 for workstation bridge cranes).
The deflection for a 34-foot bridge on a workstation bridge crane can be determined by first
changing the unit of measurement from feet to inches. A 34-foot bridge is 408 inches long (feet x
12= inches). Divide 408 inches by the specified deflection limit for enclosed bridge cranes
(L/450). That will give you a deflection of less than one inch (.9 inches).
Deflection is determined for other overhead crane systems using the same method. The criterion
is the same, but the terminology and deflection limits differ slightly from system to system. For
instance, when determining the deflection for a workstation (enclosed track) bridge crane, we
would use a deflection limit of L/450, as specified above. However, when determining the
deflection for a gantry crane, the deflection limit is L/600 for steel gantries, and L/450 for
aluminum gantries. Steel will almost always have a slightly higher deflection limit due to its
rigidity compared to that of aluminum. To determine the deflection of an all-steel gantry with a
span (beam length) of 25 feet, you would follow the same equation we used to determine the
deflection for workstation bridge cranes, only using the deflection limit for steel gantry cranes. In
order to do so, we would first have to change the unit of measurement to inches. A span of 25
feet (multiplied by 12) is 300 inches. Next, we would determine the deflection by dividing the
span of the gantry in inches by the deflection limit specified by the manufacturer. For Spanco,

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this number is, as specified above, L/600. A gantry crane spanning 300 inches has a deflection
of a half an inch (.5 inches).
To determine the deflection for a jib crane, the equation remains the same, but the terminology
can also differ from system to system, and the deflection limits differ once again. Some
manufacturers will refer to the length or span of the jib as the “reach”. That’s why you might see a
deflection limit for jib cranes referred to using the letter “R” rather than the letter “L”. It depends
on your manufacturer. But, for the purpose of determining your deflection, keep in mind that “R”
simply stands for “Reach” and “L” stands for “Length”. Whether it’s referred to as the reach, the
span, or the length is irrelevant in this case. The deflection equation still remains the same.
When determining the deflection for jib cranes, the type of jib in question is also an important
factor.
At Spanco, we have five different jib crane series, and each series has several installation types
that impact the deflection limit. For instance, our 100 Series Freestanding Jib Crane has a
deflection limit of L/150 (also known as R/150). That number is the same for our 200 Series
Mast-Style Jib Cranes and our 300 Series Wall-Mounted Jib Cranes. However, our 400 Series
Articulating Jib Cranes have a deflection limit of L/200 (or R/200), and our 500 Series
Workstation Jib Cranes have a deflection limit of L/150 OR L/225, depending on the way the
crane is mounted. For Freestanding Workstation Jib Cranes, there’s a lower deflection limit. But
for our 501 Series Wall-Cantilever Workstation Jib Cranes, we use a higher deflection limit of
L/225 due to its wall-mount. For a 501 Series Wall-Cantilever Workstation Jib Crane, the
deflection for a crane with a 12-foot span can be calculated similarly to the abovementioned
systems. First, we would need to change our unit of measurement to inches. In this case, a 12-
foot span (or reach) is equivalent to 144 inches. If we divide 144 inches by the deflection limit of
225, we get a deflection of a little more than a half an inch (.64 inches).

HORIZONTAL DEFLECTION CRITERIA

Horizontal Deflection Criteria is the maximum deflection ratio allowed for a bridge crane or
runway. Horizontal deflection, unlike vertical deflection, impacts parts of the crane that run
horizontally. This is taken into account for enclosed track systems, including workstation bridge
cranes and workstation jib booms.
Most manufacturers design for a maximum lateral deflection for runways and cranes of
L/400. The “L” in this case refers to the span of the bridge crane from the runway support center.
That number is divided by the deflection limit of 400. For example, to determine the deflection for
a ceiling-mounted workstation bridge crane with bridge length of 40 feet, we must first translate
the unit of measurement to inches. A 40-foot span is equivalent to 480 inches. If you divide 480
inches by the specified deflection limit of 400, the horizontal deflection for that particular crane is
1.2 inches.

RIGIDITY REQUIREMENTS
It’s crucial for manufacturers to conform to theoretical considerations and to subject their systems
to a variety of checks like stress analyses and horizontal and vertical deflection analyses of
bridges, beams, masts, columns, and other parts. These systems should prove to conform to
theory and their static structural response must preserve the response of the original crane
structure in order to pass these tests.
According to rigidity requirements laid out by OSHA and ANSI the following maximum values for
the deflection of the crane girder must normally not be exceeded in order to avoid undesirable
dynamic effects and to secure the function of the crane:

 Vertical deflection is defined as the maximum permissible deflection ratio allowed for a
lifting device. For bridge cranes this value is usually L/700. For a Workstation Bridge
Crane, the value is less (L/450) because the enclosed track is lighter.
 Horizontal deflection is a maximum deflection ratio allowed for a bridge crane or runway. For regular
bridge cranes, this value is usually L/600. For a Workstation Bridge Crane, the value is less (L/400).

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In the absence of more detailed calculations, it is acceptable to assume that the top flange
resists the whole horizontal force. The rigidity requirement for horizontal deflection is essential to
prevent oblique traveling of the crane. The vertical deflection is normally limited to a value not
greater than 25 mm to prevent excessive vibrations caused by the crane operation and crane
travel.

TESTING REQUIREMENTS
According to OSHA and ASME, crane load tests are typically specified at 125 percent of the
crane’s rated capacity. Neither standard, however, specifies an acceptable tolerance over or
under the 125 percent figure. ASME B30.2 does in fact reference a figure in its interpretation of
load testing, which suggests a tolerance of 0%/-4% on the weight of the test load. In effect, this
suggested a test load weighing between 120 percent and 125 percent of the rated crane capacity
(i.e.: 125% -125% x 0.04 = 120%).
Furthermore, any overhead crane that has been significantly modified, or that was installed after
January 1999, must be load tested before being put into service. The deflection test defined by
OSHA and ASME suggests that structural deflections must be measured with loads of 100
percent of the rated capacity and must not exceed the allowable deflections specified by the
applicable design standard (deflection limits, as listed above). OSHA and ASME also specify that
the load must travel over the full length of the bridge and trolley runways during these load tests,
and only runway parts that have been successfully load tested may be placed into service.
If you have any questions about deflection or the deflection limit values outlined in this blog,
please feel free to comment below. To ensure your deflection values are correctly calculated, it’s
important to reach out to your local overhead crane distributor or a qualified engineer for more
information.

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