作者： YUWEI, YUWEI

PROCESS DUTIES

Scrap, Charging, Ladle, Slag & Maintenance

CRANE SYSTEMS

Magnet, Grab, Charging, Casting & Service

OPERATING DUTY

Process-Specific Heavy Duty, A7–A8 Available

PRICE BASIS

Engineered Project Quotation

01 · Scrap Yard Magnet or Grab Crane

Handles incoming scrap, stockpile management, sorting, blending and charge-bucket loading. Electromagnets suit ferrous scrap with an approved magnet-control strategy; orange-peel grabs suit loose or mixed scrap. The crane is selected from scrap density, attachment mass, pile geometry, bucket volume and hourly throughput.

02 · Scrap Charging Crane

Lifts the filled charge bucket from the preparation area and transfers it to the EAF charging position. Capacity includes the bucket, scrap charge, lifting beam or chains and all below-hook components. Furnace roof, electrode mast, fume duct, platform and building clearances govern the approach envelope.

03 · Ladle Transfer or Casting Crane

Transfers the full molten-steel ladle from the tapping area to LF, VD, VOD, RH or continuous casting. Double-girder and four-girder configurations use a metallurgical trolley, gantry beam and plate hooks, with main and auxiliary lifting functions selected for transfer and pouring duties.

04 · Slag Pot Handling Crane

Moves slag pots between the furnace, cooling area and downstream slag-treatment stations. The crane and attachment are designed around gross pot mass, trunnion geometry, radiant heat, possible deposits, route conditions and the approved tipping or set-down method.

05 · Furnace Maintenance Crane

Handles furnace roof sections, electrodes, panels, burner assemblies, refractory equipment and maintenance loads during planned work. It is not a molten-metal or scrap-charging crane unless its structure, mechanisms, controls and acceptance basis explicitly cover those operations.

06 · Automated EAF Crane System

Adds position feedback, variable-frequency motion, route zoning, anti-sway functions, load monitoring and plant handshakes. Automatic or assisted sequences are engineered with the furnace supplier and plant integrator so that every permissive, safe state and manual recovery method has a defined owner.

The crane study begins with a coordinated plan and elevation of the scrap yard, charge-bucket preparation area, EAF bay, tapping aisle, secondary metallurgy stations, continuous caster, slag bay and maintenance zones. Pickup and set-down coordinates are checked against the furnace shell, retractable roof, electrode mast, fume-extraction duct, platforms, ladle cars, transfer cars and adjacent crane envelopes.

The route analysis identifies load elevations, hook approaches, bucket swing, ladle pickup tolerances, obstructions, crane passing rules and emergency set-down locations. A process-ready arrangement also provides inspection access outside uncontrolled heat and traffic zones.

Separating production and maintenance functions protects throughput. A ladle crane remains available for tapping and caster supply while service equipment supports furnace work. Shared runways require collision avoidance, traffic priority and recovery procedures.

Double-Girder Casting Crane Range

Henan Mine Crane product-family data covers 50–150 t capacity, 10–35 m span, 6–25 m lift and A7–A8 duty, with final values customized to the project.

Four-Girder Casting Crane Range

YZS product-family data covers 200/50–500/200 t capacity, 10–40 m span, 6–30 m lift and A7–A8 duty. Final selection follows the EAF project.

Load Path and Attachment Verification

The bridge, trolley, hoist, ropes, blocks, beam, hooks, plate hooks, chains and bucket or ladle interface are evaluated as one load path. Engagement geometry, wear limits, inspection access and permissible load orientation are documented for the specific handled object.

Hoisting Brakes and Protective Functions

Service and emergency braking functions, operating and final limits, overspeed detection, overload monitoring and safe response to power or drive failure are selected from the governing standard and project risk assessment. The molten-metal crane receives its own critical-function architecture.

Furnace Charging Permissions

Charging motion is permitted only within the plant-approved furnace state. Roof and electrode position, charging opening, extraction equipment, crane location, load condition and personnel exclusion can form part of the interlock matrix developed with the furnace supplier and plant integrator.

Thermal, Dust and Fume Protection

Heat shields, protected equipment locations, ventilation or cooling, suitable insulation systems, heat-resistant cables, sealed or pressurized cabinets and guarded access are selected from measured environmental data rather than a single assumed furnace temperature.

Controlled Motion and Collision Management

Variable-frequency drives, controlled acceleration, creep speeds, position feedback, anti-sway functions, inter-crane spacing, restricted zones and traffic priority support stable movements through the furnace, refining and casting bays.

Emergency Set-Down and Recovery

Approved set-down positions, backup functions, manual recovery boundaries, communications, rescue access and incident response are established with plant operations. Recovery planning addresses a loaded charge bucket, a full ladle and a maintenance load as separate scenarios.

Scrap Charging, Ladle Transfer and Process Automation

A charging cycle starts after the scrap bucket has been prepared and released for transfer. The crane engages the approved pickup points, raises the bucket to travel height and follows the permitted route to the EAF. Final approach uses controlled speed. Charging proceeds only after the furnace system confirms the required roof, electrode, extraction and exclusion-zone conditions.

Molten-steel transfer follows a separate sequence. The ladle crane engages both trunnions through the gantry beam and plate hooks, lifts from the tapping or ladle-car position and travels to secondary metallurgy or continuous casting. Controlled acceleration, low-speed approach, route permissions and emergency set-down provisions protect the load and process equipment.

Automation can coordinate positions, speed zones, load identification, anti-sway functions, weighing, collision avoidance, monitoring and plant handshakes. The control narrative defines crane and plant responsibilities, communication-failure behavior and recovery of an interrupted cycle. Higher automation follows validation of routes, sensors and safe states under production conditions.

Design Basis Package

Approved load schedule, charge bucket and ladle drawings, cycle histogram, general arrangement, clearance study, duty calculations, wheel loads, runway reactions, heat-zone map, station coordinates and compliance matrix.

Safety and Control Documents

Functional description, operating modes, brake philosophy, limit and interlock matrix, PLC and network architecture, safe states, charging permissions, emergency set-down logic, alarm list and recovery procedures.

Manufacturing Quality Records

Material traceability, welding procedures, welder qualifications, dimensional inspection, NDT, heat treatment or stress-relief records, machining checks, assembly records and coating reports as defined in the contract.

Factory and Site Acceptance

No-load and functional tests, brake and limit verification, overload functions, travel motions, communications, fault simulation, proof-load plan, site commissioning, dry process trials and operator-maintenance training.

Runway and Site Readiness

Survey rail span, elevation, alignment and runway capacity; confirm furnace, duct, platform and station clearances; verify erection access, electrification, control networks, construction sequence and shutdown windows before shipment.

Installation and Assembly

Bridge sections, end carriages, trolleys, reeving, beams, attachments, heat shields, conductor systems and control cabinets are assembled under approved lifting, alignment, bolting, welding, torque and electrical procedures.

Commissioning and Process Trials

Testing progresses from no-load motions and protective functions to proof loading, brake verification, positioning, interlocks, communications, dry charging-route simulation, ladle-route simulation and controlled production trials.

Inspection and Maintenance Strategy

The program covers ropes, drums, sheaves, brakes, hooks, plate hooks, beams, bucket interfaces, structures, wheels, heat shields, cables, sensors, cabinets and controls. Intervals follow actual duty, environment, regulation and manufacturer instructions.

Crane Equipment

Bridge, trolley, hoists, drives, brakes, ropes, wheels, platforms, access and electrification.

Process Attachments

Magnet, grab, charging beam, bucket rigging, gantry beam, plate hooks and slag-pot interface.

Safety and Automation

Limits, monitoring, VFDs, PLC, positioning, zoning, plant signals and process sequences.

Project Services

Engineering, FAT, packing, freight, erection, commissioning, load tests, trials and training.

01 · Melt-Shop Process

EAF size and heat schedule, scrap practice, tapping route, LF/VD/VOD/RH stations, continuous casting interface, shifts, annual hours and required availability.

02 · Crane Responsibilities

Identify separate duties for scrap receiving, bucket loading, furnace charging, ladle transfer, slag pots, furnace maintenance and general service.

03 · Maximum Gross Loads

Scrap, bucket or ladle, refractory, slag, beam, plate hooks, chains, blocks, magnet or grab and every suspended component for each permitted load case.

04 · Load Drawings

Charge bucket dimensions and pickup points; ladle diameter, height, trunnion size and spacing; center of gravity, tilt point and interface tolerances.

05 · Building and Runway

Plans, sections, rail span, runway length and elevation, rail type, allowable wheel loads, headroom, end approaches, building reserve and erection access.

06 · Stations and Clearances

Scrap bays, charging position, furnace roof and electrodes, ducts, platforms, ladle cars, refining stations, caster, slag bay and emergency set-down coordinates.

07 · Duty and Performance

Lifts per heat, cycle time, travel distances, load spectrum, main and creep speeds, acceleration limits, positioning accuracy and load-sway requirements.

08 · Environment and Protection

Ambient and radiant temperatures by zone, dust, fumes, scale, splash, humidity, altitude, outdoor exposure, ventilation and operator environment.

09 · Controls and Compliance

Control stations, manual or automated modes, PLC and network preferences, signal list, destination standards, inspection body, FAT and acceptance requirements.

10 · Commercial Scope

Delivery location and trade term, packing, freight, runway and electrification boundary, erection, commissioning, local labor, training, spares and target schedule.

Is an EAF crane one specific crane type?

No. The term covers cranes serving an electric arc furnace melt shop. Scrap handling, charge-bucket transfer, ladle handling, slag handling and maintenance should each be assigned a defined crane configuration and operating boundary.

What is the difference between an EAF charging crane and a ladle crane?

A charging crane handles the scrap-filled bucket and approaches the furnace charging position. A ladle crane handles a vessel containing molten steel after tapping. The load interface, hazard, route, redundancy and process permissions are different.

How is scrap charging crane capacity calculated?

Use the maximum filled bucket mass plus the bucket, lifting beam, hooks or chains, blocks and all suspended tooling. Include all permitted charge recipes and abnormal but approved load cases in the load schedule.

Can one crane handle scrap charging and molten-steel ladles?

Only after a project-specific engineering and risk assessment demonstrates compatible attachments, load paths, duty, clearances, heat protection, controls and production availability. Dedicated cranes are often the more robust plant arrangement.

When is a four-girder casting crane considered?

Four-girder multi-rail construction is considered for ultra-heavy ladles, intensive duty, separate main and auxiliary trolleys, high structural stiffness and critical availability. Building reactions, erection and lifecycle maintenance must support the choice.

What data is needed to check furnace clearances?

Provide coordinated plan and elevation drawings for the furnace shell, roof, electrodes, mast, extraction duct, platforms, bucket, lifting attachment, crane rails and neighboring equipment in every operating position.

Can EAF crane operation be automated?

Yes. Position feedback, VFD motion, anti-sway functions, route zoning, load identification and plant handshakes can support assisted or automatic operation. Safe states, signal ownership and manual recovery must be validated.

Which standards apply to an EAF crane?

The applicable basis depends on destination, buyer requirements and crane duty. The contract should identify the governing structural, mechanical, electrical, functional-safety, inspection and load-testing standards in a compliance matrix.

What determines EAF crane price?

Crane duty, gross loads, span, lift, bridge and trolley structure, attachments, heat protection, safety architecture, automation, wheel loads, documentation, shipping, erection and commissioning determine the commercial scope.

Can an existing runway be reused?

Reuse requires survey and structural verification of rails, runway beams, columns, foundations, wheel-load capacity, fatigue condition, alignment and clearances. The assessment must also consider the new crane duty and thermal environment.

PROCESS AREAS

Smelter, Anode Plant, Tankhouse & Maintenance

HANDLING DUTIES

Vessels, Anodes, Cathodes, Bulk Materials & Equipment

DESIGN CONDITIONS

Heat, Dust, Fumes, Corrosion & Intensive Duty

PRICE BASIS

Engineered Project Quotation

01 · Molten Copper and Vessel Handling Crane

A heavy-duty metallurgical overhead crane for a defined ladle, crucible, slag pot or transfer vessel. The design considers gross suspended load, trunnion or lifting-beam interface, center of gravity, route, radiant heat, motion control, braking, redundancy and emergency load-set-down procedure.

02 · Charging and Bulk-Material Crane

A grab, bin or hook crane selected for concentrates, fluxes, returns, slag or other approved bulk materials. Material bulk density, particle size, temperature, abrasiveness, moisture, dust behavior, required throughput and receiving equipment determine the attachment and crane duty.

03 · Anode Handling Crane

A crane for lifting cast copper anodes between the casting area, cooling or preparation stations, storage and tankhouse logistics. The lifting beam or gripper is matched to anode geometry, quantity per lift, spacing, surface condition and required orientation.

04 · Electrolytic Copper Tankhouse Crane

A process crane with a specialized spreader for grouped anode and cathode handling. It can be configured for cell loading and unloading, plate transfer, stacking and maintenance support, with positioning, corrosion protection, wash-down compatibility and automation selected for the refinery process.

05 · Insulated or Special-Environment Crane

Where the electrical study identifies credible current paths or the zone has exceptional corrosive exposure, an insulated or specially protected crane may be required. Insulation barriers, coating system, materials, enclosures and testing are defined from verified plant conditions rather than assumed from the industry name.

06 · Maintenance and Auxiliary Crane

A double-girder or electric-hoist bridge crane for furnace components, pumps, motors, ducts, molds, tools and shutdown maintenance. This configuration is economical for general lifting but must not be substituted for molten-metal or automated tankhouse duties.

Match the Crane to the Copper Process Area

A plant-wide handling study identifies every pickup point, destination, process time, attachment, operating envelope and interface. It also separates duties that cannot share one machine because of load consequence, contamination, corrosion, incompatible attachments or required availability.

For furnace and converter areas, the study records the vessel or pot drawing, gross mass, contents, temperature, trunnions, lifting points, travel route, pouring or tipping requirement and safe set-down locations. For the anode and tankhouse areas, it records plate dimensions, plate quantity per lift, cell pitch, aisle geometry, stacking arrangement, washing sequence and production cycle.

Maintenance loads, building clearances, runway capacity, fume extraction, electrical zones, access platforms and shutdown windows complete the design basis. The result is a crane responsibility matrix rather than one generic plant-wide specification.

High-Consequence Suspended Loads

Molten-metal or slag-vessel duties require a load-consequence review covering hoist arrangement, brakes, limits, overload protection, rope path, attachment retention, emergency power-loss response and approved set-down areas.

Heat and Thermal Exposure

Radiant heat and hot-air exposure are evaluated at the bridge, trolley, cabin, electrical enclosures, cables, sensors, lubricants and lifting device. Shields, separation, cooling and heat-resistant components follow measured conditions.

Fumes, Acid Mist and Corrosion

Coating systems, stainless or corrosion-resistant parts, sealed enclosures, cable materials, fasteners and ventilation are selected from the verified gas, mist, humidity and wash-down exposure in each operating zone.

Dust and Material Containment

Dust-resistant housings, protected brakes and drives, suitable filtration and interfaces to plant extraction limit contamination. Bulk-material attachments are selected to reduce uncontrolled release at pickup and discharge points.

Stable Motion and Positioning

Variable-frequency motion, controlled acceleration, braking, anti-sway functions, position feedback and travel zoning support predictable vessel transfer and plate placement. Required accuracy is stated at the actual load interface.

Operator and Maintenance Access

Cabin position, remote stations, cameras, alarms, access platforms, isolation points, rescue provisions and component replacement routes are coordinated with visibility, heat exposure and the plant work-permit system.

Electrolytic Copper Crane and Tankhouse Automation

In an electrorefinery, the crane is part of the production system rather than a general hook crane. The spreader must engage the specified number of anodes or cathodes, maintain the required pitch and orientation, clear the cell and busbar arrangement, and place plates without unacceptable contact or distortion.

Manual, assisted, semi-automatic and higher-automation operating concepts are possible. Position feedback, cell identification, automatic travel paths, restricted zones, spreader permissions, load confirmation, anti-sway control, plate-washing interfaces and production-data exchange can be integrated where the refinery layout and process controls support them.

The quotation should define the boundary between crane automation, lifting-device controls, cell management, wash equipment, anode preparation, cathode stripping, conveyors and the plant supervisory system. Undefined interfaces are a major source of commissioning delay.

Relevant Heavy-Metallurgy Project Reference

360-Ton Four-Girder Foundry Crane Project

Henan Mine Crane published a 360-ton foundry-crane project supplied for Jinsheng’an Group. The machine uses a four-girder, four-rail, dual-trolley architecture for an ultra-heavy molten-metal duty, with structural analysis, balanced wheel-load distribution, redundant main-hoist arrangements, multiple braking and limit protections, thermal shielding and monitored controls.

The project is relevant evidence of heavy metallurgical engineering, manufacturing and commissioning capability. It is not presented as a copper-smelter operating reference. A copper project still requires independent verification of the vessel, copper-process route, temperatures, fumes, corrosion, runway, duty and purchaser standards.

For copper-smelter procurement, the transferable engineering disciplines are load-path analysis, structural redundancy, high-temperature protection, manufacturing traceability, factory testing and controlled site commissioning—not automatic reuse of the same 360-ton configuration.

View the 360-Ton Metallurgical Crane Project →

Design Basis

Approved load and process schedule, duty calculations, general arrangement, attachment envelope, wheel loads, environment, utilities, code matrix and responsibility boundary.

Control Documentation

Electrical diagrams, PLC and network architecture, operating modes, interlock matrix, alarms, safe states, recovery logic and plant communication schedule.

Manufacturing Records

Material traceability, welding procedures, welder qualifications, dimensional inspection, NDT records, machining checks, coating reports and component certificates as contracted.

Factory Acceptance

Drive, brake, limit, overload, alarm and interlock tests; attachment functions; control modes; communications; simulated sequences and purchaser witness points.

Site Readiness

Confirm runway survey, rail condition, building reserve, erection route, laydown area, power, extraction interfaces, access controls, shutdown window and hot-work restrictions before shipment.

Installation

Bridge and trolley assembly, rail and conductor checks, cabin and platform installation, lifting-device integration, utilities and plant-network connections follow approved method statements.

Commissioning

Testing progresses from no-load motions and safety functions to proof testing, dry sequence simulation and controlled production trials. Loads, materials, witness points and acceptance values are agreed beforehand.

Lifecycle Support

Training covers operation, attachment change, isolation, alarms, recovery and inspection. Preventive maintenance is organized by structure, mechanisms, controls, lifting device and environmental protection.

Crane and Lifting Device

Bridge, trolley, hoists, vessel interface, grabs, spreaders, hooks, cabins, platforms and maintenance access.

Controls and Protection

Drives, PLC, positioning, anti-sway, communications, automation, heat protection, corrosion protection and cameras.

Delivery and Services

Engineering, documents, inspection, FAT, packing, freight, insurance, spares, installation, commissioning and training.

Plant Interfaces

Runway, rails, conductor system, reinforcement, extraction, utilities, network connection and production-trial support.

01 · Plant and process area

New plant, expansion or replacement; smelter, converter, anode plant, tankhouse, maintenance bay or material store; production schedule and crane role.

02 · Building and runway

Layout, sections, rail span, runway length, rail elevation, headroom, columns, end approaches, rail data and allowable wheel loads.

03 · Loads and attachments

Vessel, ladle, pot, anode, cathode, process material or maintenance-load drawings; gross mass, contents, temperature and lifting points.

04 · Process route and coverage

Pickup, operating and set-down coordinates; furnace, converter, casting, cell, wash, stacking or maintenance interfaces; obstacles and restricted zones.

05 · Performance

Required capacity, lift height, speeds, positioning, cycles per hour, shifts, annual hours, availability target and standby philosophy.

06 · Environment

Ambient and radiant heat, dust, gases, acid mist, humidity, wash-down, altitude, electrical hazards and hazardous-area classification where applicable.

07 · Controls and utilities

Power supply, control stations, manual or automatic modes, plant network, communication protocol, extraction, compressed air and other services.

08 · Compliance and acceptance

Destination country, governing codes, purchaser standards, inspection authority, witness points, FAT, load test and production-trial requirements.

09 · Delivery and site scope

Destination port or site, trade term, packing, freight, installation, commissioning, local labor, lifting equipment, training and production support.

10 · Schedule and lifecycle

Required delivery date, shutdown window, documentation language, recommended spares, maintenance capability, response expectations and support plan.

Is a copper smelter crane one standard crane model?

No. The term can cover molten-vessel cranes, charging or grab cranes, anode-handling cranes, electrolytic copper tankhouse cranes and maintenance cranes. The process duty determines the configuration.

What is the difference between a smelter crane and a tankhouse crane?

A smelter crane may handle hot vessels, bulk materials or furnace equipment. A tankhouse crane is a process machine for anode and cathode plates, requiring a specialized spreader, accurate positioning and corrosion protection.

How is the crane capacity selected?

Capacity includes the product, vessel or lifting-device tare and any process contents. Dynamic effects, operating orientation, off-center conditions and required redundancy are evaluated for the defined load cases.

Can a general double-girder crane handle molten copper?

Not by default. Molten-load service requires a project-specific review of the hoist, brakes, limits, controls, load path, attachment, heat protection, emergency response and applicable regulations.

How is tankhouse corrosion addressed?

The verified acid-mist, humidity, chemical and wash-down exposure guides coating, material, fastener, cable, enclosure, ventilation and maintenance-access selection. Generic paint specifications are insufficient.

Can an electrolytic copper crane be automated?

Yes. Depending on plant interfaces, options include automatic positioning, cell identification, sequence control, restricted zones, spreader permissions, plate confirmation, anti-sway and production-data exchange.

Can an existing runway be retained?

Only after the rail geometry, alignment, support condition, wheel-load capacity, longitudinal forces, clearances and erection access are checked against the proposed crane and operating load cases.

Does every copper plant need an insulated crane?

No. Insulation is specified when the electrical study identifies credible current paths and required isolation. Corrosion protection, electrical insulation and explosion protection are separate design questions.

Why do advertised copper smelter crane prices vary widely?

Listings often omit the process attachment, duty, heat and corrosion protection, automation, runway, testing, delivery and commissioning. The same nominal tonnage can represent fundamentally different equipment.

What should final acceptance include?

Acceptance should cover documentation, visual and dimensional inspection, safety functions, load testing, lifting-device operation, controls, communications, dry process simulation, production trials, training and handover records as contracted.

PROCESS AREAS

Feed, Smelting, Casting & Refining

CRANE TYPES

Grab, Bin, Casting & Maintenance

PRIMARY EXPOSURES

Heat, Dust, Fumes & Corrosion

PROJECT BASIS

Process, Load, Duty, Route & Risk

Concentrate and Flux Handling

Grab and transfer concentrate, silica flux, coke, recycled material or other approved bulk feed between storage, blending, bins and process interfaces.

Furnace Charging and Bin Transfer

Lift, position and empty charge boxes or bins through a controlled sequence coordinated with furnace doors, hoods, feeders and exclusion zones.

Matte and Slag Pot Transfer

Move declared molten or semi-molten vessels between furnace, converter, slag-cleaning and cooling positions using a purpose-designed load path and vessel attachment.

Blister Copper and Anode Refining

Support vessel transfer, furnace service and maintenance from converting through anode refining, with heat protection and interlocks matched to the operating route.

Anode Casting and Product Handling

Handle casting equipment, molds, ladles, anodes and maintenance assemblies around the casting wheel or mold line without conflicting with hot-metal routes.

Electrorefinery Tankhouse

Transfer anode and cathode groups, stripping-line loads or cell-service equipment with mechanical lifting frames, corrosion protection and busbar clearances.

Acid Plant and Off-Gas Systems

Provide maintenance lifting for fans, ducts, pumps, heat exchangers and process equipment with protection based on measured chemical exposure and area classification.

Shutdown and Major Maintenance

Remove furnace, converter, hood, electrode, burner, pump or drive components using planned maintenance clearances, drop zones and laydown areas.

1. Bridge and runway interface: transfer vertical, lateral, longitudinal, buffer and fatigue loads to the smelter building while maintaining furnace, hood and duct clearances.
2. Process trolley and hoist: provide the main and auxiliary capacities, reeving, braking, drives, speed range and duty required for the declared vessel or material cycle.
3. Load-handling device: connects to a charge box, pot, ladle, lifting trunnion, anode or cathode frame, grab, mechanical clamp, hook or maintenance spreader.
4. Thermal and environmental package: protects structure, ropes, brakes, motors, panels, sensors and cab from radiant heat, dust, fumes, acid mist, condensation and corrosion.
5. Safety and control system: coordinates limits, load monitoring, brakes, collision protection, restricted zones, process interlocks, safe states and controlled recovery.
6. Power and plant interface: covers crane electrification, emergency-energy philosophy, PLC communication, operating modes, event records and interfaces with furnace, converter or casting equipment.

Process and Load Matrix

Material or vessel identity, empty and full mass, temperature, dimensions, center of gravity, trunnions, attachment, normal cycle, abnormal condition and maintenance lifts.

Production Duty

Lifts per heat or batch, starts per hour, average and maximum load, travel distance, shifts, annual hours, standby time, production consequence of outage and maintenance window.

Load Path and Interfaces

Pickup, transfer and placement coordinates; furnace or converter status; casting equipment; vehicle crossings; occupied areas; emergency landing positions and interlocked machinery.

Environmental Data

Ambient and radiant temperature, duration of heat exposure, dust composition, SO₂ and acid mist, humidity, condensation, corrosive chemicals, washdown and hazardous-area classification.

Building and Runway

Rail-center span, runway length and elevation, headroom, hook approaches, wheel-load limits, clearances to ducts and hoods, expansion joints, rail condition and erection access.

Safety and Acceptance

Applicable law and standard, required redundancy, failure-response philosophy, operator location, access control, inspection route, representative-load tests and measurable process acceptance.

A molten-copper crane is a process-safety system, not a general overhead crane with additional heat shields. The design basis must define what occurs after loss of one motor, reducer, brake, rope path, encoder, controller, incoming supply or communication link. The required redundant architecture depends on capacity, process risk, local law and the selected design standard.

• Specify the main-hoist load path, service and emergency braking arrangement, upper-limit architecture and overspeed or unintended-motion protection where required.
• Define whether a remaining drive can hold, lower or complete a controlled safe-placement cycle after a single failure.
• Provide a predetermined landing or containment position for a retained molten load; emergency energy must have a stated function and duration.
• Keep routine travel away from occupied rooms, control stations, escape routes and water hazards wherever the plant layout permits.
• Interlock vessel transfer with furnace, converter, hood, door, aisle and casting equipment states as defined by the process hazard review.
• Prohibit tandem or simultaneous operations unless the cranes, controls, load-sharing method and lift plan are engineered for that operation.

Thermal Protection

Heat shields, insulated structural zones, protected ropes and drums, high-temperature cables, suitable lubricants, remote panels and component-temperature monitoring are selected from exposure and duration.

Dust Management

Enclosures, filtration, positive-pressure cabinets, sealed bearings, accessible cleaning points and cable routing are matched to dust loading, conductivity and abrasion.

Fume Exposure

Cab location, filtered pressurization, HVAC intake position, remote operation, viewing systems and escape route are coordinated with SO₂ and other process-fume mapping.

Corrosion System

Surface preparation, coating, fasteners, enclosure materials, seals and corrosion allowance are chosen from chemical concentration, temperature, condensation and maintenance practice.

Tankhouse Electrical Interface

Busbar clearance, grounding, isolation, conductive-liquid carryover, prohibited bridging paths and fault-current consequences require coordination with the plant electrical design.

Hazardous Areas

Explosion-protected equipment is selected only from a documented zone, gas or dust group, temperature class and protection concept. A copper smelter is not automatically one uniform hazardous area.

Wheel Loads and Fatigue

Provide maximum, minimum and concurrent trolley wheel loads, lateral and longitudinal forces, buffers, fatigue spectrum and rail tolerances for structural verification.

Process Clearances

Coordinate bridge depth, trolley envelope, vessel swing, hook approach, hoods, ducts, stacks, columns, access platforms and operating equipment in every position.

Runway Survey

For an existing building, survey rail gauge, elevation, alignment, joints, wear, fasteners, beams, brackets, columns and foundations before final crane reactions are accepted.

Maintenance Access

Define platforms, guardrails, walkways, lighting, isolation points, component-removal routes, trolley service position and lifting points for crane maintenance.

Critical Spares Strategy

Identify brakes, ropes, wheels, bearings, encoders, drives, PLC modules, contactors, sensors, seals and attachment wear parts from production consequence and replacement lead time.

Erection and Outage Plan

Establish delivery splits, access opening, site lifting method, temporary works, outage duration, hot-work restrictions, tie-in sequence and commissioning area.

Design Review

Approve classifications, load cases, redundancy, structural and mechanism calculations, attachment drawings, wheel loads, environmental protection and safety functions.

Manufacturing Records

Define material traceability, welding procedure and personnel qualification, nondestructive examination, heat treatment, machining, assembly and coating records.

Factory Acceptance

Verify mechanisms, brakes, limits, overload system, control modes, alarms, process simulation, fault responses, interface signals and documentation before shipment.

Site Acceptance

Confirm runway geometry, commissioning tests, proof load, representative vessel or material handling, interlocks, protected routes, emergency functions and agreed production cycles.

Henan Mine Crane has published a 360 t foundry-crane project reference for Jinsheng’an Group. The delivered crane uses a four-girder, four-rail, dual-trolley arrangement for ultra-heavy molten-metal service and incorporates project-specific structural, hoisting, braking and thermal-protection measures.

The reference demonstrates manufacturing and commissioning experience with a large-capacity metallurgical crane, including trolley coordination, high wheel loads, heat exposure and molten-material risk controls. Henan Mine Crane also publishes a four-girder casting-crane platform for steel and non-ferrous smelting applications, explicitly including molten copper handling in its application description.

A copper-smelter proposal would still be developed from the copper vessel, trunnion and attachment data; matte, slag or anode-copper process; plant layout; environmental measurements; required compliance basis and acceptance plan.

Design Basis

Process description, load cases, classifications, standards, redundancy philosophy, environment, reliability target, interfaces and exclusions.

Calculation Package

Structure, mechanisms, fatigue, ropes, drums, brakes, wheels, wheel loads, attachment, heat protection and safety-related controls as contractually required.

Interface Drawings

General arrangement, vessel and attachment, runway reactions, clearances, electrification, PLC signals, access, maintenance and erection splits.

Inspection and Test Plan

Hold points, traceability, welding records, nondestructive examination, factory tests, proof load, process simulation and site acceptance scenarios.

Operating Documentation

Manuals, inspection schedules, fault-response procedures, rescue and recovery, software backups, attachment register and operator training.

Commercial Schedule

Inclusions, exclusions, Incoterm, freight, civil work, erection, utilities, commissioning, spares, warranty, schedule and local support responsibility.

Process and Load Data

Smelting technology and process zone; material or vessel; empty, normal and maximum mass; temperature; dimensions; center of gravity; attachment and operating sequence.

Vessel and Attachment Drawings

Pot, ladle, bin, charge box, trunnion, tipping lug, anode/cathode frame, grab or spreader drawings with allowable contact and clearance zones.

Duty and Production Cycle

Cycles per heat or hour, shifts, annual hours, load spectrum, travel distances, simultaneous motions, speed targets, outage consequence and maintenance window.

Plant Layout and Runway

Plan and cross-section, span, runway length and elevation, rail data, wheel-load limits, process clearances, hot-load route, emergency position and installation access.

Environment and Controls

Ambient and radiant heat, dust, fumes, chemicals, humidity, corrosivity, hazardous-area classification, power supply, control mode, signals and plant communication protocol.

Compliance and Commercial Scope

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

Which crane is used in a copper smelter?

Grab cranes handle dry bulk feed, bin cranes serve charge boxes, casting cranes handle approved molten-material vessels, tankhouse cranes move anodes and cathodes, and general double-girder cranes support maintenance. Each duty requires a separate specification.

Can an electromagnetic crane lift copper?

No conventional steel-lifting electromagnet should be specified for copper plate, anodes or cathodes because copper is not ferromagnetic. Mechanical hooks, frames, clamps, grabs or purpose-designed attachments are required.

How is casting-crane capacity calculated?

The basis is the heaviest gross suspended load: vessel, refractory, maximum process contents, adhered material, lifting beam, hooks and every accessory. Tipping, eccentric and simultaneous main/auxiliary-hook cases are evaluated separately.

Is every copper smelter crane explosion-proof?

No. Explosion protection is determined by the documented area classification, substance group, temperature class and selected protection concept. High temperature, corrosion resistance and explosion protection are different design requirements.

What duty class is required?

Molten-material and bulk-feed cranes commonly require high-duty classifications, while shutdown maintenance cranes may be lower duty. The correct class follows the load spectrum, cycles, speeds, annual hours and consequence of downtime.

Can an existing runway be reused?

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

How much does a copper smelter crane cost?

Public listings reviewed in September 2026 included US$156,000 for one configurable foundry-crane listing and US$80,000–500,000 for a 400/100 t four-beam listing. A complete copper-smelter crane remains quotation-based because the published scopes are incomplete.

What should be tested before handover?

Testing should cover mechanisms, brakes, limits, overload protection, attachment engagement, representative loads, process interlocks, safe states, single-fault responses, emergency placement, proof load and agreed operating cycles.

01 · Rail-Mounted Gantry Crane

An RMG travels on fixed rails and spans container rows plus truck or railway lanes. It supports high stacking density, precise positioning, electric power and advanced automation. Rail foundations, block alignment, storm restraints and a fixed operating envelope are integral to the project.

02 · Rubber-Tyred Gantry Crane

An RTG runs on rubber tyres and can serve different yard blocks when the pavement, steering system and traffic plan permit. Diesel-electric, hybrid, battery or externally electrified arrangements may be evaluated. Mobility must be balanced against tyre care, route control, energy supply and block-change time.

03 · Container Straddle Carrier

A straddle carrier lifts, carries and stacks containers with one mobile machine. It can reduce fixed rail infrastructure and provide flexible transfer between quay, yard and landside interfaces. Fleet sizing, traffic separation, turning space, pavement loading, battery charging or fuel service and maintenance access govern the operating concept.

04 · Container Overhead Crane

A container overhead crane runs on an elevated building or freestanding runway above a fixed bay. It is suitable for indoor transfer, manufacturing logistics, specialized depots or controlled rail and truck interfaces where weather protection and unobstructed floor access are required.

05 · Automated RMG or RTG System

Remote or automated operation can integrate anti-sway, absolute positioning, container recognition, truck-lane guidance, path control, collision avoidance and terminal operating system communication. Automation scope is defined with network architecture, data ownership, cybersecurity, recovery modes and manual intervention points.

06 · Intermodal and Rail Yard Crane

An intermodal yard crane spans railway tracks, truck lanes and storage rows to transfer containers between railcars and the stack. Rail operating windows, wagon profiles, track clearances, locomotive restrictions, grounding, signaling interfaces and terminal peak schedules become part of the design basis.

Electric and Mobile Power

RMG cranes commonly use cable reels or busbar systems. RTG and straddle-carrier projects can evaluate diesel-electric, hybrid, battery or externally electrified arrangements. Grid connection, charging demand, redundancy, cable routes, block mobility and lifecycle energy cost are reviewed together.

Spreader and Load Confirmation

Twistlock position, landed status, all-corners-locked confirmation, container size selection, load measurement and spreader cable management support controlled pickup. Interlocks prevent hoisting or travel when the defined engagement state is not achieved.

Anti-Sway and Positioning

Mechanical or electronic anti-sway, absolute position feedback, laser or camera guidance, truck alignment and controlled micro-speed can reduce settling time and support repeatable placement. Required positioning accuracy is defined for each interface.

TOS, RCMS and Remote Operation

Terminal operating system and crane management interfaces can exchange work orders, container identity, equipment status, alarms and completed moves. Remote-control stations require camera coverage, communications redundancy, ergonomic review and defined degraded-operation procedures.

Collision and Traffic Protection

Travel limits, buffers, anti-collision devices, obstacle detection, lane interlocks, warning systems, emergency stops and controlled access are coordinated with trucks, tractors, railcars, personnel and adjacent cranes. The functional design assigns responsibility for every interface.

Wind and Outdoor Protection

Anemometers, operating and parking wind limits, rail clamps, storm pins or anchors, lightning protection, corrosion-resistant coating, sealed enclosures, drainage and temperature-rated components are selected for the destination and agreed design conditions.

Design basis

Approved container schedule, block layout, cycle model, load spectrum, duty calculation, wind data, availability target, code matrix and interface register.

Interface engineering

General arrangement, rail or pavement reactions, power demand, spreader data, TOS/RCMS signals, communications, civil tolerances and maintenance access.

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, spreader simulation, control sequences, alarm and interlock verification, data-interface tests and witnessed inspection when included.

Before Manufacture

Confirm the topographic survey, yard and lane geometry, rail alignment or pavement capacity, foundations, wheel loads, drainage, storm restraints, power route, substations, communications, maintenance facilities and division of site responsibilities.

Erection and Integration

Coordinate delivery sequence, unloading, site lifting, assembly, rail or tyre-path survey, electrical installation, spreader setup, TOS/RCMS data exchange, network testing, traffic control and access for terminal operations.

Commissioning and Support

Complete no-load and rated-load testing, container pickup trials, braking, anti-sway, travel, wind and emergency functions, interface tests, performance verification, operator and maintenance training, spare-parts handover and acceptance records.

What is a container yard crane?

A container yard crane lifts, stacks and transfers ISO containers within a marine terminal, dry port, rail yard, logistics hub or depot. Common systems include RMG cranes, RTG cranes, straddle carriers and fixed container overhead cranes.

Which is better for a container yard: RMG or RTG?

RMG cranes are generally preferred for fixed, high-density blocks with electric power and substantial automation. RTG cranes are generally preferred where block mobility and phased expansion are more important. The final decision follows throughput, infrastructure, energy and lifecycle analysis.

How is container yard crane capacity specified?

Capacity is specified as rated load under the spreader for the defined single- or twin-lift operation. The spreader tare, container gross mass, dynamic loads, eccentricity, wind and structural load combinations are included in engineering verification.

How many container rows and tiers can one crane cover?

Coverage is project-specific. It depends on container width, clearances, truck or rail lanes, cantilevers, span, lifting height and stacking policy. Henan Mine Crane publishes RMG and RTG reference spans up to approximately 35 m and project lifting heights up to approximately 21 m.

Can a container yard crane handle 20 ft, 40 ft and 45 ft containers?

Yes. A compatible telescopic spreader can be configured for the approved container lengths, corner fittings and load range. Container recognition, telescoping interlocks, twistlock status and flippers are defined within the spreader and control specification.

Can an RMG or RTG be automated?

Yes. Anti-sway, absolute positioning, container recognition, truck guidance, obstacle detection, remote operation and TOS/RCMS integration can support semi-automatic or automated service. Functional requirements, network architecture and recovery modes must be agreed before system design.

What power options are available?

RMG cranes commonly use grid power through cable reels or busbars. RTGs and straddle carriers may use diesel-electric, hybrid, battery or external electrification. Site grid capacity, block mobility, emissions objectives, charging schedule and redundancy determine the preferred system.

How is yard crane throughput calculated?

Throughput is modeled from spreader engagement, hoist, trolley and gantry travel, positioning, set-down, release and operating delays. Long and short cycles, rehandles, truck or rail arrival patterns, equipment availability and peak demand are included.

How much does a container yard crane cost?

Market observations vary from approximately US$100,000–US$500,000 for conventional RTG equipment and US$250,000–US$1.2 million for conventional RMG equipment to US$700,000–US$2.5 million or more for high-specification RTGs and US$1–US$7 million or more for advanced RMG projects. Scope matching is essential.

What information is needed for a container yard crane quotation?

Provide container sizes and weights, yard layout, rows, tiers, lanes, rated load, peak moves, annual TEU, duty, operating hours, power strategy, automation interfaces, environment, destination, applicable code, civil information and the required delivery and installation boundary.

CORE CONFIGURATIONS

RTG, RMG, Straddle and Fixed Crane

CONTAINER DUTY

20 ft, 40 ft and 45 ft Containers

YARD INTERFACES

Stack, Truck, Rail and Transfer Lane

PROJECT PRIORITY

Throughput, Density and Lifecycle Cost

Annual and Peak Throughput

Annual TEU, peak gate moves, vessel exchange peaks, rail windows, operating hours and reserve capacity establish crane quantity and duty.

Block Geometry

Rows under the span, truck lanes, stack height, block length, reefer aisles and maintenance access define span, lift and travel envelope.

Container and Spreader Duty

Container size, maximum gross mass, single or twin lift, empty-container share and out-of-gauge work determine rated load and spreader functions.

Mobility and Layout Stability

Changing blocks favor mobile RTG or straddle systems; permanent high-density blocks support rail-mounted and automated configurations.

Civil and Power Infrastructure

Pavement bearing, wheel loads, rails, settlement, drainage, substations, cable routes and charging or fueling strategy affect total project scope.

Automation and TOS Interfaces

Remote operation, positioning, OCR, truck guidance, equipment-control and terminal-operating-system interfaces require defined ownership and acceptance criteria.

Crane capacity alone does not establish yard performance. Block orientation, container dwell profile, import and export segregation, reefer positions, hazardous-container areas, empty stacks, truck appointments and rail schedules determine how often a crane must travel, rehandle or wait.

The span is normally developed from the number of container rows, clearances and one or more truck or transfer lanes. Lift height follows the required stack height plus safe spreader clearance. Cantilevers add exchange positions without placing trucks inside the rail gauge, but they also increase structural and civil demands.

Layout studies should model normal flow, peak-hour congestion, crane outages, maintenance access, emergency routes and future block expansion before final equipment quantities are released.

RTG cranes suit phased terminals, changing block assignments and yards where fixed rail construction is not justified. Their block-change capability improves deployment flexibility, while steering control, tire condition, pavement quality and power transition require disciplined maintenance and operating procedures.

RMG cranes suit stable blocks, high rail share, wide spans and automation-led operating concepts. Grid power and a fixed travel path support repeatable positioning, but rail foundations, settlement control and crane-interference management increase front-end engineering. A mixed fleet can retain RTG flexibility while dedicating RMG blocks to high-volume flows.

Demand Profile

Peak vessel exchanges, gate appointments, train windows and import dwell create the design workload.

Cycle Components

Hoist, trolley, gantry, alignment, twistlock confirmation and data handshakes define theoretical cycle time.

Operational Allowance

Traffic conflicts, rehandles, block changes, inspections and weather reduce net productive availability.

Redundancy

Maintenance reserve and recovery plans protect gate, rail and berth service commitments during crane outages.

Diesel-Electric RTG

Independent block operation and relocation without fixed conductors; fuel, emissions, noise and engine maintenance remain lifecycle inputs.

Hybrid or Battery RTG

Stored energy and regeneration can reduce engine operating hours; battery duty, charging strategy and thermal management require cycle analysis.

Cable-Reel or Busbar E-RTG

Grid electricity supports lower local emissions; conductor layout, street crossing and off-grid block-change travel must be engineered.

Grid-Powered RMG

Fixed rails and electrical supply suit stable high-duty blocks; substation capacity, harmonics, cable management and backup strategy are included in system design.

Automation scope can progress from operator-assistance functions to remote operation and fully automated stacking cycles. Typical functions include auto-steering, anti-sway, stack profiling, container positioning, truck guidance, collision prevention, equipment-condition monitoring and automated job reporting.

The interface matrix identifies data ownership between the terminal operating system, equipment control system, crane PLC, OCR, positioning, gate and rail systems. Message timing, exception handling, cybersecurity, time synchronization and manual recovery are included in the functional design.

Acceptance uses stated scenarios: normal container moves, wrong-container prevention, blocked lanes, lost communications, sensor degradation, emergency stops, power recovery and return to automatic service.

RTG wheel loads, tire pressure, turning zones and surface tolerance are coordinated with pavement design. Drainage grates, utility covers, crossfalls and transitions cannot interrupt steering or load distribution. Accurate lane markings and reference paths support auto-steering and truck positioning.

RMG projects require verified rail gauge, rail elevation, straightness, foundation stiffness, differential settlement, end stops, buffers and storm anchoring. Wheel-load envelopes cover normal operation, acceleration, braking, wind and out-of-service conditions.

Civil drawings and crane data sheets are exchanged before manufacture so wheel reactions, rail tolerances, conductor routes, cable pits and maintenance access are consistent across contracts.

Load and Motion Protection

Overload protection, hoist limits, overspeed protection, brakes, travel limits, buffers, emergency stops and fault monitoring are matched to the design code and risk assessment.

Collision and Traffic Control

Crane-to-crane protection, stack collision prevention, truck guidance, pedestrian exclusion and audible or visual warnings are defined by the operating concept.

Wind Management

Operating wind limits, alarm thresholds, parking procedures and out-of-service securing are established from site wind data and the selected structural code.

Corrosion Protection

Coating system, surface preparation, enclosed-component protection, stainless hardware and electrical enclosure ratings follow salt, humidity, rainfall and pollution exposure.

Access and Maintenance

Stairs, ladders, platforms, fall protection, machinery access, lighting, isolation points and component-removal routes support planned maintenance.

Contract Codes

Applicable ISO, FEM, EN, IEC, electrical, machinery and local port requirements are stated in the contract with an agreed document hierarchy.

Taicang Port International Hub

Henan Mine Crane published a 40.5 t rail-mounted container gantry crane project for Taicang Port. The crane was configured as core container-yard handling equipment for an international logistics hub.

The disclosed project functions include integration with the terminal logistics-management platform, remote operating-status visibility, automatic container seeking and lifting-device guidance. The lifting-device concept also supports interchangeability for containers and selected non-container cargo duties.

This project demonstrates the combined engineering boundary of crane mechanics, spreader functions, positioning, controls and terminal data integration. Site-specific performance remains governed by the final contract and acceptance program.

View the Published Project

Technical Proposal

General arrangement, design basis, load definition, duty, speeds, power, controls, spreader and environmental criteria.

Civil Interface Data

Wheel loads, rail gauge, tolerances, pavement reactions, conductor route, buffers, anchors and maintenance clearances.

Electrical and Controls

Single-line data, connected load, drive philosophy, control architecture, network requirements and interface register.

Quality Documentation

Inspection and test plan, material records, welding and NDT records, certificates, factory tests and document schedule.

Site and Acceptance Scope

Transport, erection, commissioning, proof load, functional trials, productivity tests, training and handover requirements.

Lifecycle Support

Recommended spares, special tools, preventive-maintenance schedule, remote diagnostics, warranty and service response.

Is a container yard crane the same as a container gantry crane?

Often, but not always. RTG and RMG cranes are container gantry cranes and are the most common yard systems. The broader term can also include straddle carriers and fixed container overhead cranes.

Which crane suits a flexible or expanding yard?

RTG cranes and straddle carriers can relocate without fixed travel rails. The final choice depends on stacking density, horizontal-transport concept, pavement, traffic and fleet size.

Which crane suits a fixed high-density block?

An RMG or automated stacking crane block can provide wide coverage, grid power and repeatable positioning when the yard layout and transfer zones remain stable.

How are span and lifting height selected?

Span covers the required container rows, clearances and truck or transfer lanes. Lifting height covers the specified stack plus safe spreader clearance and operating margin.

Can a manual yard crane be prepared for later automation?

Automation-ready design can reserve control capacity, sensors, networks, positioning references and safety interfaces. Later feasibility still depends on structure, drives, braking, data quality and the operating environment.

What belongs in a turnkey yard-crane contract?

The contract can include cranes, spreaders, electrification, controls, automation, selected rails or civil interfaces, freight, erection, commissioning, performance tests, training, spares and warranty. Included and excluded items should be scheduled explicitly.

TERMINAL ZONES

Berth, Yard, Gate and Rail Interface

CORE CRANES

STS, RTG, RMG and Straddle Carrier

CONTAINER DUTY

20 ft, 40 ft and 45 ft Containers

SYSTEM PRIORITY

Balanced Berth and Yard Throughput

A productive terminal matches the capacity of every transfer stage. Excess STS capacity cannot improve vessel turnaround when horizontal transport or yard blocks are congested. A dense RMG yard cannot reach design throughput when truck exchange positions, rail slots or gate appointments restrict the flow.

The equipment schedule is developed from vessel calls, peak exchange volume, import and export dwell time, transshipment share, reefer demand, empty-container handling, rail share and planned operating hours.

1. Vessel Interface

STS cranes transfer containers between vessel cells and the quay apron according to ship geometry and stow plan.

2. Horizontal Transport

Terminal tractors, shuttle carriers, AGVs or straddle carriers connect the quay with assigned yard blocks.

3. Yard Stacking

RTG or RMG cranes stack containers by service, destination, dwell profile and retrieval sequence.

4. Landside Exchange

Truck lanes, rail tracks and inland-transfer positions complete the handover to road or rail transport.

Vessel and Berth Profile

Maximum vessel beam, container rows, hatch-cover arrangement, air draft, tidal range, rail gauge, wharf elevation and allowable quay loads establish the STS envelope.

Throughput and Peak Demand

Annual TEU, peak vessel exchange, operating windows, target berth productivity and acceptable queue time determine fleet size and redundancy.

Yard Layout and Density

Block length, lane count, stacking height, reefer rows, hazardous-container areas, empty stacks and truck or rail interfaces shape the yard-crane configuration.

Container and Spreader Duty

20 ft, 40 ft and 45 ft containers, single-lift, twin-lift, tandem duty, out-of-gauge loads and hatch covers define rated load and attachment functions.

Power and Automation

Grid capacity, cable route, busbar, battery or hybrid strategy, remote operation, OCR, positioning and terminal operating system interfaces are defined early.

Marine Environment

Operating and out-of-service wind, salt spray, humidity, rainfall, temperature, lightning, seismic criteria and storm securing affect structure and protection.

The following ranges are published by Henan Mine Crane for its terminal product platforms. They establish available equipment boundaries, not a preselected terminal specification. Final dimensions and ratings follow the agreed operational model and site data.

Rated capacity is confirmed under the spreader or hook as stated in the project specification. Container weight, spreader deadweight, eccentric loading, wind and dynamic effects are included in the design load cases.

Berth Crane Demand

Required STS working positions, safe crane spacing, boom profile, hatch access, ship bay sequence and maintenance reserve establish the berth fleet.

Yard Block Demand

Stack height, lane count, dwell time, rehandle strategy, exchange positions and block occupancy establish RTG or RMG quantity.

Transfer Fleet Demand

Distance, route conflicts, charging or fueling, interchange time and dispatch logic determine tractor, AGV, shuttle or straddle-carrier fleet size.

Maintenance Reserve

Planned inspections, rope and spreader service, wheel or tyre work, storm securing and corrective maintenance are reflected in available fleet calculations.

Future Expansion

Reserved rail length, electrical capacity, data network, block extension, additional exchange lanes and larger vessel calls support staged investment.

Performance Acceptance

Contract targets state test conditions, container mix, route, operator mode, weather limit, availability basis and exclusions.

RTG cranes suit terminals that value flexible block assignment, incremental expansion and the ability to relocate cranes. RMG cranes suit fixed, high-density blocks, rail terminals and automation programs where a stable travel path and grid power justify the rail infrastructure.

The comparison includes pavement or rail civil works, electrical distribution, fleet dispatch, block-change losses, tyres or rail systems, energy use, maintenance access, automation scope and expected service life. Additional technical and lifecycle factors are covered in the RMG vs. RTG cost analysis.

Single and Twin Lift

Rated load and hoist arrangement reflect single 20/40/45 ft containers, twin 20 ft containers or a project-specific tandem configuration.

Anti-Sway and Positioning

Mechanical rope geometry, drive control, encoders and position references can reduce residual sway and support accurate ship, stack, truck or rail placement.

Load and Twistlock Status

Load measurement, landed confirmation, all-corners lock status and interlocks prevent lifting before the required engagement sequence is complete.

Skew, Trim and List

Controlled adjustment aligns containers with vessel cells, chassis, rail wagons and stacks where the working geometry requires compensation.

Automation can be introduced in stages: operator assistance, auto-steering, anti-sway, stack profiling, target positioning, remote operation, automated truck handling and fully automated yard cycles. Each stage requires an interface matrix between the crane controls, equipment control system, terminal operating system, OCR, vehicle management and safety systems.

The functional specification states task messages, container identity, target coordinates, permission states, data ownership, network availability, clock synchronization, alarm handling, degraded modes and manual recovery. Cybersecurity architecture covers access control, network segmentation, remote service and software change management.

Acceptance includes normal cycles, exception cases, lost communication, sensor disagreement, emergency stops, obstacle detection, controlled restart and traceable event records.

Grid-Electric RMG and STS

Substations, peak and regenerated power, harmonics, cable reels, conductor systems, emergency supply and energy metering are coordinated with the terminal grid.

RTG Power Options

Diesel-electric, hybrid, battery and cable-fed configurations are compared by block-change duty, grid availability, charging, fuel, maintenance and emissions targets.

Total Cost of Ownership

Civil works, equipment, energy, tyres or rails, ropes, brakes, spreaders, labor, software, planned downtime, spares and modernization are evaluated over the intended service life.

Terminal cranes operate in wind, salt-laden air, rain, heat, cold and intensive ultraviolet exposure. The corrosion category, coating system, sealed and ventilated enclosures, stainless hardware, cable protection, drainage, dehumidification and inspection intervals are specified for the site.

Operating wind, restricted-operation wind and out-of-service design wind are separate values. The storm plan identifies anemometer alarms, boom position, rail clamps, wheel brakes, storm pins, tie-downs, anchors, travel to securing points, backup power and authorized personnel.

Wharf and yard drainage, lightning protection, seismic actions, settlement, rail alignment and pavement condition remain part of lifecycle inspection. Crane wind devices do not replace the terminal storm procedure.

Protective Functions

Overload, overtravel, boom and trolley limits, anti-collision, gantry skew protection, emergency stop, storm alarms, restricted zones and safe isolation.

Factory Acceptance Test

Document review, drives, brakes, controls, spreader logic, alarms, interfaces, simulated faults, load testing and contracted performance functions.

Site Acceptance Test

Rails or pavement, power, rated and proof loads, spreader engagement, clearances, wind devices, interfaces, operating cycles and emergency recovery.

Operational Acceptance

Representative containers, vessel or yard positions, truck or rail exchange, TOS messages, automation exceptions and agreed productivity conditions.

Taicang Port International Hub

Henan Mine Crane published a 40.5 t rail-mounted container gantry crane project for Taicang Port. The crane serves container-yard handling and was configured for integration with the terminal’s logistics-management platform.

Published functions include variable-frequency motion control, remote equipment monitoring, container-seeking assistance, lifting-device guidance and a changeable lifting-device concept for containers and other approved cargo forms.

This case represents the yard-handling stage of a container terminal. STS berth equipment, horizontal transport, civil works and terminal interfaces remain separate project scopes unless expressly included in the contract.

View the Published RMG Project →

Design Basis

Terminal flow, throughput, container mix, duty, environment, standards, operating modes, automation level and exclusions.

General Arrangement

Crane envelope, rails or wheel paths, outreach, lift heights, clearances, maintenance access, parking and storm positions.

Civil and Electrical Loads

Wheel loads, rail forces, storm loads, tie-down reactions, pavement loads, connected power, peaks, regeneration and earthing.

Interface Control Document

TOS, equipment control, OCR, network, power, civil works, spreader, transfer vehicles and safety-system responsibilities.

Inspection and Test Plan

Material records, manufacturing checks, load tests, spreader and control tests, interface simulation, site tests and hold points.

Commercial Schedule

Price, Incoterm, milestones, freight, erection, commissioning, acceptance, documentation, training, spares, warranty and exclusions.

Is a container terminal crane the same as an STS crane?

Not always. STS refers specifically to the quayside vessel crane. Container terminal crane is a broader term that can include STS, RTG, RMG, straddle carriers and intermodal container cranes.

Which yard crane provides the highest flexibility?

RTG cranes can relocate between blocks and support phased layouts. RMG cranes remain on fixed rails but can provide wider spans, stable grid power and a strong automation platform.

How is STS outreach selected?

Outreach follows the maximum vessel beam, container rows, waterside rail position, fender line, lashing platform and required service margin. Future vessel classes should be included where berth expansion is planned.

Can existing terminal cranes be automated later?

Some cranes can receive positioning, anti-sway, remote-operation or automated functions after structural, electrical, control, sensor, network and safety assessments. Interface capacity and remaining design life affect feasibility.

What is included in a turnkey terminal crane quotation?

The contract can include crane equipment, spreader, electrification, automation, rails or selected civil interfaces, freight, erection, commissioning, testing, training and spares. Every included and excluded item should appear in the commercial schedule.

What determines delivery time?

Concept approval, detailed engineering, long-lead drives and spreaders, structural fabrication, controls, factory testing, ocean transport, civil readiness, erection method and site integration determine the project schedule.

01 · Yard Layout

Confirm block length, container rows, truck or rail lane location, end clearances and permissible crane travel limits.

02 · Load Basis

State maximum container gross mass, rated load under spreader and the spreader type and mass.

03 · Stack Height

Specify target tiers, clearance over the top container, spreader headroom and the highest required lift point.

04 · Operating Demand

Provide projected peak moves, annual volume, operating shifts and the required availability and redundancy plan.

05 · Power Supply

Assess fixed power feed, cable or conductor arrangements, generator use and the feasibility of RTG electrification.

06 · Ground Interface

Check rail alignment and foundations for RMG or pavement bearing, tyre paths and turning space for RTG.

07 · Site Exposure

Establish working and parked wind conditions, seismic criteria where applicable, temperature and salt exposure.

08 · Control Interface

Define operator station, positioning aids, telemetry, yard-system interfaces and the intended level of automation.

For an inland-port operating concept, Henan Mine Crane presents a 40.5 t rail-mounted container gantry crane application. Its planning emphasis is rail-served container handling, stack access and integration of the crane with the inland terminal’s traffic flow.

This published application illustrates a proposed configuration; it does not establish a specific delivered terminal, accepted performance figure or operating record. Project-specific evidence, drawings, inspection records and reference availability can be addressed during technical qualification.

Equipment Supply

Crane structure, drives, electrical cabinets, spreader, controls, safety provisions, factory inspection and specified spares.

Terminal Infrastructure

Rails and foundations or yard pavement, electrical distribution, cable systems, communications and operating-area preparation.

Delivery and Commissioning

Packing, inland and ocean freight, duties where applicable, site assembly, tests, training and post-handover support.

What is a container gantry crane used for?

It lifts and stacks containers in terminal, depot and intermodal yard operating blocks.

What is the difference between RMG and RTG?

An RMG follows a fixed rail route; an RTG runs on tyres over a prepared yard surface.

Is an RMG suitable for rail intermodal terminals?

Yes, where the crane’s rail-served envelope, wagon access and yard traffic plan are coordinated.

Can an RTG move between yard blocks?

Block-to-block movement depends on the crane’s steering configuration, pavement, turning geometry and power connections.

How is container crane lifting capacity defined?

Specify the permitted container load under the spreader and account separately for spreader and attachment masses.

Can the crane handle 20 ft and 40 ft containers?

A suitably specified telescopic spreader can handle both; 45 ft, twin-lift and special containers require confirmation.

How many container tiers can it stack?

The number depends on lifting height, container height, spreader headroom and travel clearance.

Is an electric RTG available?

Electrified RTG concepts can be evaluated where yard layout and electrical infrastructure support the selected supply arrangement.

Does the price include rails and installation?

Only when expressly included. Civil works, freight, site assembly and commissioning must be identified in the quotation.

What determines the delivery schedule?

Engineering approval, component selection, manufacturing scope, inspection, shipment and site readiness establish the project schedule.

Rail-Mounted Gantry Crane (RMG)

Fixed-track stacking for container yards and intermodal facilities.

Rubber-Tyred Gantry Crane (RTG)

Mobile tyre-mounted container stacking across designed yard blocks.

Container Straddle Carrier

Alternative equipment for container transfer and yard stacking.

Ship-to-Shore Crane (STS)

Quayside vessel handling upstream of container yard operations.

Portal Harbor Crane

Berth-side equipment for multipurpose cargo handling.

Port Crane Product Range

Explore the full terminal and cargo-handling equipment portfolio.

ATTACHMENT OPTIONS

C-Hook, Tong & Magnet

TYPICAL COIL WEIGHT

5 t – 25 t

CRANE CAPACITY CLASS

5 t – 50 t

COIL SERVICE DUTY

A5 – A7 Continuous

Coil Storage and Rack Handling

Cranes place and retrieve coils from storage racks, saddles and stacked positions. Placement accuracy protects both the coil surface and the rack structure, and the storage layout defines the coverage the crane has to deliver.

Blanking Line Feed

Coils are delivered to blanking and cut-to-length lines in the sequence the line calls for. Cycle rate at the line sets the duty class of the crane — continuous blanking service is among the most demanding in the plant.

Press Shop Decoiler Service

Loading coils onto decoilers and mandrels combines heavy loads with tight positioning. Eye orientation, mandrel alignment and gentle set-down decide whether the line threads up quickly or loses time every coil change.

Coil Transfer Between Bays

Coils move from receiving to storage, from storage to preparation and between bays. Transfer cranes and where required gantry links carry these moves, with eye rotation where the receiving position differs from the storage orientation.

Return and Residual Coil Handling

Part-used and residual coils return to storage with documented identity and surface condition. The same cranes handle these lighter but more frequent moves, often across a wider area of the coil yard.

Scrap and Skeleton Handling

Blanking skeletons and scrap return from the presses. Where the same bay handles both, magnet or grab duty is specified alongside the coil attachment on a dual-purpose configuration with the higher of the two duty classes.

The C-hook is the standard device for coil handling in stamping plants. It enters the coil eye, carries the coil on its saddle, and works with any material — ferrous, non-ferrous, coated or bare. Lined contact surfaces and controlled set-down protect the finish, and no power supply is needed at the hook. Coil tongs grip the outside diameter instead of the eye, for narrow coils, tight rack positions or where the eye is not accessible.

Magnetic beams pick ferrous coils by direct magnetic contact, in oval or rectangular layouts matched to the coil orientation, and cycle faster than mechanical devices because there is no hook to place. They depend on material, temperature and surface condition, and they need magnet power, control and a defined release procedure. Rotating magnetic beams and slewing-trolley cranes add rotation between eye orientations, so a coil received eye-vertical can be stored or delivered eye-horizontal without a separate handling step.

The crane under the attachment is typically a double girder bridge crane — the capacity class, hook approach and stiffness that coil service needs — with variable frequency travel control for smooth acceleration and micro-speed positioning on saddles and mandrels. Single girder cranes cover light coil and auxiliary duty. Every attachment is rated and certified as a below-the-hook lifting device, separately from the crane certification.

01 · Coil Schedule and Weight

List every coil by weight, width, outer diameter and eye diameter. The heaviest coil plus the attachment tare sets the rated capacity — a 25 t coil on a 5 t C-hook demands a crane rated above 30 t, not 25 t.

02 · Material and Surface Class

Ferrous, non-ferrous, coated or exposed surface — the material decides between magnetic and mechanical attachment, and the surface class sets the lining, contact pressure and handling limits that protect the finish.

03 · Eye Orientation and Rotation

Coils arrive eye-vertical or eye-horizontal, and storage, decoiler and rack positions do not always match. Where orientation changes, a rotating beam or slewing trolley removes a whole handling step from the cycle.

04 · Cycle Rate and Duty Class

Coils per hour, shift pattern and travel distances convert into mechanism classifications. Continuous blanking and decoiler feed duty typically requires A6–A7; intermittent warehouse duty may justify A5. Duty class set too low is the most common cause of early coil crane failure.

05 · Storage Geometry

Rack positions, saddle types, stacking heights and aisle widths define the hook path and placement accuracy the crane must achieve. The storage layout is agreed with the crane specification, not after it.

06 · Magnet Power and Control

Magnetic attachments need their power supply, controller, cable management and a defined behaviour on power loss. Battery backup and monitored release are specified where the coil schedule justifies them.

07 · Automation and Line Integration

Coil identification, position feedback, anti-sway, rack interlocks and communication with the line or storage system turn a crane into part of the material flow. The functional scope belongs in the specification, not in later site improvisation.

08 · Attachment Certification and Boundary

Below-the-hook devices carry their own rated certification, separate from the crane’s declaration. Runway interface, installation, testing, spares and documentation are assigned in writing before quotations are compared.

Classified Surface Handling

The surface class of each coil family sets the permitted contact areas, lining materials, pressure limits and acceleration curves. Exposed and pre-coated material is handled to a different standard than black steel — by design, not by operator care.

Duty Class From the Cycle

Continuous blanking and decoiler feed service typically requires A6–A7 mechanisms and structure; intermittent warehouse work may justify A5. A general-duty crane running continuous coil cycles consumes its design life in a fraction of the rated period.

Controlled Set-Down

Variable frequency travel with micro-speed steps and anti-sway behaviour places coils on saddles and mandrels without shock. On decoiler loading, positioning accuracy converts directly into line uptime every coil change.

Attachment and Documentation

Below-the-hook devices carry their own rated certification. Structural calculations, test reports and acceptance criteria support commissioning and the plant’s audit systems, with the documentation scope agreed before manufacture.

A coil handling project typically defines the crane and the attachment together, as one lifting system: the bridge crane platform, the C-hook, tong or magnetic beam sized to the coil schedule, the magnet power and control equipment where applicable, the saddle and rack interfaces, and the storage layout the crane has to serve. Henan Mine Crane engineers the package against the full coil list, the cycle rate and the surface classes of the specific plant, so the attachment, duty class and control behaviour come from data instead of assumptions.

A complete supply definition states the crane structure and machinery, the rated attachment with its certification, the control and positioning functions, the runway interface, safety functions, the overload and acceptance testing regime, and the delivery, installation and commissioning responsibilities. Automation scope — coil identification, position feedback, rack interlocks and line communication — is defined in the same functional specification when the plant requires it.

Standard crane configurations are typically delivered within 30 to 45 days after drawing approval. Engineered coil handling systems with special attachments, rotation or automation run on confirmed project schedules agreed before production starts.

TYPICAL AUTO COIL WEIGHT

5 t – 25 t

ATTACHMENT OPTIONS

C-Hook, Tong, Magnet

STANDARD DELIVERY

30 – 45 Days

ENGINEERED DUTY RANGE

A5 – A7 Coil Service

Coil and Material Data

Coil weights, widths, outer and eye diameters, material, surface class, eye orientation at every position and any rotation requirement between them.

Storage and Line Geometry

Rack and saddle layout, stacking heights, span or rail centers, hook heights, decoiler and blanking line positions, and the coverage each handling point requires.

Cycle and Duty Data

Coils per hour per line, shift pattern, travel distances, load spectrum and any automation or line-integration requirements.

Attachment and Commercial Data

Preferred attachment type, required certification, power supply, destination and Incoterm, installation responsibility, spares and requested delivery schedule.

What crane handles coils in an automotive plant?

Double girder bridge cranes with C-hooks or coil tongs are the standard configuration for moving coils between storage, blanking lines and decoilers. Magnetic beam cranes handle ferrous coils at higher cycle rates, and rotating beams or slewing-trolley cranes add orientation changes between eye positions.

C-hook, tong or magnet — which one for automotive coils?

C-hooks and tongs handle every material including coated and non-ferrous coil with lined, controlled contact. Magnets cycle faster but only lift ferrous material and carry marking risk on exposed surfaces. Many automotive plants run C-hooks for surface-critical coil and magnets for black steel and scrap duty.

Does the C-hook weight count towards crane capacity?

Yes. Rated capacity covers the total suspended load — the coil plus the hook, tong, beam, rotator and every interface below the crane hook. A 25 t coil on a 5 t C-hook requires a crane rated above 30 t, not 25 t.

How much does an automotive coil handling crane cost?

A 10–20 t double girder crane for coil service sits roughly between US$12,000 and 40,000 as equipment, before the attachment and special controls. Complete coil handling configurations with rated C-hooks or tongs typically run US$35,000–120,000, and heavy 20–50 t coil systems from about US$50,000. Freight, duty and installation typically add 20–50 % on top.

What duty class does coil service need?

Continuous blanking and decoiler feed duty typically requires A6–A7 mechanisms and structure; intermittent warehouse duty may justify A5. Duty class is calculated from the measured cycle profile — lifts per hour, load spectrum and travel distances — not from tonnage alone.

Can coil handling cranes be automated?

Yes. Position feedback, anti-sway, coil identification, rack and line interlocks and communication with storage or line control systems are integrated within a defined functional specification. Automation scope is quoted per project against the actual coil flow.

01 · Overhead Crane with C-Hook

A balanced C-hook enters the bore of an eye-horizontal coil and supports it from the inside. The simple mechanical structure is suitable for repeated transfer where aisle width, bore access and insertion clearance are available. Counterweight, lower-arm length, usable throat, coil-width range and protective lining are engineered for the coil schedule.

02 · Crane with Coil Tongs

Mechanical or motorized tongs grip the coil from the sides or through a dedicated engagement geometry. They can serve close stacking and variable widths where C-hook insertion is restricted. Gripping force, jaw travel, fail-safe locking, coil detection and contact-pad pressure must be validated to avoid slip or product damage.

03 · Magnetic Coil Handling Crane

Electromagnetic or electro-permanent magnetic lifters can eliminate bore insertion for approved ferromagnetic coils. Magnet arrangement, contact area, material test, temperature, power-loss behavior, current monitoring and release logic are part of the safety case. This option is not suitable for non-ferrous coils.

04 · Rotating Coil Crane

A powered rotator, rotating beam or slewing trolley aligns a coil with a line, rack, vehicle or storage lane without ground-assisted steering. Rotation range, speed, cable management, headroom, center of gravity and collision envelope must be coordinated with the attachment and building.

05 · Automated Coil Handling Crane

Position feedback, profile scanning, anti-sway, automatic path control, rack or line interlocks, load identification and MES or WMS communication can support repeatable unmanned transfer. Safe zones, recovery modes, data ownership and manual fallback are defined in the functional specification.

06 · Hook Crane with Coil Rigging

An approved sling or lifting beam can suit low-frequency or mixed-load service where manual rigging is acceptable. The method requires defined lifting points, sling protection, exclusion zones and competent rigging. It is generally less suitable for high-cycle coil production than a dedicated attachment.

Crane Motion Protection

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

Attachment-State Interlocks

Hoisting and travel permissives can verify C-hook engagement position, tong open/closed state, gripping confirmation, magnet current or magnetized state, coil presence and attachment identification before a transfer begins.

Magnetic Safety Strategy

Electromagnetic systems require a defined response to power failure, loss of one magnet, insufficient current, overheating and incomplete release. Battery or UPS holding, redundant circuits or electro-permanent technology may be selected from the risk assessment.

Product Protection

Replaceable wear pads, polyurethane or approved lining, contact-pressure limits, reduced acceleration, anti-sway, micro-speed positioning and coil-saddle alignment can protect finished surfaces and coil edges.

Automated Area Control

Position encoders, laser or camera sensing, restricted zones, collision avoidance, obstacle detection, warning devices and controlled access separate automated crane movement from personnel and vehicles.

Identification and Inspection

Each attachment is permanently marked with its rated load and operating range. Inspection points, discard criteria, test records and maintenance intervals cover the structure, contact surfaces, locking elements, sensors, wiring and controls.

Design basis

Approved coil schedule, operating sequence, duty calculation, load combinations, wheel reactions, clearances and applicable-code matrix.

Attachment engineering

General arrangement, load path, structural calculations, engagement range, contact protection, controls, interlocks and rated-load marking.

Manufacturing records

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

Factory acceptance

Functional checks, brake and limit tests, control simulation, attachment cycle test, magnetic or gripping verification and witnessed testing where specified.

Before Manufacture

Confirm runway geometry and capacity, building clearances, pickup and placement coordinates, coil saddle and rack details, access routes, power supply, control interfaces and site responsibilities.

Erection and Commissioning

Coordinate unloading, lifting method, runway survey, mechanical and electrical installation, alignment, no-load testing, proof load, attachment functions, trial coils, line interlocks and operator training.

Planned Maintenance

Maintain brakes, ropes, drums, wheels, rails, reducers, fasteners and electrics together with attachment structure, wear pads, jaws, locks, magnets, backup power, sensors, cables and control logs.

What is the best crane attachment for steel coils?

A C-hook is effective for eye-horizontal coils with adequate bore and aisle clearance. A tong suits close stacking or restricted insertion. A magnet suits verified ferromagnetic coils where material, contact and power-loss conditions support magnetic lifting.

Can one C-hook handle different coil sizes?

Yes, within its approved weight, ID, OD and width envelope. The lower arm, usable throat, counterweight, load center and protective surfaces must be checked against every coil in the schedule.

Can magnets lift every steel coil?

No. Magnetic suitability depends on steel grade, coil construction, contact area, air gap, surface condition, temperature and required holding force. Representative material testing is required before final approval.

How are aluminum and copper coils handled?

Non-ferrous coils normally require a mechanical device such as a C-hook or engineered tong. Contact pressure, protective lining and acceleration are controlled to prevent marking, edge damage or deformation.

How is coil handling crane capacity calculated?

Capacity covers the maximum coil weight plus C-hook, tong or magnet tare, lifting beam, rotator and all suspended interfaces. Dynamic effects, load eccentricity, trolley reactions and runway capacity are then verified.

Can a coil handling crane be automated?

Yes. Position feedback, anti-sway, profile scanning, coil identification, path planning, collision avoidance, rack or line interlocks and MES/WMS communication can be integrated within a defined functional specification.

How are finished coil surfaces protected?

Protective pads, controlled contact pressure, reduced acceleration, VFD micro-speed, anti-sway and accurate saddle alignment are selected for the specific coating, edge condition and permitted contact areas.

What crane duty is required for coil service?

Duty is calculated from operating hours, lifts per hour, load spectrum, travel distances, attachment actions and design life. Continuous production service may require A6 or A7, while intermittent warehouse work may justify a lower class.

How much does a coil handling crane cost?

Observed factory equipment ranges for a conventional 10–20 t double-girder crane are approximately US$12,000–US$40,000 before the coil attachment and special controls. A complete heavy-duty or automated coil system requires a project quotation.

What information is needed for a coil crane quotation?

Provide the full coil schedule, material and surface data, eye orientation, pickup and placement drawings, cycle rate, building and runway dimensions, duty, power, controls, destination, applicable code and required delivery and installation scope.

PRIMARY ARCHITECTURE

Top-Running Double Girder

COIL ATTACHMENTS

C-Hook, Tong, Mandrel or Magnet

OPERATING PROFILE

Process-Defined Duty

CONTROL OPTIONS

Cabin, Radio, PLC & Automation

Receiving and Unloading

Unload coils from trucks, rail wagons or internal transfer cars. Vehicle clearances, side approach, securing-removal sequence and exclusion zones are coordinated with the crane lift path.

Pickling, Rolling and Annealing

Transfer coils between process lines, buffers and furnace areas. Heat, fumes, moisture, scale and restricted access influence component protection and maintenance arrangements.

Slitting and Processing Lines

Place master coils on uncoilers and remove finished coils or scrap reels. Low-speed positioning, approach limits and attachment clearance are coordinated with line equipment.

Finished-Coil Warehouse

Stack and retrieve coils by order, grade, width and destination. Position feedback, storage maps and inventory integration support higher storage density and traceability.

Truck and Rail Dispatch

Load coils into approved transport saddles or cradles. Loading sequence, vehicle identification and confirmation of stable placement are defined before release.

Outdoor Coil Yard

Outdoor gantry or bridge systems require wind, rain, corrosion, drainage, rail protection and parking or storm-restraint provisions in addition to coil-handling controls.

A process map should identify every pickup position, coil orientation, storage saddle, line center, vehicle lane, personnel route and prohibited zone. It should also record the required cycle rate, queuing logic and production consequence of a crane outage.

For plant-wide planning, steel mill crane systems should separate coil, plate, slab, scrap, roll-change, maintenance and molten-metal duties.

Bridge and End Carriages

Girders, diaphragms, wheels and travel drives are designed from span, duty, fatigue spectrum, wheel loads, lateral forces and runway stiffness.

Process-Duty Hoist

Drum, wire rope, sheaves, reducer, motor and brakes are selected for gross load, lift, speeds, starts per hour and the required reliability strategy.

Coil Attachment

C-hooks, tongs, inside-diameter lifters and approved magnetic systems engage different coil geometries. Attachment mass and center of gravity form part of the load case.

Engagement Confirmation

Limit switches, proximity sensors, load measurement, tong-position feedback or other validated devices establish a permissive before lifting.

Variable-Speed Drives

VFD-controlled hoisting and travel provide smooth acceleration, controlled creep speed and repeatable approach to storage saddles or process-line centers.

Positioning and Data

Encoders, laser positioning, cameras, barcode or RFID readers and warehouse interfaces can identify coils and confirm storage locations.

Coil Geometry

Minimum and maximum mass, outside diameter, inside diameter and face width; eye-horizontal or eye-vertical orientation; center-of-gravity variation; winding and banding condition.

Material Condition

Steel or aluminum grade, temperature, surface finish, coating, edge condition, permitted contact pressure and unacceptable marking or deformation.

Duty and Throughput

Lifts per hour, shifts, annual hours, load spectrum, travel distances, queue size, required cycle time and production consequence of an outage.

Pickup and Placement

Storage saddles, stack pattern, line mandrels, vehicle cradles, approach direction, insertion clearance, target tolerance and release confirmation.

Building and Runway

Rail-center span, runway length and elevation, lift, end and side approaches, roof clearance, existing wheel-load limits and installation access.

Control and Integration

Cabin, radio, semi-automatic or automatic operation; anti-sway; coil identification; WMS/MES protocol; traffic zones; manual fallback and recovery logic.

The attachment must control the coil without crushing the core, marking finished surfaces, opening the winding or allowing the load to migrate. Pads, shoes, hook arms and contact faces are selected from the declared material and surface limits.

Representative-coil testing is required whenever engagement depends on bore size, contact friction, magnet performance, tong pressure or automated recognition. A suspended dead weight does not reproduce every real coil condition.

C-Hook Design

Hook opening, arm length, back height, counterbalance, protective lining, tip shape and rated-load marking are matched to the full ID, OD and width range. The approach path must allow complete insertion without striking the bore or adjacent coils.

Coil Tong Design

Powered tongs require an approved gripping-force range, contact geometry, open/closed feedback, mechanical retention and release prevention while suspended. The control system must identify an incomplete or off-center engagement.

Inside-Diameter Lifter

Mandrel expansion, insertion depth and engagement confirmation are designed around bore tolerance and core strength. The lifter must not release until the coil is supported at the approved destination.

Magnetic Attachment

Magnetic handling is considered only after grade, temperature, air gaps, curvature, banding and contact area are validated. The design defines monitoring, backup retention or power strategy, alarms and controlled release.

Coil Identification

Barcode, RFID, production data or machine vision associates each coil with mass, dimensions, grade, order and storage location.

Positioning and Anti-Sway

Absolute or incremental position feedback, target coordinates and load-dependent anti-sway support repeatable pickup and placement.

Inventory Integration

The interface defines task ownership, material identity, destination, status, alarms, time synchronization and recovery after communication loss.

Possible Design Routes

A project may use the ISO 4301 classification framework with applicable crane and electrical standards, the EN 13001 series with EN 15011 and relevant lifting-attachment requirements, or a North American route using CMAA specifications with applicable ASME B30 requirements. The contract states the selected basis.

Engineering Deliverables

General arrangement, wheel loads, duty basis, coil matrix, attachment data, clearance study, electrical drawings, control narrative, interface list, inspection plan and maintenance-access arrangement.

Manufacturing Inspection

Material identification, welding procedure and welder qualification, specified NDT, dimensional checks, attachment inspection, machinery alignment, panel inspection and coating records.

FAT and Site Acceptance

Functional tests verify motions, limits, brakes, interlocks, attachment engagement, alarms and available automation before shipment. Site testing then covers runway, erection, load testing, representative-coil trials, interfaces, training and handover.

Coil Data

Material and grade; minimum and maximum mass, OD, ID and width; eye orientation; temperature; surface condition; banding; center of gravity; permitted contact marks; drawings or photographs.

Process and Duty

Pickup and placement stations; storage pattern; cycle sequence; lifts per hour; shifts; annual hours; load spectrum; travel distances; target cycle time; outage consequence.

Building and Runway

Span, runway length, rail section and elevation; required lift; approaches; clearances; existing wheel-load limits; runway drawings; installation access and site survey.

Controls and Commercial Scope

Manual or automatic operation; positioning tolerance; WMS/MES protocol; safety zones; voltage and frequency; environment; destination; design standard; Incoterm; installation, testing and documentation scope.

How is coil handling crane capacity calculated?

The starting point is the maximum gross suspended load: coil plus C-hook, tong, mandrel, magnet, hook block and every other item below the hoist. Duty, load distribution and dynamic effects are then applied under the selected design standard.

Is a C-hook or coil tong better?

A C-hook is mechanically simple and effective where the coil bore is accessible. A powered tong supports automated engagement and variable widths but adds mechanisms, sensors and maintenance. Coil geometry, cycle rate, access and automation level determine the selection.

Can magnets safely lift steel coils?

Only when the steel grade, coil geometry, contact area, temperature, air gaps, banding and retention strategy have been validated. A magnetic system cannot be assumed suitable from coil mass alone.

Can one attachment handle the full coil range?

It is possible only when every OD, ID, width, mass, orientation and surface condition falls within the approved envelope. Wide ranges may require adjustable or interchangeable attachments and dedicated storage stands.

How much does a coil handling crane cost?

Public information reviewed in September 2026 included approximately US$9,800–110,000 for a generic 50 t double-girder price guide and US$35,000–140,000 for one 10 t C-hook or clamp-tong coil-crane listing. A final price requires the approved crane, attachment and project scope.

Can an existing runway be reused?

Only after rails, beams, columns, brackets, connections and foundations are checked for condition, alignment, fatigue and the new crane reactions. The crane must remain within verified structural limits or the runway must be strengthened.

Can the crane connect to WMS or MES?

Yes. The interface specification defines tasks, coil identity, coordinates, inventory status, protocol, time synchronization, safety boundaries, cybersecurity, manual override and recovery after a network interruption.

What should be tested before handover?

Testing covers crane motions, brakes, limits, load protection, attachment engagement and release, representative coils, placement tolerance, safety zones, failure responses, interfaces and manual recovery under agreed acceptance criteria.