Cracks in a brake wheel or disc should be treated as a high-priority safety issue—especially on hoisting mechanisms. Cracks can propagate under thermal cycling and mechanical stress, and in worst cases can lead to sudden failure, loss of braking surface integrity, or severe vibration. For overhead and gantry cranes, the safest practice is to stop operation and assess immediately.
Whether replacement is mandatory depends on crack type, depth, and location, but many OEMs and safety programs require replacement once cracking is detected, particularly if it’s heat-related (thermal checking) or extends toward critical sections. Even small cracks can indicate chronic overheating or dragging that will continue to damage new parts if not corrected.
Do not “grind it and run” unless the OEM explicitly allows and provides limits. Correct the root cause (dragging, undersizing, improper lining material, control timing) before returning to service. For safety-critical cranes, conservative replacement policies reduce risk and downtime.