Cab hours in the headset.
The crane keeps producing.
Overhead and bridge crane simulators built on your own equipment, with your physical controls and your lifting procedure.
A new operator reaches the cab with the sequence already done by hand, and every session is recorded per person and per module.
Practicing on the real crane costs production, and nobody learns to handle a swinging load in a classroom.
Every hour of practice on the real equipment is an hour without moving loads, and the process that depends on that crane stops with it.
While the new operator learns up in the cab, the person teaching leaves their own job and the learner runs the machine at half speed.
Operators reach the cab with a toolbox talk and one supervised lift. With the load in the air, they freeze.
A swinging load, a hit against another crane or a lift over people on the floor cannot be practiced on purpose on the real equipment.
Each simulator follows your plant's procedure. These are six modules from the Gerdau Corsa program, a steel mill where every crane carries a different risk.
1Scrap handling from the cab, with the crane's own controls.
2Loading containers in the yard, with loose material that shifts on its own.
3Stacking billets against the clock, with a scoreboard.
4Moving the hot load over people and equipment.
5The pour, where a mistake gets no second try.
6Hooking and guiding the load from the floor, right where it is rigged.
Video from the Gerdau Corsa program, no sound.
How crane operators are trained today and what the simulator changes.
| Classroom course | Shadowing on the real crane | Overhead crane simulator | |
|---|---|---|---|
| What the person does | Listens and answers | Operates with an instructor beside them | Operates alone, with their crane's controls |
| Can they make mistakes | No | Not without risk | Yes, and that is the exercise |
| What a mistake costs | Nothing | Product, equipment or a person | The exercise restarts |
| Production | Untouched | Crane out of service or at half speed | Keeps running |
| How many repetitions | One | As many as production allows | As many as it takes |
| What is left on record | Attendance sheet | The instructor's signature | A record per operator and per module |
Under OSHA 29 CFR 1910.179(b)(8), only designated personnel may operate overhead and gantry cranes: people the employer selects as qualified (a)(35). OSHA has read "qualified" in light of the ASME B30.2 standard.
The VR simulator adds practice hours to your training program. Designating and evaluating operators stays with the employer.
For the start of the shift in the bay, the overhead crane toolbox talk has the script to read, three questions for the crew and the PDF with a sign-in sheet.
Your plant sets the standard; we turn it into practice.
The sequence of every lift, what counts as an error and how it is scored are set by your plant, from its operating standard.
Modeled from photos, drawings or CAD, with the real view from the cab and the people on the floor in sight.
The crane's physical levers are connected, so the hand learns what it will use up there.
A training simulator takes about three months and a complex one three to six. Each new crane is added on the same platform.
A custom simulator starts at about 15,000 USD for delivery outside Mexico and 10,000 USD within Mexico (2026 pricing guide). A multi-crane program grows module by module, as Gerdau Corsa's did, and if you need your own number before a project there is the Diagnostic Pilot.
In seven years the program grew from one family of crane simulators to eleven modules: six cranes, the floor-level overhead crane, the electric arc furnace, lockout/tagout, a 360 induction and the platform that hosts them.
Program catalog, August 2026.
Figure reported by the plant.
Practice happens away from the equipment.
No. It is the practice the course cannot give. Operator qualification and the employer's designation stay with your company and your training provider. What the simulator adds is each person's practice, recorded per module, before they get on the crane.
Yes. In the Gerdau Corsa program every crane has its physical controls connected to the simulation: operators use the same levers they use in the cab.
A custom simulator starts at about 15,000 USD for delivery outside Mexico and 10,000 USD within Mexico. Your range depends on how many cranes and lifts go in, and we give it to you on the first call.
More questions
Tell us what you want to solve in your plant. Fyware designs extended reality around the equipment and constraints of your operation, and builds it to grow from a pilot to the whole site.
Tom Klukowski, Fyware Partner · Valcre Marketing We reply in under 24 business hours, with scope, timeline and investment range.In the meeting you see the simulator running and what it would take to bring it to your plant, with scenarios adapted to your layout. And if you need to sell it internally, this page is your presentation: share it with your team.
