175/25T Bridge Crane Modernization

Advanced Crane Technologies led a full modernization of NASA’s 175/25-ton bridge crane inside the Vehicle Assembly Building at Kennedy Space Center. This 50-year-old crane—critical to lifting rockets and flight components—received an all-new state-of-the-art control system, motors, brakes, operator’s cab, and wire/conduit infrastructure. The modernization included hook rotation drive, new trolley power tracks, and a powered cable reel. Safety was a key focus, with new systems for over-wrapping detection, load cells, bridge and trolley anti-skewing control, and OSHA-compliant walkways, ladders, and stairs.

The new “active front end” control system regenerates power back to the grid during lowering operations, eliminating outdated dynamic braking and providing a more energy-efficient, environmentally friendly solution. ACT implemented ultra-precise motion control capable of positioning massive loads within thousandths of an inch. Advanced single-failure-proof features include PLC-based SIS and PES systems, broken shaft and unbalanced load detection, dual 24″ HD control screens, extensive diagnostics, and redundant safety mechanisms. To ensure safety and efficiency during installation, the entire crane was lowered to ground level—a strategic move enabling optimal access for this highly specialized modernization.