8 Common Problems That Occur When Clients Underestimate Crane Capacity Needs

Every construction site runs on precision — from scheduling trades to managing deliveries. Yet one of the most underestimated aspects of project planning is correctly assessing crane capacity. Choosing a crane that is too small for the job may look like a cost-saving decision at first, but in reality, it can lead to severe delays, safety hazards and unexpected financial losses.

Underestimating crane requirements doesn’t just affect one lift; it can create a chain reaction that impacts the entire project timeline. In this blog post, we'll explore the common problems when builders and site managers misjudge their crane needs — and how professional crane hire services help prevent them.

A crane’s lifting capacity must match the project’s heaviest loads and required reach. When a smaller crane is chosen, operators often discover mid-lift that the equipment can’t safely handle the load. Work stops immediately, and precious time is lost sourcing a replacement.

Delays caused by poor crane selection can disrupt multiple trades waiting on critical lifts and extend hire periods for other on-site equipment. The flow-on effect can quickly push projects behind schedule.

Key factors that contribute to these delays include:



• Underestimating the weight or reach of materials.
• Misjudging site access or setup limitations.
• Re-booking and mobilising a larger crane after work has already begun.

An overloaded crane is a significant safety hazard. Exceeding a crane’s rated capacity puts immense strain on its structure, hydraulics and stability systems, creating the risk of tipping or mechanical failure.

These incidents endanger workers and trigger compliance investigations that can halt the entire job. A single overloaded lift can lead to serious injuries, equipment damage and expensive remediation work.

Common safety hazards linked to overloading include:



• Boom collapse or structural failure.
• Loads swinging uncontrollably or dropping without warning.
• Ground instability or crane tipping due to uneven weight distribution.

A crane beyond capacity accelerates mechanical wear, particularly in components like hydraulic cylinders, wire ropes and slew bearings. Over time, this extra stress shortens the machine’s lifespan and increases the frequency of maintenance or breakdowns.

For construction managers, this means higher downtime costs and reduced productivity as faulty equipment is taken out of service for repair.

Typical issues caused by overuse include:



• Hydraulic leaks and pressure loss.
• Premature fatigue in structural joints and booms.
• Repeated component failures that require specialist attention.

A miscalculated lift doesn’t just harm the crane—it can also damage valuable building materials or partially completed structures. If a crane cannot maintain a steady lift due to insufficient power or reach, the load may sway, collide or drop unexpectedly.

Such incidents can destroy prefabricated panels, steel beams or glass components, resulting in financial loss and rework. In confined worksites, a mishandled lift can damage scaffolding or existing structures, adding further complications.

To avoid this:



• Verify the weight and dimensions of every load before lifting.
• Ensure correct rigging methods and load balancing are used.
• Confirm the crane has adequate capacity for both weight and radius.

While hiring a smaller crane might appear economical initially, it often proves far more expensive in the long run. Once the wrong equipment is identified, contractors must source a larger crane — often at short notice and at a premium cost. The process of demobilising, rehiring, and resetting the crane can add days of lost time.

Budget overruns frequently occur when:



• Additional transport or mobilisation fees are incurred.
• Workers remain idle while waiting for the correct crane.
• Overtime costs rise as projects try to make up lost time.
  

Many large construction jobs require multiple lifts at various heights and radii. A crane that manages early stages of a project might struggle as structures rise higher or heavier materials are introduced. When equipment reaches its limit midway through a build, work efficiency plummets.

The result is constant repositioning, partial lifts, or the need to bring in supplemental cranes — all of which slow productivity.

Inefficiencies commonly appear when:



• Cranes cannot reach final installation points without repositioning.
• Loads must be broken down into smaller sections for lifting.
• Coordination between trades suffers due to unpredictable lifting schedules.

Every crane operation in Australia must adhere to strict Workplace Health and Safety (WHS) regulations and manufacturer guidelines. When a lift exceeds the safe working load, it becomes a compliance breach — potentially invalidating insurance and exposing contractors to penalties or litigation.

Ignoring capacity limits can also result in safety authority investigations that delay project progress and damage a company’s reputation.

Key compliance risks include:



• Violating WHS legislation governing load limits and rigging.
• Invalidation of insurance coverage for damaged equipment or injuries.
• Increased liability for site supervisors and builders responsible for safety oversight.
  

The most effective way to avoid these challenges is to engage a crane hire team with extensive industry knowledge. Experienced professionals perform detailed site assessments, accounting for load weights, reach requirements, terrain conditions and access restrictions before recommending the right crane.



This proactive approach ensures safety and streamlines operations from start to finish.

Working with an expert crane hire team provides:

• Accurate load assessments and tailored lift planning.
• Access to a versatile fleet suited to various site conditions.
• Qualified operators who prioritise efficiency and compliance.
• Reduced risk of costly errors, delays or equipment strain.
  

At AMAC Cranes Group Pty Ltd, we understand the pressures builders and site managers face when coordinating complex lifting operations. Our builder crane hire services on the Sunshine Coast are designed to help you plan effectively, lift safely and keep your project on schedule.

We assess each site individually, recommend the right crane for your requirements and provide qualified operators who ensure every lift is completed efficiently and safely.

For expert advice and reliable crane hire solutions, contact our team to arrange a site assessment. Lift smarter, work safer, and keep your project moving with confidence.