STS crane breakdown: a root cause checklist
The first-hour checklist
- What the crane was doing: operation, load, position, weather.
- Alarms, fault codes and screenshots from the crane control system before they are reset.
- Time the failure started, when it was reported and when service was restored.
- What was repaired or replaced, by whom, and which spare part was used.
- Photos of the failed component and nearby equipment, with the part kept if possible.
- Names of the operator and technicians who can describe the event.
Classify by system
| System | Questions to ask |
|---|---|
| Hoist and boom hoist | Motor, brake, gearbox, wire rope or drive fault? Overload or slack rope? |
| Trolley and gantry | Drive, motor, wheels, rails, limits or sensors? |
| Spreader | Electrical, hydraulic or mechanical? Twistlock or sensor faults? |
| Power and cable systems | Festoon, cable reel, switchgear, transformer or supply issue? |
| Controls and communication | PLC, network, sensors, software or settings change? |
Is it a repeat?
Compare the failure with the crane's history and with the other cranes. Repeats on the same crane suggest a local cause, repeats across cranes suggest a common cause such as a specification, a procedure or the environment.
When to start a full root cause analysis
Set clear triggers so that the team does not argue each time. Common triggers are:
- The same failure twice within a period you choose.
- Downtime longer than a set number of hours.
- Any event with safety potential.
- High repair cost or damage to other equipment.
From checklist to RCA
The checklist gives you the facts. A root cause analysis then asks why until it reaches a cause you can control, and ends in owned actions. See how to do a root cause analysis in 5 steps.
Frequently asked questions
What is the difference between a breakdown report and an RCA?
A breakdown report records what failed and how it was repaired. An RCA goes further and finds why it failed, so the cause can be removed.
Which STS crane failures deserve a full RCA?
Repeat failures, long downtime, events with safety potential, and expensive damage. Set your own triggers and apply them consistently.
Describe the failure or add a photo or file, and RapidRCA builds the 5 Whys, fishbone, actions and report, using the ROOTS method.
Start an RCA
Last updated 14 October 2026. These guides explain a method and give examples. Always follow your equipment manufacturer's manual, your site procedures and applicable regulations.