Crane Simulation Training at Bay Ltd.: Advancing Skills and Reducing Risks

Bay Ltd., a full-service industrial contractor with over 70 years of experience, has always been at the forefront of delivering high-quality services in the industrial and construction sectors. Known for their work in refinery maintenance, heavy hauling, and modular fabrication, Bay is now taking its training efforts to the next level with ITI’s crane simulators. These simulators play a key role in developing operator skills, improving safety, and engaging the next generation of crane operators.

Michael Bieber, Safety Supervisor at Bay Ltd., runs and organizes the simulator training at their Corpus Christi location. With a deep background in rigging and crane operations, Michael knows firsthand how simulation training can supplement in-person training, bridge knowledge gaps, and create safer, more efficient operators.

The Training Evolution at Bay Ltd.

Before introducing ITI’s crane simulators, Bay’s training program was primarily instructor-led. Although effective, this approach had challenges, such as limited operator seat time and the need for significant supervision during hands-on crane practice.

“We still do instructor-led training, but the simulator adds a whole new level of preparation,” explains Michael. “Operators can get hands-on time without needing to set up a real crane, which frees up resources and increases their confidence before getting into the real thing.”

Bay uses two ITI motion-base crane simulators to train over 100 operators—one at its main yard in Corpus Christi and another in West Texas. These simulators are equipped with a belly box for realistic operator training and simulate nine different crane models, including overhead cranes, enabling operators to develop skills across various equipment types.

Assessing New Hires and Ensuring Skill Readiness

Hiring crane operators is not without its challenges. Resumes and interviews rarely paint the full picture of an operator’s actual skill level. To address this, Bay Ltd. has integrated ITI’s crane simulators into its hiring process, using the fully immersive 360-degree VR experience to assess mechanical aptitude and on-the-job decision-making. Unlike traditional methods, ITI’s simulators allow operators to react to real-world scenarios, including failures and mid-lift complications, providing a level of evaluation that competitors without VR technology simply can’t match.

“When someone applies for a crane operator position, we can’t just take their word for it when they say they’ve got experience,” explains Michael. “The simulator helps us verify their skills in a safe and controlled environment. It gives us a detailed performance report, showing exactly what they did right—and more importantly, where they need improvement.”

By running new hires through the simulator, Bay can spot weaknesses early and provide targeted training before operators handle real-world projects. “It’s helped us catch things we might not have seen otherwise,” says Michael. “If someone struggles with a particular skill, we can work on that before they’re out in the field where mistakes can have serious consequences.”

This approach reduces risk and ensures that operators start their jobs with a higher level of confidence and readiness. For Bay, it’s about setting every new hire up for success while maintaining the company’s high standards for quality, safety, and performance.

Reducing Risk and Building a Safer Workforce

Safety is a cornerstone of Bay Ltd.’s operations. With many projects taking place in high-risk environments such as refineries, construction sites, and wind farms, proper training is essential to prevent accidents and ensure safe operations. The ITI crane simulator is an invaluable tool in refreshing important safety lessons and helping operators recognize and avoid common crane-related dangers like two-blocking, outrigger failures, and operating with a lack of situational awareness.

By practicing in a controlled, immersive environment, operators develop the skills and procedures needed to anticipate and avoid hazards on the job—experiencing realistic challenges without real-world risks.

“The simulator mimics real-world scenarios, allowing operators to experience potential hazards in a controlled environment that looks like the real thing,” says Michael. This realistic training helps operators build situational awareness, which is critical for preventing dangerous incidents.

Supporting Career Growth and Progression

Bay Ltd. requires its operators to complete four hours of training each year to keep their skills up to date. While taking operators off the job for training can be challenging, the ITI simulators make it more manageable and cost-effective by enabling on-site training that doesn’t disrupt project schedules.

The company is also dedicated to providing its employees with growth and career advancement opportunities. The ITI simulator plays a role in helping riggers and aspiring operators develop their skills and climb the career ladder—if they’re motivated to do so. “We have an open-door policy—anyone who wants to learn or sharpen their skills is welcome to come in and train,” says Michael.

Bay encourages employees to pursue their chosen career path through a mix of hands-on experience, instructor-led training, and simulator practice to build their confidence and expertise before transitioning to real-world crane operations.

“We’ve had fresh operators who were chomping at the bit to get in the simulator,” Michael says. “Once they’ve completed their instructor-led courses and certification and spent time in the simulator, it doesn’t take long for them to be field-ready. Within a couple of weeks, they can operate a crane confidently under supervision.”

Engaging the Next Generation of Crane Operators

The ITI crane simulator has proven particularly popular with younger operators, who are more accustomed to using technology in their daily lives. “For them, it’s like a video game,” Michael says. “Some guys even downloaded crane simulation apps at home to practice before coming in for training.”

While older operators were initially skeptical, many have embraced the technology after experiencing its realism and seeing its benefits. “At first, some of the older guys didn’t take it seriously,” Michael admits. “But once they got in and saw how realistic it was, they came around. Now they say it feels just like being in the cab of a crane.”

The Mobile VR Truck: A Scalable Recruitment and Training Tool

To make training even more accessible, Bay Ltd. developed a mobile VR truck equipped with the ITI simulator. This enclosed trailer travels to job fairs, high schools, and community events, offering people a chance to experience crane operations firsthand.

“We take the VR truck to job fairs and even cook-offs,” Michael says. “It’s a great recruiting tool. We let students and potential recruits try it out, show them what it’s like to operate a crane, and talk to them about career opportunities at Bay.”

The mobile VR truck also doubles as a traveling training unit, allowing Bay to train employees at remote sites without bringing them to Corpus Christi. “It’s multi-purpose,” Michael explains. “We’ve taken it to Houston to train our guys there. It saves time and keeps our training consistent across locations.”

Preparing for the Future of Crane Training

As Bay continues to expand its operations, ITI’s crane simulators will remain an important part of its training strategy. The program’s scalability and flexibility ensure that Bay can meet the evolving needs of its workforce while maintaining high standards of safety and performance.

“I definitely see simulation training playing a bigger role in the future,” Michael notes. “Especially with the younger generation coming in. They’re all for it.”

ITI’s crane simulators have helped Bay Ltd. modernize its training program, enhance safety, and create opportunities for career growth. From assessing new hires to developing the next generation of crane operators, the simulator is an essential tool in Bay’s training arsenal.