How to repair cracked booms on lifts

Understanding the Issue

A crack in a lift boom begins as a local stress concentration and can propagate under repeated loading, vibration, or corrosion. On boom-type lifts and aerial devices, cracks commonly appear near welds, mounting points, or cutouts where geometry changes concentrate forces. For commercial lifts on service trucks or trailers, a small hairline crack can quickly affect boom alignment or load-handling capacity. Understanding whether a crack is superficial or has compromised structural members determines whether repair, reinforcement, or component replacement is required.

Common Causes or Warning Signs

Typical causes include overloading, repeated side loads, impact damage during transport or operation, corrosion that weakens metal, and fatigue from frequent cycles. Warning signs to watch for are visible hairline fractures or spreading seams, new or worsening flexing under load, unusual noises when the boom moves, paint separation or flaking around an area, and loose pins or fasteners near the affected zone. Regular visual checks and simple dye-penetrant or magnetic inspections can reveal developing cracks before they grow larger.

How Motor City Truck Collision Approaches This Issue

Motor City Truck Collision begins with a careful, documented inspection to determine crack extent and any related damage. Technicians clean the area to expose the metal, evaluate surrounding attachments, and use appropriate non-destructive techniques to map the crack. Repairs focus on restoring structural integrity: controlled removal of damaged material, properly prepared welds by experienced fabricators, and reinforcement or gusseting where engineering calls for added strength. After metalwork, parts are treated to prevent corrosion and finished with compatible coatings. Post-repair checks confirm alignment, function, and safe load handling before returning equipment to service.

Prevention Tips or Best Practices

Maintain a routine inspection schedule that includes boom surfaces, welds, pins, and mounting hardware; inspect more often during heavy-use seasons. Operate within the rated capacity and avoid abrupt side loads or impacts when positioning booms. Keep booms clean and free of salt or corrosive residues—regular washing during Michigan’s winter months helps prevent corrosion that accelerates cracking. Tighten and replace worn fasteners promptly, document repairs, and train operators to recognize early warning signs so small issues are caught before they develop into structural failures.

Need Help With This Issue

If you suspect a crack or need a professional assessment, Motor City Truck Collision offers experienced inspection and repair services to get your equipment back in safe working order.

Tip: For suspected structural cracks, avoid placing equipment back into service until a qualified technician has inspected the repair.