Yes, a KBK system can in most cases be installed in an existing industrial building without major structural modifications. Both building-mounted and freestanding configurations make it possible to integrate a light crane into an existing structure, provided the load-bearing capacity and available space allow for it. In this article, we answer the most frequently asked questions about installing a KBK rail in an existing building.
What are the technical requirements for installation in an existing building?
For the installation of a KBK system in an existing industrial building, the most important technical requirements are: sufficient clear height beneath the structure, a load-bearing roof structure or columns, and a stable floor for any freestanding support. A structural assessment of the existing construction is always the first step.
In practice, this means the following aspects are evaluated in advance:
- Clear working height: There must be sufficient space beneath the KBK rail for the hoist and the load to be transported.
- Load-bearing capacity of the structure: The roof trusses, columns, or walls must be able to absorb the static and dynamic loads of the crane system.
- Floor load: In a freestanding system, the forces are transferred via columns to the floor, making floor strength a relevant factor.
- Travel clearance and obstructions: Existing installations, pipework, and structures also determine the design of the KBK rail.
A structural calculation makes clear whether the existing building is suitable, and if not, what modifications are required to safely install the crane system.
How is a KBK system attached to an existing structure?
A KBK system is attached to an existing structure via steel suspension structures or brackets that are connected to roof trusses, columns, or walls. The exact fixing method depends on the type of structure and the desired travel direction of the overhead crane or light crane.
In practice, there are two common methods:
- Direct suspension from trusses: The KBK rail is attached to the existing roof trusses via steel suspension rods. This is the most compact solution and requires minimal additional space.
- Attachment to columns: When the roof structure has insufficient load-bearing capacity, the rail guides can be attached to existing or new steel columns along the walls of the building.
In both cases, the connections are calculated for the maximum load, including dynamic forces during travel and lifting. All fixing points are dimensioned in accordance with the applicable standards for crane installations.
What is the difference between a freestanding and a building-mounted KBK system?
The key difference is where the load-bearing forces go: a building-mounted KBK system is suspended from the existing building structure, while a freestanding system stands on its own columns and transfers the forces directly to the floor, independently of the building.
Building-mounted KBK system
In a building-mounted configuration, the KBK rail is suspended from the roof trusses or attached to the columns of the building. This is ideal when the existing structure has sufficient load-bearing capacity. The advantage is that no additional floor space is lost to support columns, keeping the working floor clear and unobstructed.
Freestanding KBK system
A freestanding system has its own steel structure that is completely independent of the building. This is the preferred choice when the existing building does not have a sufficiently load-bearing structure, or when the building owner does not permit modifications to the structure. A freestanding KBK system is also easier to relocate or expand in the future.
What work is required for installation in an existing building?
The installation of a KBK system in an existing building typically includes: a structural assessment of the building, the design of the rail structure, fabrication of the components, mechanical assembly and electrical connection, followed by an official inspection and test run.
Step by step, the installation process looks as follows:
- Survey and assessment: A technical specialist assesses the existing structure and surveys the space.
- Design and calculation: Based on the survey, a custom design is created, including structural calculations.
- Fabrication: The KBK rail, suspension structures, and any columns are fabricated to measure.
- Mechanical assembly: The rail sections and beams are installed in the building, often with the aid of a scissor lift or mobile crane.
- Electrical installation: The power supply, controls, and safety components are connected and tested.
- Inspection and commissioning: The system is inspected in accordance with the applicable standards and, upon approval, put into service.
Can production continue during the installation of a KBK system?
In most cases, production can continue partially or even fully during the installation of a KBK system. By planning the installation in phases and working outside regular production hours, disruption to the business process is kept to a minimum.
The extent to which production can continue depends on the scale of the project and the layout of the building. For a smaller crane installation, assembly is often completed within one or two days, limiting the impact on daily operations. For larger or more complex systems, the work is carefully scheduled so that critical workstations are out of service for as short a time as possible.
Good communication and a clear plan in advance are essential. A detailed installation plan makes clear which zones will be temporarily unavailable, so that production can be adjusted accordingly.
When is a KBK system the right choice for an existing building?
A KBK system is the right choice for an existing building when there is a need for a flexible, lightweight lifting solution for loads up to approximately 2,000 kg, where the available space and structure do not allow for a heavy overhead crane, or when a modular system is desired that can be easily expanded.
Specific situations in which a KBK rail is the preferred option:
- The building has limited clear height, making a traditional overhead crane unsuitable.
- The existing roof structure is not designed for heavy crane loads.
- There is a need for a travel path serving multiple workstations via a branched rail system.
- The company is growing and wants a system that can be easily expanded at a later stage.
- The lifting frequency is high and an ergonomic light crane provides a better working environment than manual handling.
If the required lifting capacity exceeds what a KBK system can offer, a custom overhead crane in an existing building may be a better solution. A technical consultation helps in making the right choice based on the specific situation.
How BKRS helps with the installation of a KBK system in your existing building
We guide the entire process from consultation to inspection, so you know exactly where you stand. As a specialist in custom crane systems, we assess the possibilities in your existing industrial building and design a KBK system that seamlessly fits your work process. What we take care of for you:
- A free technical survey and structural assessment of your building
- Custom design of the KBK rail, including structural calculations
- Fabrication and assembly by certified installers
- Electrical installation and connection of controls and safety components
- Official inspection and commissioning in accordance with applicable standards
- Annual inspection and maintenance after delivery
Would you like to know whether your industrial building is suitable for a KBK system? Contact us for a no-obligation consultation. We are happy to think along with you about the best lifting solution for your situation.
Frequently Asked Questions
How long does the installation of a KBK system in an existing building typically take?
The installation time depends on the scale and complexity of the system. A simple single KBK rail is often installed within één to two days, while an extensive branched rail system may take several days. BKRS prepares a detailed installation plan in advance so you know what to expect.
What are the maintenance obligations after the installation of a KBK system?
A KBK system must be inspected and maintained annually in accordance with the applicable standards for lifting and transport equipment. During this inspection, wear, fixings, electrical components, and safety provisions are checked. Regular maintenance extends the service life of the system and prevents unexpected downtime.
Can an existing KBK system be expanded or modified at a later stage?
Yes, the modular nature of a KBK system makes expansion or modification relatively straightforward. Additional rail sections, switches, or workstations can be added without replacing the entire system. It is, however, advisable to already account for future expansions during the initiële design.
What maximum lifting capacity does a KBK system support?
A KBK system is suitable for loads up to approximately 2,000 kg, depending on the chosen rail profile and the hoist used. For heavier loads, a custom overhead crane is generally the better choice. A technical consultation will help you determine which system best suits your lifting capacity and working environment.