The plant systematically maintains the crane facilities and hoisting equipment in good technical condition, because their uninterrupted operation is an important component of the production process, employee safety and comfortable working conditions.
"Today, 230 hoisting mechanisms and 447 cranes are in operation at the plant. They regularly undergo maintenance, repairs and modernization with the implementation of modern solutions in the health and safety area. Specialists perform comprehensive tasks every day: from technical audits and timely fault detection to staff training and implementation of modern safety standards. On average, about 250 audits and six training programs regarding cranes and hoisting equipment are conducted every year. This approach allows not only to ensure smooth production operations, but also to create safer and more comfortable working conditions for employees," said Kyrylo HAVRYLIUK, Health and Safety Director of Zaporizhstal.
Reliability = Safety
In 2025, the plant carried out several major overhauls of crane equipment amounting in a total over UAH 13.6 million. An ore gantry loader was overhauled in the blast furnace shop. As part of the repair, the trolley rails were replaced, the crane and trolley travel mechanisms, the gripper lifting and closing mechanisms were repaired, safety devices, steel structures, electrical equipment, cables and wires were upgraded.
Major overhauls of dogging cranes No. 60 and No. 62 were carried out at the slabbing section of the Hot Rolling Shop. The overhauls included dismantling, repair and installation of main steel structures, replacement of main lifting and tongs control units, renewal of gearboxes, drums, bearings, rail tracks, power supply and control systems. The repair of electric motors and partial modernization of electrical equipment were also carried out.
In addition, the plant spent about UAH 170 million to maintain good technical condition and current repairs of crane equipment.
Systemic work on renewal
In 2026, Zaporizhstal continues systematic renewal of the crane facilities. Among the works already completed this year is the installation of new industrial air conditioners at overhead and crane units in the Hot Rolling Shop, Cold Rolling Shops, Open-Hearth and Blast Furnace Shops. A total of 14 crane air conditioners were replaced and installed. Besides, anti-vibration crane seats were purchased and installed for crane operators, which reduce vibrations and prevent occupational diseases. In total, almost UAH 90 million is provided for the maintenance and repair of crane facilities.
In 2026, it is also planned to overhaul the dogging crane No. 299 in the Hot Rolling Shop with an investment of more than UAH 7 million. The project provides for a comprehensive upgrade of mechanical and electrical equipment, repair and modernization of the main components, replacement of cable and wire products, control systems and a full commissioning.
For safe repair...
The plant pays special attention to the implementation of the best safety practices during repairs of hoisting equipment. In particular, drums with tension rails are used for dogging cranes, which ensure the safe movement of personnel along the crane beams without a fence and allow for safer replacement of trolley rails.
A multiple-use platform for repairing a trolley drive of dogging cranes was put into operation. The design is in accordance with the project and ensures the safety of employees during repair work and allows to abandon the use of temporary wooden platforms and reduce the time of repairs.
… and safe operation
Work to improve the level of safety continues during the operation of cranes. All lifting cranes in all subdivision of the plant are equipped with sound alarms to warn employees of crane movement.
In the Hot Rolling Shop, four cranes are additionally equipped with a system of visual accent lighting of the loading-unloading and goods movement areas. Two cranes in the Railway Shop are fitted with an automated signalling system, which automatically gives a warning signal before starting the crane lifting and movement mechanisms and blocks the operation of the equipment without such a signal. The combination of the sound warning and the visualized red accent lighting allows employees to better navigate the crane operation area and significantly reduces risks during loading and unloading operations.
