作者： YUWEI, YUWEI

MATERIALS

Plate, Profiles, Bars, Pipe & Coils

CRANE TYPES

Bridge, Magnetic, Rotating & Gantry

CONTROL LEVELS

Manual, Assisted & Automatic

PROJECT BASIS

Load, Flow, Layout, Duty & Data

1. Receiving and Unloading

Unload trucks or rail wagons within the permitted vehicle envelope, verify gross load and product identity, and place incoming steel in inspection or assigned buffer positions.

2. Identification and Inspection

Confirm material ID, heat number, grade, dimensions, weight, surface condition and release status before the storage location is recorded.

3. Storage Allocation

Assign a stack, cassette, rack or floor cell from product dimensions, grade, turnover, dunnage, stack-height limits and retrieval priority.

4. Controlled Placement

Position the load without striking adjacent stacks, racks, columns, vehicles or people, while maintaining required orientation and layer separation.

5. Retrieval and Production Supply

Retrieve the specified item or bundle, manage reshuffling where required and deliver it to cutting, fabrication or order-staging positions.

6. Dispatch and Reconciliation

Stage and load the shipping order, confirm the final vehicle handoff and update inventory only after the physical movement is completed and verified.

1. Crane structure and runway: transfer vertical, longitudinal, transverse and dynamic reactions to the building or foundations while providing full required coverage.
2. Hoist, trolley and travel drives: provide the declared capacity, lift, speed range, positioning control, braking and duty classification.
3. Load attachment: connects to plate, profiles, pipe, coils or bundles through a magnet, rotating magnetic beam, hook, spreader, clamp, tong, C-hook or custom device.
4. Sensing and protection: may include load, position, height-profile, skew, anti-collision, obstacle, access-gate, vehicle-presence and restricted-zone functions.
5. Control system: coordinates pendant, radio, cabin, assisted or automatic operation, including mode selection, safe stopping and manual recovery.
6. Warehouse data interface: exchanges material identity, location, movement order, completion status, alarms and reconciliation records with WMS, MES or ERP systems.

Material Master

Mass, length, width, thickness, diameter, section, center of gravity, ferromagnetic response, surface, coating, temperature, stiffness, nesting and permitted pickup points.

Throughput and Duty

Inbound and outbound tonnes, moves per hour, starts, average and peak travel, shifts, annual hours, load spectrum, reshuffle ratio, availability target and maintenance window.

Storage Geometry

Stack, rack or cassette dimensions; stack height; dunnage; aisle; approach clearance; floor loading; reserved zones; vehicle bays and future expansion.

Attachment and Orientation

Magnetic eligibility, single- or multi-layer lift, required rotation, hook spacing, clamp locations, coil axis, pipe support, allowable deflection and changeover method.

Building or Stockyard

Span, runway length and elevation, lift, headroom, end and side approaches, rail and beam data, wheel-load limits, foundations, wind, drainage and installation access.

Control and Acceptance

Manual, assisted or automatic mode; warehouse interface; positioning and cycle criteria; exception recovery; safety functions; standards; inspection route and measurable handover tests.

Electromagnetic handling is suitable only after the actual load range is validated. Magnetic grade, plate thickness, contact area, flatness, rust, mill scale, paint, protective film, oil, temperature and gaps between stacked products can all change holding force. A successful pickup of one plate does not validate another thickness, surface or multi-layer condition.

• Define every approved material and surface condition, including minimum thickness and maximum air gap.
• State whether single-sheet selection, multiple-sheet lifting or bundle lifting is permitted.
• Include magnet, beam and cable-reel mass in crane capacity and structural reactions.
• Specify power-loss behavior, retained-load indication, backup-energy duration and the emergency landing process.
• Segregate suspended-load routes from people and control access to loading, storage and recovery zones.

Automation Data and Acceptance Criteria

A warehouse movement record normally carries material ID, heat number, grade, dimensions, weight, storage cell, stack layer, status, order number and time stamps. The functional design also defines duplicate IDs, missing labels, mismatched weight, occupied positions, blocked routes, sensor failure, communication loss and manual recovery.

Contract acceptance should use measurable criteria such as representative-load cycle time, positioning tolerance, correct item and location confirmation, interface response, alarm handling, safe-state behavior, recovery time and sustained trial performance. Values are established for the specific layout and process rather than assumed from a generic crane.

Coverage and Approaches

Confirm rail-center span, runway length, hook and attachment approaches, loading-bay reach, cantilever coverage and positions inaccessible to the selected attachment.

Vertical Envelope

Coordinate rail elevation, crane depth, upper clearance, hook lift, beam or magnet depth, product height, stack height, vehicle height and maintenance access.

Structural Reactions

Provide maximum and minimum wheel loads, lateral and longitudinal forces, buffer loads, fatigue basis and rail tolerances for building, runway or foundation verification.

Vehicle and People Separation

Define loading zones, pedestrian routes, gates, barriers, warning devices, travel interlocks and the process for driver positioning during crane operation.

Stack and Floor Design

Confirm floor bearing, rack or dunnage capacity, stack stability, load distribution, drainage and the consequences of placing products in an incorrect cell.

Outdoor Conditions

For stockyards, specify operating and parked wind, storm anchoring, lightning, precipitation, corrosion, temperature, rail drainage and travel-path maintenance.

Design Review

Approve load cases, classification, structural and mechanism calculations, wheel loads, attachment logic, electrical architecture, safety functions and interface responsibility.

Factory Verification

Verify manufacturing records, material traceability, weld and nondestructive inspection scope, mechanism operation, control logic, alarms and documentation before shipment.

Site Acceptance

Check runway geometry, motions, brakes, limits, overload protection, collision functions, attachment performance, representative loads, proof load and agreed cycle scenarios.

Operational Readiness

Complete training, inspections, rescue and recovery procedures, attachment registers, preventive maintenance, critical spares, backup and restore, and change-control records.

Henan Mine Crane has published a specialized crane reference for a steel plate storage facility serving steel-structure, bridge and high-rise fabrication. The official project account states that full-function verification was performed on a 1,200 t crane test platform before delivery to a major steel-structure company.

Published project data identifies a 5–50 t structural range with span and lift customized to the warehouse. The delivered system reportedly managed more than 200 plate specifications. After more than one year of operation, the official reference reports a 65% increase in inbound and outbound efficiency, inventory error below 0.1% and annual labor savings exceeding RMB 1.2 million.

The application links physical plate movements with storage-location and production-order data, illustrating the value of designing the crane, attachment, control logic and warehouse software interface as one project.

Design Basis

Load matrix, duty calculation, process description, governing standards, environment, reliability basis, safety functions and exclusions.

Interface Drawings

General arrangement, wheel loads, clearances, runway and rail data, power points, communication interface, foundation actions and installation access.

Attachment Schedule

Approved products, ratings, pickup conditions, prohibited conditions, changeover, inspection, power-loss response and attachment parking.

Control Description

Operating modes, sequences, interlocks, alarms, safe states, warehouse handshake, access control, event history and fault recovery.

Inspection and Test Plan

Hold points, material and weld records, factory tests, site tests, proof load, representative-load scenarios, interface tests and acceptance criteria.

Lifecycle Package

Manuals, drawings, parts list, certificates, training, preventive maintenance, critical spares, diagnostic access, backup files and support responsibility.

Material and Load File

Product family, material grade, minimum and maximum mass, dimensions, center of gravity, surface, temperature, bundle condition, attachment and gross suspended load.

Movement and Throughput

Inbound, storage, reshuffle, retrieval and outbound routes; moves per hour; tonnes per shift; load spectrum; peak schedule; availability and maintenance window.

Warehouse Layout

Plan, cross-section, span, runway length and elevation, storage cells, stacks, racks, aisles, vehicle bays, process interfaces, clearances and expansion zones.

Existing Structure or Foundations

Rail section, beams, brackets, columns, foundations, wheel-load limits, condition assessment, geometry survey, power supply and erection access.

Controls and Warehouse Interface

Operating modes, required speed and positioning, sensors, anti-collision, WMS or ERP protocol, material fields, cybersecurity responsibility, exceptions and recovery.

Commercial and Compliance Scope

Destination, standards, Incoterm, freight, runway, installation, commissioning, inspection, load test, training, spares, documentation, warranty and target schedule.

Which crane type is suitable for a steel warehouse?

Single-girder cranes serve lighter general handling. Double-girder cranes suit heavier or intensive duty. Magnetic cranes support validated ferromagnetic loads, rotating systems control orientation, double-trolley cranes support long loads and gantry cranes serve outdoor stockyards.

How is steel warehouse crane capacity calculated?

Capacity starts with the maximum gross suspended load: steel product plus magnet, beam, clamps, slings, C-hook, shackles, hook block and every accessory. Eccentric load, unequal pickup and dynamic cases are then evaluated.

Can one magnet lift every steel plate?

No. Magnetic grade, thickness, flatness, coating, rust, scale, temperature, air gap and number of layers affect holding force. Each approved plate family and pickup condition requires validation.

When is a rotating magnetic beam required?

Rotation is considered when long steel arrives in one orientation but must be stored, processed or loaded in another. The design must include the complete rotation envelope and adjacent-stack clearance.

Can an existing warehouse runway be reused?

Only after rails, beams, brackets, columns, connections and foundations are checked for condition, geometry, fatigue and the proposed vertical, lateral, longitudinal and dynamic reactions.

Does warehouse automation require a new ERP?

Not necessarily. The required material fields, task handshake, ownership of location data, error codes, recovery process and communication protocol determine whether an existing WMS, MES or ERP can interface with the crane control system.

How much does a steel warehouse crane cost?

Public references reviewed in September 2026 ranged from US$4,000 for one configurable 8 t equipment listing to US$28,500 for a 10 t crane kit, while a complete automated warehouse remains quotation-based. These scopes are not directly comparable.

What should be tested before handover?

Testing should cover motions, brakes, limits, overload protection, attachment performance, power-loss response, representative products, protected zones, inventory transactions, alarms, manual recovery, proof load and contracted cycle scenarios.

PROCESS COVERAGE

Melt Shop to Finished Stock

CRANE FAMILIES

Hook, Ladle, Magnet, Grab and Clamp

LISTED CAPACITY COVERAGE

5–500 t, Model-Dependent

WORKING CLASS

A6–A8, Model-Dependent

Raw Materials and Scrap

Grab, magnet and dual-purpose cranes move scrap, ore, coke, flux, slag and other bulk or ferrous material.

Melting and Pouring

Charging, ladle and casting cranes support furnace feed, molten-metal transfer, treatment and controlled pouring.

Casting and Rolling

Slab, billet, bloom, coil and plate cranes transfer hot and finished material between process and storage zones.

Maintenance and Assembly

Heavy-duty hook cranes provide planned access to furnaces, rolls, motors, gearboxes, ladle cars and production equipment.

01 / MATERIAL

Load Form and Temperature

Identify molten metal, scrap, bulk feed, slag, slab, billet, coil, plate, mould or machinery; record normal and maximum temperature at pickup and travel.

02 / LOAD

Complete Suspended Mass

Include payload, ladle or container, refractory lining, magnet, grab, clamp, lifting beam, rigging and all allowances required by the governing design basis.

03 / PROCESS

Production Route and Cycle

Define pickup and set-down stations, travel distances, lifts per hour, near-capacity lifts, shift pattern, production interlocks and required cycle time.

04 / ATTACHMENT

Pickup and Release Method

Confirm trunnion, hook, magnet, clamp, tong, C-hook, grab or beam interface, including rotation, opening, closing, power and safe-release requirements.

05 / ENVIRONMENT

Heat, Dust, Fumes and Splash

Record ambient and radiant heat, conductive dust, scale, moisture, corrosive fumes, molten splash, outdoor exposure and enclosure requirements.

06 / SAFETY

Credible Failure Response

Establish the required response to power loss, brake fault, drive failure, overspeed, overload, attachment power loss, upper-limit activation and control interruption.

07 / RUNWAY

Building and Rail Interface

Verify span, lift, approaches, wheel loads, horizontal reactions, rail section, alignment, support capacity, thermal effects and erection access.

08 / PROJECT SCOPE

Controls, Standards and Supply Boundary

Define cabin, radio or automation, power supply, plant communication, governing standard, inspection plan, documentation, freight and installation responsibilities.

Stockyard and Scrap Bay

Grab and magnetic cranes unload, sort, blend and feed scrap or bulk material. Crane capacity must include the attachment, and throughput calculations must use the actual grab fill factor or magnet pickup condition.

Melt Shop and Foundry

Bin cranes charge furnaces, while foundry and casting cranes lift ladles, transfer liquid metal and support pouring. Molten-metal duty requires a defined safety architecture and thermal protection rather than a general-purpose crane specification.

Continuous Casting and Rolling

Slab and billet cranes move material between casting machines, cooling areas, reheating furnaces, rolling lines and intermediate storage. Pickup geometry, material temperature and cycle time determine the attachment and control system.

Finishing and Dispatch

Magnetic beams, clamps, tongs and C-hooks handle plate, long steel and coils. Finished-material protection, rotation, stack height, warehouse management interfaces and safe holding during power loss become primary design inputs.

Structural Load Cases

Girders, trolley frames, end carriages, wheels and runway interfaces are assessed for lifted load, attachment, dynamic effects, off-centre positions, skew forces and applicable thermal conditions.

Mechanism Duty

Motors, gearboxes, brakes, drums, ropes, sheaves, bearings and wheels are selected from starts, operating time, load spectrum, travel distances and production criticality.

Thermal and Environmental Protection

Heat shields, protected cables, metallurgical-duty motors, ventilated cabinets, insulated cabins, dust-resistant enclosures and temperature monitoring are applied where the measured exposure requires them.

Safe-Failure Architecture

Multiple brakes, redundant drives, drum brakes, backup power, magnet holding, limits, overload protection and emergency placement can be specified when required by risk and governing rules.

Motion and Positioning

Variable-frequency control, creep speed, anti-sway, encoders, coordinated drives and automatic positioning support stable ladle movement and repeatable material stacking.

Plant Integration

PLC and HMI systems can exchange task, position, load, alarm and status data with plant controls, warehouse systems or manufacturing execution systems under an agreed interface specification.

Engineering Package

• Design criteria and duty classification basis
• General arrangement and hook-coverage drawings
• Wheel loads and runway reaction schedule
• Attachment, safety-function and control narratives

Manufacturing Controls

• Material identification and certificate review
• Welding, dimensional and structural inspection
• Mechanism, wheel, rope, brake and attachment checks
• Heat shielding, cabin and electrical enclosure inspection

Testing and Handover

• Factory mechanism, brake, limit and interlock tests
• Inspection records and component certificates
• Site commissioning and specified load testing
• Operation, maintenance and spare-parts documents

Shipment and Site Readiness

Transport segmentation, packing, unloading route, erection equipment, runway completion, power availability, production shutdowns and work permits are coordinated before dispatch.

Erection and Alignment

Installation covers bridge and trolley assembly, rail and wheel interface checks, attachment installation, cabin systems, electrification and verification of process clearances.

Commissioning and Acceptance

Commissioning verifies motions, brakes, limits, overload functions, emergency responses, attachment controls, alarms, plant interlocks and specified no-load and load tests.

Lifecycle Maintenance

Maintenance plans address ropes, drums, sheaves, hooks, attachments, brakes, wheels, rails, heat shields, cabins, magnets, grabs, electrical systems and safety functions based on duty and condition.

Double-Girder Casting Crane

YZ double-girder, single-trolley crane for heavy ladle transfer and foundry production duty.

Four-Girder Casting Crane

YZS four-girder, dual-trolley system for ultra-heavy molten-metal and multi-function handling.

Metallurgical Bridge Crane

High-duty overhead crane family for hot-metal, foundry and steel-production handling.

Slab Handling Crane

Metallurgical process crane for hot or ambient slab, billet, stacking and transfer operations.

Rotating Magnetic Overhead Crane

Rotating electromagnetic beam system for plate, billet, bar and long-steel handling.

Intelligent Grab Overhead Crane

Double-girder grab crane for ore, coke, slag and bulk-material transfer in steel plants.

PRIMARY LOADS

Plate, Beam, Pipe & Frames

CRANE OPTIONS

Bridge, Gantry & Semi-Gantry

LOAD-HANDLING OPTIONS

Hooks, Beams, Clamps & Magnets

CONTROL OPTIONS

Pendant, Radio, Cabin & PLC

Receiving and Raw Stock

Unload and store plate, H-beams, I-sections, angles, pipes and bars with hooks, approved clamps, spreader beams or magnetic systems matched to the material.

Cutting and Preparation

Feed plasma, laser, oxy-fuel, saw, drill and edge-preparation stations while controlling plate orientation, table approach and clearance above machinery.

Fit-Up and Welding

Position beams, shells, stiffeners, frames and subassemblies at jigs, rotators and welding stations using creep speed and clear operator sight lines.

Turning and Repositioning

Rotate or tail long fabrications only through a documented lifting method using two hooks, two cranes, a turning beam or purpose-designed fixtures.

Blasting, Painting and Finishing

Transfer finished steel through cleaning, coating, curing and inspection zones with environmental protection selected for dust, moisture, paint and solvent conditions.

Assembly and Dispatch

Support trial assembly, dimensional inspection, weighing, staging and truck loading for structural frames, vessels, modules and completed equipment.

1. Bridge, gantry or semi-gantry structure: provides the required work area while transferring vertical, transverse, longitudinal and dynamic loads to the building or ground-supported runway.
2. Hoist or process trolley: supplies the capacity, lift, speed, reeving, brakes and duty required for the declared fabrication cycle.
3. End carriages and drives: move the crane along the runway with speed control, alignment, braking and wheel loads matched to the structure.
4. Below-hook equipment: connects hooks to plate, sections, pipe or assemblies through approved slings, beams, clamps, magnets or custom fixtures.
5. Power and controls: coordinate lifting and travel through pendant, radio, cabin or PLC-assisted operation, including limits, overload monitoring and optional anti-sway.
6. Runway and electrification: include rails, beams, columns or brackets, conductor system, isolators, access and maintenance provisions where specified.

Load Matrix

Raw plate and sections, work-in-process and finished assemblies; minimum, normal and maximum mass; dimensions; center of gravity; stiffness; pickup points and attachment mass.

Material Route

Receiving, stock, cutting, drilling, fit-up, welding, inspection, blasting, coating and dispatch locations; required transfers, crossings, buffers and future expansion.

Duty and Cycle

Lifts per hour, starts, travel distance, shifts, annual hours, load spectrum, simultaneous motions, peak production, maintenance window and consequence of downtime.

Long-Load Control

Maximum component length, permissible deflection, hook spacing, two-hoist or two-crane operation, synchronization, load sharing, permitted rotation and tag-line method.

Building and Runway

Rail-center span, runway length and elevation, headroom, hook approaches, column spacing, wheel-load limits, clearances, foundations and installation access.

Attachment and Surface

Hook, slings, beam, clamp, magnet or vacuum device; material grade, surface condition, temperature, edge geometry, coating and acceptable contact marks.

Environment

Indoor or outdoor use, ambient range, welding fume, grinding dust, blasting media, humidity, paint or solvent area, wind, corrosion and wash-down requirements.

Control and Acceptance

Pendant, radio, cabin or automation; creep speed; anti-sway; restricted zones; collision avoidance; proof load; representative-load trial and documentation.

Long beams, trusses, shells, pipes and welded frames may be lighter than the crane capacity but still govern the design. The lift plan must control bending, torsion, pickup spacing, local contact stress, center-of-gravity uncertainty and the effect of unequal hoist motion.

• One hoist with spreader: suitable when the beam or fixture distributes the load and the center of gravity remains within the approved range.
• Two hoists on one crane: supports adjustable hook spacing and controlled load sharing for long components.
• Two independent trolleys: offers broader spacing and separate operation, with synchronization only when engineered and permitted.
• Two-crane tandem lift: requires defined command control, compatible speeds, capacity allocation, communication and a site lifting plan.
• Turning operation: requires a documented sequence, approved attachments, controlled load path and adequate clear space; it is not created by capacity alone.

Attachment Capacity Is Part of Crane Capacity

A 10 t workpiece with a 2 t beam and rigging requires more than a 10 t crane. The same principle applies to magnets: the published crane rating may include the magnet mass, so usable material capacity must be confirmed explicitly.

Attachment storage, changeover, electrical connections, identification, inspection status and the prevention of wrong-device selection should be included in the operating concept.

New Workshop

Coordinate crane wheel loads, rail elevation, column grid, roof clearance, maintenance access and electrification before structural steelwork is released for fabrication.

Existing Runway

Survey rails, beams, brackets, columns, connections and foundations for geometry, wear, corrosion, fatigue and the reactions from the proposed crane and duty.

Outdoor Yard

Define foundations, rail drainage, vehicle crossings, stormwater, wind operating limits, storm securing, corrosion category, temperature and safe parking position.

Control Strategy

Radio control commonly supports mobile fabrication teams and a direct view of the load. Pendant control can suit local, lower-speed work. A cabin may be justified for heavy, repetitive or long-travel service. PLC-assisted functions can add stored positions, restricted zones, anti-sway, collision avoidance, diagnostics and production-system interfaces.

Required positioning should be stated as a measurable tolerance at a defined load, speed and location. Creep speed, brake response, load swing and operator visibility are often more important at a welding jig than maximum travel speed.

Environmental Review

Welding fumes, conductive grinding dust, blasting media, humidity and outdoor corrosion influence motor, brake, cable, bearing, enclosure, coating and maintenance decisions. A paint or solvent area requires a documented hazardous-area review before electrical equipment is selected.

An explosion-protected crane is not selected solely because painting occurs somewhere in the plant. The owner’s area-classification documents, substance data, ventilation and local rules establish whether special electrical protection is required.

Design Review

Load and duty matrix, classification, fatigue basis, deflection criteria, wheel loads, attachment, control philosophy, environmental data, access and interface schedule.

Factory Inspection

Material traceability, welding and NDT records as specified, dimensions, mechanism tests, panels, software, limits, alarms, coating and document review.

Site Acceptance

Runway and alignment checks, functional and load tests, attachment trial, long-load sequence, controls, safety functions, training, spares and final documentation.

Load and Attachment Data

Maximum gross load, normal load distribution, dimensions, center of gravity, material and surface, pickup points, lifting beam, clamps, magnets, slings and finished-product drawings.

Production Duty

Process map, lifts and starts per hour, shifts, annual hours, load spectrum, travel distance, simultaneous motion, cycle target, availability and future capacity plan.

Workshop and Runway

Rail-center span, runway length and elevation, lift, headroom, approaches, column spacing, rail and beam details, existing wheel-load limits, foundations and installation access.

Long-Load Operations

Maximum length, stiffness, hook spacing, two-point load sharing, synchronization tolerance, turning sequence, tandem operation and clearance envelope.

Controls and Environment

Pendant, radio, cabin or automatic mode; speed and positioning; anti-sway; collision zones; power supply; dust, fumes, paint area, humidity, corrosion, temperature and outdoor wind.

Commercial and Compliance Scope

Destination, standards, inspection route, Incoterm, freight, runway, installation, electrification, commissioning, load test, operator training, spares, documentation and warranty.

Which crane is suitable for a steel fabrication shop?

Single-girder cranes commonly serve light-to-medium general handling. Double-girder cranes suit heavier or more intensive duty. Long loads may require two hoists or trolleys, while outdoor stock normally favors a gantry crane.

How is crane capacity calculated?

Add the heaviest workpiece, beam, magnet, clamps, slings, shackles, hook block and every suspended component. Then evaluate eccentric loading, multiple pickup points, load sharing, dynamics and approved turning cases.

When are two hoists or two trolleys required?

They are considered when a long or flexible assembly needs two support points, when hook spacing must change, or when an approved turning sequence requires separate control. Capacity split and synchronization must be specified.

Can an electromagnetic crane lift every steel plate?

No. Magnetic properties, thickness, flatness, temperature, coating, rust, scale, air gaps and stacked layers affect holding performance. The magnet and power-loss strategy must be validated against each approved load family.

How much does a steel fabrication crane cost?

Public equipment references reviewed in September 2026 ranged from US$2,600–5,500 for one ordinary 1–10 t single-girder listing to US$28,500 for a 10 t crane kit. Neither represents a complete installed project; final price depends on the full technical and commercial scope.

Can an existing runway be reused?

Only after rails, beams, brackets, columns, connections and foundations are checked for condition, geometry, fatigue and the proposed vertical, horizontal and dynamic crane reactions.

Is radio control suitable for fabrication?

Radio control can provide a direct view of the load and mobility between workstations. The risk assessment must still define operator position, emergency stop coverage, travel warnings, restricted zones and control of multiple cranes.

What should be tested before handover?

Testing covers motions, brakes, limits, overload protection, controls, attachments, positioning, collision functions, representative long loads, tandem modes, proof load and the agreed emergency response.

HANDLED MATERIAL

Hot & Ambient Steel Slabs

ATTACHMENT OPTIONS

Clamp, Magnet or Beam

SERVICE PROFILE

A7–A8 Published Range

CONTROL OPTIONS

Cabin, PLC & Automation

01 · Mechanical Slab Clamp Crane

Side-gripping mechanical or powered tongs engage approved slab faces. The arrangement avoids dependence on magnetic holding power and suits defined thickness and width ranges. Jaw geometry, closing force, locking status, surface scale and anti-release protection require project approval.

02 · Electromagnetic Slab Crane

A suspended magnet beam lifts magnetically responsive slabs without side access. Fast pickup and release support high-throughput yards, but magnetic duty, slab temperature, air gaps, power continuity, residual magnetism and emergency retention strategy govern suitability.

03 · Fixed-Orientation Transfer Crane

A non-slewing lifting system transfers slabs along a consistent storage or production axis. Reduced rotating mass and simpler control can support dependable repetitive handling when pickup and placement orientations remain aligned.

04 · Rotating Slab Handling Crane

A slewing trolley or rotating beam changes slab orientation between process bays, stacks, inspection lines and dispatch lanes. Rotation envelope, cable management, load inertia, collision zones and positioning accuracy form part of the crane design.

05 · Automated Slab Warehouse Crane

PLC control, encoders, ranging devices, anti-sway, stack coordinates and plant communication support unmanned or supervised automatic cycles. Manual recovery, safe-zone logic, inventory reconciliation and degraded-mode operation remain essential.

06 · Synchronized Dual-Lift System

Two lifting points or a 50+50 t arrangement distribute load along long slabs and specialized clamps. Load sharing, hoist synchronization, skew monitoring, rope reeving and independent protective functions limit twist and unequal loading.

Clamp Status and Release Interlocks

Open, closed and locked states are monitored where applicable. Hoisting permission, load presence and release conditions are interlocked so that a clamp cannot be opened during an unsafe suspended state.

Magnet Power-Loss Strategy

Magnetic systems require a documented response to supply interruption. Battery or alternate power, holding-time monitoring, alarms, controlled lowering and restricted personnel zones are selected from the load risk.

Hoist and Load Protection

Overload limitation, dual-point synchronization, upper and lower limits, brake monitoring, rope guidance and low-speed positioning protect the lifting path and prevent unequal loading.

Anti-Sway and Position Control

Mechanical reeving, VFD motion profiles, encoder feedback and optional electronic anti-sway reduce pendulation. Position tolerance is specified at the attachment and verified through commissioning.

Travel, Rotation and Collision Zones

End limits, buffers, anti-collision, slewing limits, clearance monitoring and protected storage coordinates prevent contact with structures, equipment, adjacent cranes and slab stacks.

High-Temperature Protection

Heat shields, protected electrical cabinets, temperature-rated cables, appropriate lubrication and component placement reduce radiant exposure. Inspection intervals reflect scale, heat and thermal cycling.

Automated-Mode Safeguards

Access control, zone scanning, permissive logic, fault diagnosis, safe stop, controlled restart and manual recovery govern unmanned or supervised cycles.

Operator and Maintenance Safety

High-visibility cabin design, cameras, warning devices, isolation points, platforms, access routes and component-removal space support controlled operation and maintainability.

Heavy slab service commonly uses a top-running double-girder bridge with an engineered winch trolley. The arrangement provides structural stiffness, mechanism access and space for synchronized hoists, a rotating platform or a suspended clamp beam. Long slabs may require two lifting points so that load sharing and slab deflection remain controlled throughout acceleration, travel and placement.

Headroom is governed by more than hook height. Rail elevation, bridge depth, trolley structure, rope geometry, clamp opening height, slab thickness, required clearance above stacks and maintenance-removal paths must be shown on one dimensioned vertical section. A rotating attachment also requires a verified plan-view envelope at every operating elevation.

An automatic cycle normally includes destination validation, approach at controlled speed, attachment alignment, secure pickup confirmation, vertical clearance, bridge and trolley travel, optional rotation, stack-position verification, controlled lowering and release confirmation. Fault recovery must define retained load condition, safe manual access and the route back to a known coordinate.

Stack height, cooling separation, grade segregation, retrieval sequence and buffer locations determine travel distance and cycle time. Motion values should follow the process model rather than maximum speed alone.

Henan Mine Crane manufactured a 50+50 t slab clamping crane for the Rizhao high-quality products base of Shanshan Iron & Steel. The project applies an electrically adjustable slab clamp with positioning control to large-tonnage steel-mill material handling.

The documented configuration addresses high-temperature radiation stated above 650°C through heat-resistant structural and protective measures. Digital speed control and a guiding arrangement support stable heavy-load motion and accurate placement. PLC control, weighing, fault alarms and operating-data functions provide a foundation for monitored production and later automation integration.

The case demonstrates that dual-point load control, clamp adjustment, thermal protection, positioning, monitoring and maintenance access must operate as one system. Temperature and performance values remain project-specific.

View Project Case →

Site and Runway Verification

Confirm rail centers, elevation, alignment, supporting structure, maximum wheel loads, horizontal forces, conductor location, erection access and available assembly space before shipment.

Shipping and Erection Plan

Define transport divisions, lifting points, temporary supports, girder assembly, trolley placement, attachment installation, high-temperature protection and site responsibility matrix.

Cold Commissioning

Verify travel alignment, brakes, limits, encoders, clamp or magnet functions, rotation, alarms, interlocks, communication and manual recovery without a process load.

Load and Process Acceptance

Conduct contracted static, dynamic and functional tests, then validate pickup, transfer, positioning and release using approved trial slabs and controlled operating zones.

Attachment Maintenance

Inspect clamp jaws, pins, bushes, locks, guides and sensors; check magnet insulation, cables, power backup and beam condition. Wear limits and replacement criteria belong in the manual.

Thermal and Electrical Inspection

Monitor heat shields, cable protection, cabinet cooling, seals, lubrication condition, brakes, ropes and temperature-affected components at intervals derived from actual exposure.

Automation Support

Maintain coordinate calibration, sensor health, network interfaces, backups, fault logs and recovery procedures. Software changes require controlled authorization and documented validation.

Critical Spare Parts

Plan brakes, encoders, sensors, contactors, VFD-related components, limits, seals, clamp wear parts, cable assemblies and selected magnet-power components around production consequence.

Slab Size and Mass Range

Minimum and maximum length, width, thickness, unit mass, number lifted per cycle, camber, edge condition and center-of-gravity variation.

Temperature and Surface Condition

Maximum slab surface temperature, ambient temperature, radiant exposure, scale, moisture, contact restrictions and cooling pattern.

Handling Route and Stack Plan

Pickup and placement coordinates, transfer distance, stack orientation, maximum stack height, gaps, retrieval logic and vehicle interfaces.

Capacity and Attachment

Required payload, proposed clamp or magnet, attachment mass, opening range, rotation requirement, auxiliary hook and special handling modes.

Duty and Throughput

Moves per hour, load spectrum, shifts, annual hours, target cycle time, production criticality and standby or redundancy requirements.

Building and Runway

Rail centers, bridge travel, rail elevation, runway beam and rail data, column spacing, roof obstructions, wheel-load limits and maintenance access.

Control and Automation

Cabin or supervised control, automatic operating zones, positioning accuracy, anti-sway, cameras, plant PLC/MES interface and recovery philosophy.

Power, Destination and Scope

Voltage, frequency, destination country, governing requirements, delivery term, runway scope, installation, testing, training and required schedule.

How is slab crane capacity calculated?

Capacity begins with the maximum slab or slab group and the complete lifting attachment. The contract must state whether rated capacity means net slab payload or gross suspended load. Dynamic and design factors are then applied under the governing engineering basis.

Which attachment is suitable for hot slabs?

A temperature-rated mechanical clamp is a common direction where side access and slab geometry permit positive gripping. A magnetic system requires confirmed temperature capability, air-gap conditions and power-loss controls. Final attachment selection follows a documented risk and geometry review.

Can one clamp handle different slab widths and thicknesses?

An electrically or hydraulically adjustable clamp can cover an approved operating range. Minimum and maximum dimensions, jaw contact zones, opening clearance, clamping force and locking indication must be defined for every permitted slab family.

Can a slab handling crane rotate the load?

Yes. A slewing trolley or rotating lifting beam can change slab orientation. Rotation angle, envelope, inertia, cable routing, stopping accuracy and collision protection are incorporated into the crane and building layout.

Can the crane operate near 650°C slabs?

Henan Mine Crane publishes configurations for high-temperature slab exposure up to the stated product limit and documents a 50+50 t case for severe radiant heat. Final approval distinguishes slab surface temperature, ambient air, distance, exposure time and thermal cycling.

Is an electromagnetic system safe during a power failure?

Safety depends on the engineered retention and recovery concept. Backup power, monitored holding time, alarms, restricted access and controlled lowering may be required. A generic magnet without a documented power-loss strategy is not an acceptable basis.

Can the same crane handle billets?

Possible suitability depends on billet geometry, bundle condition, attachment contact and operating route. A slab clamp is not automatically suitable for billets. The complete billet range and proposed attachment require separate engineering approval.

What information determines crane duty?

Load spectrum, moves per hour, travel distance, full-load frequency, operating shifts, annual hours, motion speeds and production consequence determine structural and mechanism duty. Rated tonnage alone is insufficient.

Can slab warehouses be automated?

Yes. Automated handling can combine encoders, ranging devices, anti-sway, coordinate storage, slab identification and plant communication. Safe zones, manual recovery, calibration, inventory reconciliation and fault handling form part of the system.

What should a quotation include?

A complete quotation identifies capacity basis, attachment, span, lift, duty, speeds, controls, temperature design, safety functions, wheel loads, documentation, testing, delivery boundary, installation responsibility, schedule and exclusions.

LISTED CAPACITY FAMILY

100–450 t or Custom

TYPICAL SPAN FAMILY

40–97 m or Custom

TYPICAL LIFTING HEIGHT

35–70 m or Custom

LISTED DUTY DATA

Project-Specific A5 or A7–A8

Hull Block Assembly

Lift decks, bulkheads, side shells and preassembled hull sections between fabrication, alignment and welding positions.

Dry Dock Erection

Position bow, stern, engine-room and superstructure modules during final hull erection and pre-launch construction.

Ship Repair and Conversion

Remove or install propulsion equipment, rudders, propellers, deck machinery and conversion modules during major dock work.

Offshore Module Handling

Handle selected vessel, platform, FPSO and offshore wind modules within a defined fabrication and assembly corridor.

01 / LOAD CASE

Block Mass and Load Distribution

Define maximum and typical block mass, dimensions, centre of gravity, lifting lugs, rigging mass and allowable local loads. Individual hook, trolley, combined and turning capacities must remain distinct.

02 / TURNING PLAN

Section Rotation Method

Establish pickup points, hook spacing, required rotation angle, load transfer between hooks, control sequence and permitted forces at every stage of the turn.

03 / GEOMETRY

Span, Lift and Hook Coverage

Map rail centres, dry-dock width, highest module, lowest hook position, side approaches, cantilever needs and all interference zones.

04 / DUTY

Operating Cycle and Design Life

State lifts and turns per shift, load spectrum, travel distances, operating hours, planned vessel program and future block-size changes.

05 / CIVIL WORK

Runways and Foundations

Coordinate wheel loads, wheel spacing, horizontal forces, storm anchoring, rail tolerances, drainage and geotechnical information with the civil design.

06 / COASTAL SITE

Wind and Corrosion Basis

Provide site wind data, storm procedures, temperature, salt exposure, humidity, rainfall and coating-life requirements.

07 / CONTROL

Power and Operating Philosophy

Define site supply, cable route, control stations, variable-speed motions, synchronized lifting, communications and data interfaces.

08 / DELIVERY

Transport and Erection Strategy

Confirm shipment segmentation, route limits, unloading method, erection cranes, temporary works, assembly space and site test responsibilities.

1. Establish Every Load Case

Engineering starts with the block in its fabrication position and follows it through pickup, initial suspension, rotation, load transfer, final orientation and landing. Hook forces can change substantially as the centre of gravity moves relative to the lifting points.

2. Select the Trolley and Hook Arrangement

Upper-and-lower trolleys can pass or work at different elevations. Two trolleys can distribute a long block across separated lifting points. Multi-hook systems require defined individual capacities, combined capacity, hook spacing and permitted simultaneous movements.

3. Control Motion and Synchronization

PLC supervision and variable-frequency drives can coordinate selected motions, limit speed during critical stages and monitor deviations. The allowable synchronization tolerance and response to a sensor, drive or communication fault must be stated in the technical agreement.

4. Verify the Lifting Attachment

Spreader beams, equalizing devices, slings, shackles and block lifting lugs form part of the load path. Their masses reduce available payload, and their geometry affects headroom, hook approach and section stability.

Rigid and Flexible Leg Arrangement

A rigid leg transmits longitudinal and transverse forces while the flexible leg accommodates the deformation behavior of a very wide bridge. Girder geometry, leg stiffness, wheel groups and connections are evaluated as one structural system.

Runway and Foundation Interface

The crane proposal must provide wheel loads, wheel spacing, longitudinal and transverse actions, rail requirements and anchoring loads. Civil design must address soil conditions, differential settlement, rail alignment, drainage and access for inspection.

Wind Protection and Storm Parking

Anemometers, alarms, service brakes, rail clamps, storm anchors and tie-down provisions are selected around the governing wind basis. Current product data identifies 20 m/s operating and 55 m/s non-operating values for a specified configuration; contractual thresholds require confirmation against site wind data and the applicable design standard.

Marine Corrosion Protection

Surface preparation, coating system, dry-film thickness, edge treatment, enclosed-space protection, fastener materials and electrical enclosures must match the coastal exposure category and required coating life. Inspection access and touch-up procedures form part of lifecycle planning.

Coordinated Motion Control

PLC and variable-frequency control can coordinate selected hooks, trolleys and long-travel drives. The control narrative should define permissible simultaneous motions, speed limits and recovery from a failed device.

Load and Position Monitoring

Load values, hook positions, trolley positions, crane travel, wind speed and selected drive conditions can be displayed and recorded. Alarm and shutdown limits require defined acceptance tests.

Hoisting and Travel Protection

Overload protection, hoisting limits, travel limits, brakes, buffers, emergency stops, anti-collision and overspeed protection are specified for the selected mechanisms and applicable requirements.

Skew Control and Rail Protection

Long-span crane travel requires coordinated drives, rail-position monitoring where specified, wheel-flange protection and clear maintenance criteria for alignment and skew trends.

Design Deliverables

• Design criteria and load-case schedule
• General arrangement and hook-coverage drawings
• Wheel loads and civil-interface data
• Electrical architecture and control narrative

Manufacturing Controls

• Material identification and traceability scope
• Approved welding and inspection plan
• Dimensional control and trial-assembly checks
• Surface preparation and coating inspection

Testing and Handover

• Factory functional and control tests
• Site commissioning and applicable load tests
• Operating and maintenance manuals
• Inspection records and spare-parts schedule

Segmented Delivery Planning

Girder and leg segmentation must match road, port, vessel and site lifting limits. Packing, lifting points, temporary supports and storage conditions are agreed before dispatch.

Erection and Rail Verification

Site work includes rail survey, temporary stability, structural assembly, drive alignment, electrical installation and storm-restraint commissioning under the approved erection method.

Functional and Load Testing

Commissioning verifies individual mechanisms, coordinated movements, limits, brakes, alarms, emergency functions and applicable load cases. A section-turning demonstration requires an agreed test method.

Lifecycle Access and Spares

Platforms, access routes, isolation points and component-removal paths should be reviewed during design. Initial spares and long-term critical spares follow the operating and maintenance strategy.

Double-Girder Gantry Crane

Heavy-duty hook handling for industrial yards, fabrication and equipment assembly.

Rail-Mounted Container Gantry Crane

Rail-mounted container stacking systems for terminals and intermodal yards.

Rubber-Tyred Gantry Crane

Mobile gantry systems for container blocks or compatible yard-handling duties.

Portal Harbor Crane

Slewing and luffing crane systems for quay cargo and project-load handling.

Container Straddle Carrier

Mobile container pickup and transport equipment for terminal transfer routes.

Gantry Crane Product Range

Review the full Henan Mine Crane gantry crane range and available configurations.

01 · Electromagnetic Overhead Crane

A circular or purpose-arranged magnet lifts ferrous scrap without manual slinging. Magnet geometry, duty cycle, magnetic test results, rectifier, cable management, current monitoring, heat dissipation and power-loss holding strategy are matched to the scrap stream. This system is not suitable for aluminum, copper or other non-ferrous material.

02 · Orange-Peel Grab Overhead Crane

A multi-tine orange-peel grab penetrates and closes around loose, irregular or mixed scrap. Tine count and profile, open diameter, volume, closing force, grab tare, wear plate, rotator and rope, hydraulic or electro-hydraulic drive are selected from the material and cycle. Dynamic pull-out loads require specific verification.

03 · Magnet and Hook Dual-Purpose Crane

A magnet handles ferrous scrap while a hook supports approved maintenance, rigging or unit-load work. The magnet, lifting beam and hook have separate operating rules and rated-load conditions. Changeover, attachment recognition, control permissives and stored attachment locations are defined in the operating concept.

04 · Grab and Hook Dual-Purpose Crane

A detachable grab expands a crane from bulk handling to conventional hook service. The arrangement is appropriate where scrap transfer is important but not the only process. Hook capacity, grab capacity, reeving, hydraulic or electrical connection, attachment parking and changeover risk are specified separately.

05 · Automated Scrap Handling Crane

Laser scanning or machine vision, absolute position feedback, pile mapping, anti-sway, path planning, hopper interlocks and collision avoidance can support semi-automatic or unmanned transfer. Automation is based on a defined material envelope, controlled work zones and documented recovery modes.

06 · Outdoor Scrap Gantry Crane

A rail-mounted gantry crane covers outdoor stockpiles, loading lanes or port yards without relying on a complete building runway. Wind operating limits, storm anchoring, lightning protection, corrosion class, drainage, rail foundations and vehicle segregation become part of the project scope.

Crane Motion Protection

Overload protection, upper and lower hoist limits, travel limits, service and emergency brakes, buffers, anti-derailment measures, controlled acceleration and defined emergency-stop functions protect the lifting and travel system.

Magnet Load-Retention Strategy

Current and voltage monitoring, temperature supervision, backup energy or electro-permanent technology, alarm logic and controlled emergency placement are selected from the risk assessment. Personnel and vehicles remain outside the potential drop zone.

Grab and Rotator Protection

Closing pressure or rope force, tine position, hydraulic pressure, hose routing, rotator condition and attachment state can be monitored. Control logic limits side pulling, dragging, incomplete closure and unsafe travel near obstacles.

Operator Visibility and Segregation

Cabin position, camera coverage, radio remote control, warning devices, barriers, vehicle routes and access interlocks are coordinated with the pile, loading lanes and discharge points to maintain a controlled operating zone.

Automation and Recovery

Pile scanning, position encoders, anti-sway, obstacle detection, collision avoidance, hopper or furnace interlocks and attachment-state permissives support automatic work. Manual fallback and controlled recovery are included in the functional design.

Dust, Heat and Outdoor Exposure

Protected enclosures, filtered or conditioned cabins, heat shielding, high-temperature cabling, corrosion-resistant coating, sealed components, wind alarms, storm anchoring and lightning protection are selected for the site environment.

Design basis

Approved scrap schedule, bulk-density range, throughput, load spectrum, duty calculation, layout, wheel reactions, clearances and code matrix.

Attachment engineering

Magnetic test basis or grab volume and tine design, total tare, load path, controls, interlocks, power-loss state, wear parts and rated-load marking.

Manufacturing records

Material traceability, welding procedures, welder qualifications, dimensional inspection, NDT reports and component certificates as contractually required.

Factory acceptance

Functional checks, brake and limit tests, control simulation, attachment cycles, magnet or grab verification and witnessed testing when included in the contract.

Before Manufacture

Confirm runway or foundation geometry, supporting-structure capacity, clearances, pile and discharge coordinates, vehicle routes, power supply, process interfaces, access for attachment maintenance and site responsibilities.

Erection and Commissioning

Coordinate unloading, erection method, rail survey, mechanical and electrical installation, no-load testing, proof load, attachment functions, representative scrap trials, process interlocks and operator training.

Planned Maintenance

Maintain brakes, ropes, drums, wheels, rails, reducers, fasteners and electrics together with magnet cables and backup power or grab tines, pins, bushings, ropes, rotator, hoses, cylinders and wear plates.

Which is better for scrap handling: a magnet or an orange-peel grab?

A magnet is generally preferable for verified ferromagnetic scrap with predictable pickup behavior. An orange-peel grab is generally preferable for mixed, irregular, contaminated, non-ferrous or weakly magnetic material. Representative scrap testing should confirm the selection.

Can one scrap crane use both a magnet and a grab?

Yes, if the trolley, reeving, power supply, cable management, controls and attachment parking are designed for both. Each attachment has a separate tare, rated payload, operating mode and inspection requirement.

How is scrap handling crane capacity calculated?

Capacity includes the maximum useful scrap payload plus the complete magnet, beam, grab, rotator, power unit and suspended interface tare. Dynamic extraction, impact, eccentricity, wheel loads and runway or foundation capacity are also checked.

How is orange-peel grab volume selected?

Preliminary volume follows target payload, loose bulk density and expected fill factor. Tine penetration, open span, maximum piece size, pile geometry, closing force, discharge opening and complete grab tare then determine the final design.

What happens if power fails while a scrap magnet is lifting?

The project risk assessment defines backup energy, alarm and current monitoring, emergency placement, controlled exclusion zones and the required load-retention strategy. Electro-permanent technology may also be evaluated for suitable material and process conditions.

Can a scrap handling crane be automated?

Yes. Pile scanning, position feedback, path planning, anti-sway, attachment-state monitoring, obstacle detection, hopper or furnace interlocks and MES, WMS or DCS communication can be integrated within a defined functional specification.

What working duty is required for a scrap crane?

Continuous scrap service often requires a heavy-duty A6–A8 solution, but the final crane and mechanism classifications are calculated from operating hours, lifts per hour, load spectrum, travel distances, attachment actions and design life.

Can a scrap crane operate outdoors?

Yes. An outdoor bridge or gantry crane can be configured with suitable corrosion protection, enclosure ratings, wind alarms, operating limits, storm anchoring, lightning protection, drainage and temperature controls for the destination.

How much does a scrap handling crane cost?

Observed factory guides place conventional 10–20 t double-girder base cranes at approximately US$12,000–US$60,000 before the scrap attachment and special controls. Large grabs, magnet systems, heavy-duty design, automation, runway, freight and installation require an itemized project quotation.

What information is needed for a scrap crane quotation?

Provide material categories, density, piece size, ferrous content, temperature, photos, throughput, operating cycle, pile and discharge layout, span, height, duty, power supply, control requirements, destination, applicable code and the required delivery and installation boundary.

APPLICATIONS

Steel Mills, Scrap Yards, Recycling Plants & Foundries

LIFTING SYSTEMS

Magnet, Orange-Peel Grab, Hook or Dual Purpose

DESIGN BASIS

Material, Throughput, Duty, Layout & Environment

PRICE BASIS

Engineered Project Quotation

01 · Electromagnetic Overhead Crane

A circular or purpose-arranged magnet lifts ferrous scrap without manual slinging. Magnet geometry, duty cycle, magnetic test results, rectifier, cable management, current monitoring, heat dissipation and power-loss holding strategy are matched to the scrap stream. This system is not suitable for aluminum, copper or other non-ferrous material.

02 · Orange-Peel Grab Overhead Crane

A multi-tine orange-peel grab penetrates and closes around loose, irregular or mixed scrap. Tine count and profile, open diameter, volume, closing force, grab tare, wear plate, rotator and rope, hydraulic or electro-hydraulic drive are selected from the material and cycle. Dynamic pull-out loads require specific verification.

03 · Magnet and Hook Dual-Purpose Crane

A magnet handles ferrous scrap while a hook supports approved maintenance, rigging or unit-load work. The magnet, lifting beam and hook have separate operating rules and rated-load conditions. Changeover, attachment recognition, control permissives and stored attachment locations are defined in the operating concept.

04 · Grab and Hook Dual-Purpose Crane

A detachable grab expands a crane from bulk handling to conventional hook service. The arrangement is appropriate where scrap transfer is important but not the only process. Hook capacity, grab capacity, reeving, hydraulic or electrical connection, attachment parking and changeover risk are specified separately.

05 · Automated Scrap Handling Crane

Laser scanning or machine vision, absolute position feedback, pile mapping, anti-sway, path planning, hopper interlocks and collision avoidance can support semi-automatic or unmanned transfer. Automation is based on a defined material envelope, controlled work zones and documented recovery modes.

06 · Outdoor Scrap Gantry Crane

A rail-mounted gantry crane covers outdoor stockpiles, loading lanes or port yards without relying on a complete building runway. Wind operating limits, storm anchoring, lightning protection, corrosion class, drainage, rail foundations and vehicle segregation become part of the project scope.

A scrap handling crane should be selected from the complete material route: receiving, unloading, sorting, stockpiling, processing, furnace charging and outbound transfer. The crane layout must cover every pickup and discharge coordinate without dragging the attachment, side pulling the load or carrying scrap above occupied traffic lanes.

The rated capacity includes the useful scrap payload and the complete magnet, beam, cable, grab, rotator, power unit, hook block and suspended interface tare. For grab service, interlocked scrap can generate extraction forces above the static grab-plus-payload mass. Hoist, rope, drum, brakes, trolley and bridge structure are therefore checked against the defined operating condition.

Throughput is established from average useful payload per cycle, realistic pickup efficiency, travel distance, hoisting height, discharge time, attachment action and expected delay. Nominal crane speed alone does not establish tonnes per hour.

Crane Motion Protection

Overload protection, upper and lower hoist limits, travel limits, service and emergency brakes, buffers, anti-derailment measures, controlled acceleration and defined emergency-stop functions protect the lifting and travel system.

Magnet Load-Retention Strategy

Current and voltage monitoring, temperature supervision, backup energy or electro-permanent technology, alarm logic and controlled emergency placement are selected from the risk assessment. Personnel and vehicles remain outside the potential drop zone.

Grab and Rotator Protection

Closing pressure or rope force, tine position, hydraulic pressure, hose routing, rotator condition and attachment state can be monitored. Control logic limits side pulling, dragging, incomplete closure and unsafe travel near obstacles.

Operator Visibility and Segregation

Cabin position, camera coverage, radio remote control, warning devices, barriers, vehicle routes and access interlocks are coordinated with the pile, loading lanes and discharge points to maintain a controlled operating zone.

Automation and Recovery

Pile scanning, position encoders, anti-sway, obstacle detection, collision avoidance, hopper or furnace interlocks and attachment-state permissives support automatic work. Manual fallback and controlled recovery are included in the functional design.

Dust, Heat and Outdoor Exposure

Protected enclosures, filtered or conditioned cabins, heat shielding, high-temperature cabling, corrosion-resistant coating, sealed components, wind alarms, storm anchoring and lightning protection are selected for the site environment.

A productive scrap crane repeats a controlled sequence: identify a permitted pickup zone, position the attachment, acquire a stable load, confirm attachment state, lift clear of the pile, travel through an approved route, verify the discharge equipment is ready, release the load and return without conflict.

Automatic or assisted operation can add three-dimensional pile scanning, absolute position feedback, anti-sway control, path planning, obstacle detection, restricted zones, hopper or furnace handshakes, weight data and MES, WMS or DCS communication. The functional specification also defines ownership of every signal and the safe response to incomplete, contradictory or lost data.

Pickup Model

Material map, pile boundary, prohibited zones, magnet pickup or grab closure, attachment-state confirmation and incomplete-pick recovery.

Travel Control

Absolute position, anti-sway, acceleration limits, collision prevention, route zoning and height permissions for vehicles, walls and process equipment.

Discharge Handshake

Ready/permit signals, receiving-capacity check, target confirmation, controlled release, completion feedback and fault response for hoppers or charging systems.

Fallback and Recovery

Safe stop, retained-load response, manual takeover, camera coverage, local isolation, attachment parking, alarm history and controlled return to automatic service.

Design basis

Approved scrap schedule, bulk-density range, throughput, load spectrum, duty calculation, layout, wheel reactions, clearances and code matrix.

Attachment engineering

Magnetic test basis or grab volume and tine design, total tare, load path, controls, interlocks, power-loss state, wear parts and rated-load marking.

Manufacturing records

Material traceability, welding procedures, welder qualifications, dimensional inspection, NDT reports and component certificates as contractually required.

Factory acceptance

Functional checks, brake and limit tests, control simulation, attachment cycles, magnet or grab verification and witnessed testing when included in the contract.

Before Manufacture

Confirm runway or foundation geometry, supporting-structure capacity, clearances, pile and discharge coordinates, vehicle routes, power supply, process interfaces, access for attachment maintenance and site responsibilities.

Erection and Commissioning

Coordinate unloading, erection method, rail survey, mechanical and electrical installation, no-load testing, proof load, attachment functions, representative scrap trials, process interlocks and operator training.

Planned Maintenance

Maintain brakes, ropes, drums, wheels, rails, reducers, fasteners and electrics together with magnet cables and backup power or grab tines, pins, bushings, ropes, rotator, hoses, cylinders and wear plates.

Crane Equipment

Bridge or gantry, trolley, hoist, drives, electrics, controls, access and crane safety devices.

Scrap Attachment

Magnet, beam, rectifier and cable system or grab, rotator, hydraulic unit and wear package.

Facility Interface

Runway, rails, columns, foundations, electrification, drainage, process signals and access boundaries.

Project Services

Engineering, FAT, packing, freight, installation, commissioning, proof testing, trials and training.

01 · Scrap schedule

Material categories and proportions, ferrous content, contamination, moisture, oil and representative photographs or samples.

02 · Density and piece size

Loose bulk-density range, typical and maximum dimensions, maximum single-piece mass, bundles and pile interlocking.

03 · Temperature and environment

Scrap and ambient temperature, radiant heat, dust, fumes, corrosion, rainfall, wind, altitude and hazardous zones.

04 · Throughput and operating cycle

Required tonnes per hour, shifts, annual hours, lifts per hour, load spectrum, travel distances and availability target.

05 · Layout and coverage

Plan and sections, rail span, runway or gantry travel, pile and discharge coordinates, heights, approaches and obstacles.

06 · Preferred attachment

Magnet, orange-peel grab, hook or dual-purpose requirement; existing attachment data and required changeover method.

07 · Runway or foundation

Rail section, elevation, alignment, allowable wheel loads, building reserve, foundation data and civil-work boundary.

08 · Controls and interfaces

Cabin, radio or central control; manual or automatic mode; cameras, weighing, PLC, MES/WMS/DCS and process handshakes.

09 · Compliance and acceptance

Destination, governing standards, inspection authority, document language, witness points, proof load and material trials.

10 · Commercial boundary

Delivery location and trade term, packing, freight, installation, local labor, commissioning, training, spares and schedule.

Which is better for scrap handling: a magnet or an orange-peel grab?

A magnet is generally preferable for verified ferromagnetic scrap with predictable pickup behavior. An orange-peel grab is generally preferable for mixed, irregular, contaminated, non-ferrous or weakly magnetic material. Representative scrap testing should confirm the selection.

Can one scrap crane use both a magnet and a grab?

Yes, if the trolley, reeving, power supply, cable management, controls and attachment parking are designed for both. Each attachment has a separate tare, rated payload, operating mode and inspection requirement.

How is scrap handling crane capacity calculated?

Capacity includes the maximum useful scrap payload plus the complete magnet, beam, grab, rotator, power unit and suspended interface tare. Dynamic extraction, impact, eccentricity, wheel loads and runway or foundation capacity are also checked.

How is orange-peel grab volume selected?

Preliminary volume follows target payload, loose bulk density and expected fill factor. Tine penetration, open span, maximum piece size, pile geometry, closing force, discharge opening and complete grab tare then determine the final design.

What happens if power fails while a scrap magnet is lifting?

The project risk assessment defines backup energy, alarm and current monitoring, emergency placement, controlled exclusion zones and the required load-retention strategy. Electro-permanent technology may also be evaluated for suitable material and process conditions.

Can a scrap handling crane be automated?

Yes. Pile scanning, position feedback, path planning, anti-sway, attachment-state monitoring, obstacle detection, hopper or furnace interlocks and MES, WMS or DCS communication can be integrated within a defined functional specification.

What working duty is required for a scrap crane?

Continuous scrap service often requires a heavy-duty A6–A8 solution, but the final crane and mechanism classifications are calculated from operating hours, lifts per hour, load spectrum, travel distances, attachment actions and design life.

Can a scrap crane operate outdoors?

Yes. An outdoor bridge or gantry crane can be configured with suitable corrosion protection, enclosure ratings, wind alarms, operating limits, storm anchoring, lightning protection, drainage and temperature controls for the destination.

How much does a scrap handling crane cost?

Some online equipment offers show low entry prices, but they frequently exclude the verified magnet or grab system, heavy-duty design, runway, freight, installation and commissioning. A procurement-grade price requires an itemized quotation based on the material, throughput, duty, layout and delivery boundary.

What information is needed for a scrap crane quotation?

Provide material categories, density, piece size, ferrous content, temperature, photos, throughput, operating cycle, pile and discharge layout, span, height, duty, power supply, control requirements, destination, applicable code and the required delivery and installation boundary.