分类： Selection Guides

PRIMARY STRUCTURE

Heavy-Duty Double Girder

PROCESS LOADS

Hot Ingots, Dies & Forgings

HANDLING METHODS

Hooks, Tongs, Clamps & Turners

CONTROL OPTIONS

Cabin, Radio, PLC & Automation

Open-Die Forging Press

Support, rotate and reposition large ingots or forgings through repeated press strokes using approved hooks, tongs or a powered turning device.

Forging Hammer Bay

Transfer heated stock, dies and tooling while accounting for shock, vibration, scale and restricted approach around the hammer foundation.

Furnace Charging and Extraction

Move ingots or billets to and from heating furnaces with attachment clearance, radiant-heat protection and a controlled pickup orientation.

Die and Tool Handling

Change upper and lower dies, anvils, saddles and press tooling with the hook approach, creep speed and maintenance access required by the equipment layout.

Heat Treatment and Cooling

Transfer forged parts to normalizing, annealing, cooling or inspection positions; rapid immersion requires a separately defined quenching-crane function.

Machining and Dispatch

Move cooled forgings between cleaning, inspection, machining, weighing, storage and shipment when one crane serves the downstream production route.

1. Bridge and end carriages: carry the process trolley and distribute vertical, transverse and longitudinal reactions to the runway.
2. Main hoist: supports the maximum forging, ingot, die or suspended turning assembly and provides controlled lifting under the declared duty.
3. Auxiliary hoist: supports turning, tailing, tool handling or secondary positioning when the approved operation requires two lifting points.
4. Below-hook device: may be a hook rig, tong, clamp, spreader, chain-turning assembly or powered turning unit designed for the workpiece.
5. Drives and controls: coordinate hoisting, trolley travel, bridge travel, creep speeds, interlocks, monitoring and optional press-line communication.
6. Thermal and environmental protection: shields structures, ropes, cables, motors, brakes, panels, sensors and the operator station from the declared exposure.

Load Matrix

Minimum, typical and maximum mass; workpiece dimensions; center-of-gravity range; dies and tooling; attachment mass; single- or dual-point lifting; off-center cases.

Forging Sequence

Furnace pickup, press or hammer approach, rotation angle, number of turns, hold time, transfer path, handover to manipulator and downstream placement.

Temperature and Environment

Workpiece and furnace temperatures, radiant-heat intensity and duration, ambient range, scale, dust, smoke, oil mist, water spray, vibration and corrosive exposure.

Duty and Dynamics

Cycles per hour, starts and reversals, shifts, annual hours, load spectrum, press interaction, permitted shock, required buffering and production consequence of downtime.

Building and Equipment Interface

Rail-center span, runway length and elevation, wheel-load limits, headroom, hook approaches, press columns, furnace doors, manipulator envelope and maintenance access.

Control and Acceptance

Cabin or radio control, visibility, cameras, creep speed, positioning tolerance, press/MES signals, fallback modes, proof load, representative-workpiece test and documentation.

Turning a forging creates load cases that may be more demanding than a straight vertical lift. The center of gravity moves, sling or chain angles change, one hook can temporarily carry a larger share, and the workpiece may contact a saddle, manipulator or die. The approved method must define the load path through every stage.

Thermal Mapping

Evaluate workpiece temperature, exposure distance, dwell time and radiant paths at the hooks, trolley, girders, cabin, panels and maintenance platforms.

Protected Hoisting System

Select ropes, drums, sheaves, bearings, lubrication, brakes and cables for the measured environment and shield them from direct heat and scale.

Electrical Protection

Use suitable enclosures, cable routing, cooling or equipment relocation and monitor critical temperatures where the risk assessment requires it.

Shock and Vibration

Define permitted process forces, acceleration limits, buffering and structural fatigue cases; the crane must not be used to absorb undefined press or hammer impacts.

Operator Visibility

Coordinate cabin position, heat-resistant glazing where specified, cameras, lighting, audio communication and safe radio-control locations.

Maintainability

Provide safe access to brakes, ropes, sheaves, drives, panels and attachment points, with guards and shields removable under an isolation procedure.

Possible Design Routes

A project may use ISO 4301 classification principles with applicable crane standards; EN 13001 with EN 15011 and EN 13155 where applicable; or a North American route using CMAA 70 with applicable ASME B30.2, B30.20 and ASME BTH-1 requirements. The contract states the selected basis and local additions.

Engineering Deliverables

General arrangement, load-case schedule, duty calculation, wheel loads, clearance and turning study, attachment data, thermal assessment, electrical drawings, control narrative, interface list, inspection plan and maintenance-access arrangement.

Manufacturing Inspection

Material traceability, welding procedures and welder qualification, specified NDT, dimensional checks, machinery alignment, drum and rope inspection, attachment inspection, electrical-panel tests, coating and document review.

FAT and Site Acceptance

Functional tests verify motions, brakes, limits, overload protection, control modes, alarms and interfaces. Site testing then covers runway, erection, proof load, representative workpieces, turning sequence, power-loss response, positioning, press coordination, training and handover.

Workpiece and Attachment Data

Minimum, typical and maximum mass and dimensions; temperature at pickup; center of gravity; material and surface; dies and tooling; required tongs, clamp, turner, spreader or rigging; drawings and photographs.

Process and Duty

Furnace, press, hammer, manipulator and heat-treatment sequence; lifts and turns per hour; shifts; annual hours; load spectrum; required cycle time; permitted process forces and production consequence of downtime.

Workshop and Runway

Rail-center span, runway length, rail and elevation; required lift; headroom and approaches; existing wheel-load limits; press, furnace, platform and duct drawings; installation access and site-survey data.

Controls and Commercial Scope

Cabin, radio or automatic control; positioning tolerance; press/MES protocol; voltage and frequency; environment; destination; compliance route; Incoterm; runway, electrification, installation, commissioning, testing and documentation scope.

How is forging crane capacity calculated?

Capacity begins with the maximum workpiece and adds tongs, turning device, spreader, rigging, hook blocks and other suspended equipment. The design then evaluates off-center loads, main/auxiliary load sharing, dynamics and the selected duty classification.

Is a forging crane the same as a foundry crane?

No. A forging crane principally handles solid ingots, dies and forgings and may assist rotation at a press. A foundry crane handles ladles and molten metal under a different risk profile and safety architecture.

When are main and auxiliary hooks required?

They are considered when the approved process requires tailing, turning, secondary positioning or tool handling. Hook spacing, capacity split, simultaneous loading and the complete rotation sequence must be defined before selection.

Can a standard overhead crane handle hot forgings?

Only after a dedicated engineering review. Radiant heat, scale, duty, process dynamics, attachment, visibility and component temperatures can require structural, mechanical, electrical and control measures beyond a general-purpose crane.

How much does a forging crane cost?

A public 25 t forging-application listing reviewed in September 2026 showed US$42,000 per set, while dedicated 180–550 t forging cranes were generally price-on-request. Final cost depends on the full process, attachment, thermal design, duty, runway, controls and delivery scope.

Can a forging crane coordinate with a hydraulic press?

Yes, when the crane, press, manipulator and safety systems share an approved functional specification. The signal matrix defines command ownership, permissives, timing, safe states, independent stops and recovery after a fault.

Can an existing runway be reused?

Only after the rails, beams, brackets, columns, connections and foundations are checked for condition, alignment, fatigue and the new crane reactions. Heavy process trolleys and special attachments can change wheel loads materially.

What should be tested before handover?

Testing covers motions, brakes, limits, overload protection, control modes, attachment functions, representative workpieces, turning sequences, power-loss response, positioning, interfaces, safety zones and manual recovery under agreed criteria.

BRIDGE DESIGN

Single or Double Girder

RUNWAY ARRANGEMENT

Top Running or Underhung

LIFTING EQUIPMENT

Hoist or Trolley to Suit the Task

PROJECT INTERFACES

Load, Coverage, Structure and Power

Connect Production Stations

Transfer components between fabrication, machining and assembly positions within one crane bay. Include the load orientation and lifting attachment required at each station.

Serve Storage and Loading Areas

Reach designated storage lanes and loading positions from above. Check obstructions, vehicle access and the available hook approach at the ends of the runway.

Handle Maintenance Lifts

Lift equipment clear of its mounting and move it to a service area. Allow enough hook height for the lifting gear and enough horizontal clearance for the complete component.

01 / LOAD

Start with the Lifted Load

Describe the cargo and the slings, lifting beams, grabs or other attachments. Their weights and geometry affect the required rating, hook height and usable payload.

02 / COVERAGE

Map the Working Area

Mark every pickup and placement point on the building plan. Include machine enclosures, doors, stored goods and services that could restrict the load or hook path.

03 / OPERATION

Match the Production Duty

Separate occasional maintenance lifting from repetitive production handling. Load spectrum, operating time and travel distances help determine the crane and mechanism duties.

04 / INSTALLED SCOPE

Review the Complete Installation

Compare the crane with its runway, supporting structure, power supply and service access. A lower equipment price can come with a different building or installation requirement.

Span Is Not Hook Coverage

Span is based on the runway centreline spacing. Side and end approaches, together with any engineered overhang, determine where the hook can travel. Check the resulting working area against the layout.

Lifting Height Is Not Building Height

Determine the required highest hook position from the load, lifting gear and obstacle clearance. Then check the complete crane envelope against roof members, lighting, ductwork and maintenance space.

The Load Needs Clearance Too

A reachable hook position does not guarantee that a long beam or bulky machine can pass through the same area. Check the suspended load’s dimensions and intended orientation along the full route.

New Building

Coordinate the crane drawing with the structural design before fixing runway elevations and column positions. Include power routes, end clearances and access to the lifting and travel equipment.

Existing Building

Survey the rails, runway beams, connections and supporting structure. Use the proposed wheel loads, wheel spacing and horizontal reactions for the structural review.

Replacement Crane

Compare the actual interfaces of the old and proposed cranes. The same rated capacity can come with different crane weight, wheelbase, loading, hook approaches and electrical demand.

Hoist or Trolley Arrangement

Compare the selected hoist layout, lifting height, hook block, maintenance access and available speeds. The arrangement also affects the hook approaches and structural loads.

Main, Auxiliary or Dual Hoists

Identify the task for each hook and any permitted combined operation. Ratings, hook separation, shared loads and control coordination must be defined for multi-hook handling.

Operating Cycle

Record the frequency of near-rated lifts, mechanism running time, starts and travel distances. These inputs help distinguish intermittent workshop use from repetitive production service.

Pendant, Radio or Cabin Control

Select around operator visibility, walking routes and the handling task. Multiple control stations require a defined selection priority and response to a loss of command signal.

Power Feed and Distribution

Confirm site voltage, frequency, phases and the connection point. Distinguish the runway power system from the cable or conductor arrangement supplying the moving hoist or trolley.

Speed and Positioning

Specify hoisting, trolley travel and bridge travel separately. Include acceleration, stopping and placement needs; maximum travel speed alone does not define the handling cycle.

Henan Mine Crane manufactures overhead lifting equipment for industrial production and material handling. View the company’s manufacturing workshops for published factory photographs.

The order documentation should connect the selected crane configuration with the equipment supplied. Agree the following requirements before manufacture:

• General arrangement drawing showing rated capacity, span, hook limits, crane dimensions and runway interfaces.
• Hoist, motor, drive and control schedule with electrical diagrams and protection functions.
• Material and fabrication inspection scope, including specified weld examination and dimensional checks.
• Factory and site test requirements, acceptance records, manuals and a parts list.

Define witness points and the records needed at handover. Any required conformity documentation must apply to the ordered equipment and its destination.

Prepare the Installation

Coordinate delivery with runway readiness, power availability, assembly space and access for lifting equipment. Identify the party responsible for unloading, erection and electrical connections.

Agree Acceptance

Define alignment checks, functional tests, protection checks and the applicable load-test scope. Allocate responsibility for test loads, witnessing, records and operator familiarisation.

Plan Maintenance Access

Provide safe access and isolation arrangements for hoists, ropes, brakes, wheels and electrical equipment. Follow the supplied manuals and actual duty when setting inspection and lubrication intervals.

What is the difference between an overhead crane, bridge crane and EOT crane?

Overhead crane and bridge crane commonly refer to the same moving-bridge arrangement. EOT means electric overhead travelling and identifies an electrically powered design. The selected bridge, hoist and runway arrangement still need to be specified.

Should I choose a single-girder or double-girder overhead bridge crane?

Compare the load, span, highest hook position, duty, runway reactions and installed cost. Double-girder designs allow different trolley arrangements, while a single-girder system may suit general handling. The project layout determines the practical choice.

Are top-running and underhung cranes different from single- and double-girder cranes?

Yes. Top running and underhung describe how the bridge travels on its runways. Single and double girder describe the bridge beams. An under-running hoist can be used on a top-running single-girder bridge.

Can an overhead bridge crane use an existing building?

It may be possible after the structure and runway are assessed for the proposed crane. Provide building drawings, runway details and condition information. An existing crane’s lifting capacity alone is insufficient to establish compatibility.

Can the hook reach every part of the crane bay?

Coverage is limited by side and end approaches, hook height and obstructions. Show each required lifting position on the plan and check both the hook and the suspended load against the proposed crane dimensions.

Do you offer 5-ton and 10-ton overhead bridge crane configurations?

The single-girder reference tables include metric 5 t and 10 t examples. Final span, lift, duty and building interfaces need confirmation. Explore the 5 Ton Overhead Crane options or send your full specification for selection.

What information is needed for an overhead bridge crane quotation?

Send the required capacity and unit, span, lifting height, runway length, working cycle and power supply. Include load details, the installation country, a building drawing and the required equipment and service scope.

Single-Girder Bridge Crane

Electric-hoist configurations for workshop, assembly and maintenance lifting.

Double-Girder Electric-Hoist Crane

Two bridge girders supporting a hoist trolley for a defined lifting envelope.

Multi-Support Underhung Crane

Suspended bridge coverage across an engineered multi-runway structure.

Double-Trolley Overhead Crane

Two lifting points with defined independent or coordinated operation.

Frequency-Conversion Overhead Crane

Electric-hoist arrangements with specified speed control and optional monitoring.

Explosion-Proof Overhead Crane

Crane configurations selected for a defined hazardous area.

PRIMARY DUTY

Aircraft Maintenance, Repair and Overhaul

TYPICAL LOADS

Engines, Landing Gear, Tooling and Components

SYSTEM OPTIONS

Underhung, Bridge, Monorail and Multi-Point

PROJECT PRIORITIES

Clear Floor, Low Sway and Aircraft Protection

The crane schedule should follow the actual maintenance work package and aircraft fleet. A narrow-body engine-change bay, wide-body heavy-maintenance hangar, military depot, business-jet facility and helicopter maintenance workshop can require different spans, service loads, access arrangements and restricted zones.

Separate lifting arrangements can be assigned to high-value aircraft components, general tooling and elevated maintenance access so that each duty receives the appropriate control, attachment and inspection regime.

Engine Removal and Installation

Controlled vertical movement, accurate lateral positioning and a compatible engine cradle support disconnection, lowering, transfer and reinstallation without uncontrolled sway.

Landing-Gear Service

Load control and fine positioning help maintain component orientation during removal, overhaul support, replacement and alignment with approved fixtures.

Flight-Control and Airframe Parts

Flaps, rudders, elevators, fairings, doors and structural panels may require long spreaders, protected contact surfaces and several balanced support points.

Cabin and Interior Modules

Monorails, light suspension cranes or service hoists can move seats, monuments, galleys, test equipment and maintenance materials along defined routes.

Maintenance Docks and Tooling

The crane can reposition calibrated fixtures, engine stands, access-dock sections and maintenance equipment while preserving clear marked routes around the aircraft.

Overhead Maintenance Access

A purpose-engineered telescopic platform can provide stable access to upper fuselage, tail and wing areas when platform duty, personnel protection and emergency recovery are included in the system design.

Aircraft Fleet and Work Scope

Aircraft models, parking positions, maintenance checks, removable components, approved procedures and future fleet changes define the required coverage.

Rated and Net Hook Load

The heaviest component, fixture, spreader, sling, powered attachment and credible center-of-gravity position are included in the load schedule.

Coverage and Hook Approach

Plan and elevation drawings verify service around the nose, wings, engines and tail, including door pockets, roof trusses, docks and parked equipment.

Motion Quality

Low-speed range, acceleration, braking, sway control, travel accuracy and radio-control ergonomics are defined for the most sensitive maintenance task.

Hangar Structure

Roof capacity, runway beams, support spacing, deflection, fatigue, connection details, seismic criteria and erection access govern the structural arrangement.

Maintenance Environment

Temperature, humidity, washing, coatings, lighting, fire systems, paint or solvent areas and required enclosure protection are documented by bay.

Henan Mine Crane publishes a multi-support double-girder underhung platform for aircraft manufacturing plants and aircraft maintenance hangars. The crane is suspended from several support rails to distribute reactions and preserve an unobstructed floor.

The ranges below define available product boundaries rather than one standard hangar model. Final ratings, motion speeds, number of supports, clearances and structural reactions are selected from the aircraft maintenance duty and verified building data.

Engine and landing-gear work requires a defined lifting method, not only a hook over the work area. The technical schedule identifies component mass, center of gravity, approved attachment points, fixture deadweight, extraction direction, required orientation and every temporary support state.

Variable-frequency motions provide controlled acceleration and low-speed adjustment. Load monitoring can identify overload or unequal load share. Where two or more hoists lift one component or fixture, encoder feedback, synchronization limits and a safe fault response keep the points within the permitted relative-height window.

The aircraft multi-point lifting solution covers hangar maintenance, engine handling, landing-gear work and specialized maintenance tooling.

Service Trolley

A hoist trolley supports engines, components and tooling. Capacity, hook approach, power transfer and bridge compatibility are coordinated across every approved route.

Telescopic Platform

A rigid telescopic mast can reduce platform sway and reach upper aircraft zones. Rated occupancy, tools, rescue, emergency lowering and personnel-lifting compliance form part of the design basis.

Bridge Locking and Transfer

Mechanical alignment, positive locking, position confirmation, motion inhibition and load-state logic prevent transfer until both bridge paths are safely connected.

Zoned Motion

Position monitoring can impose slow zones, no-go areas, height limits and defined parking positions around aircraft tails, doors, docks and other cranes.

Power and Communications

Busbars, festoons, cable management, radio control and data communications are arranged to avoid snagging and maintain service across transfer interfaces.

Maintenance and Rescue Access

Inspection platforms, isolation points, retrieval provisions and manual or powered recovery routes are included for bridges, hoists and personnel-access units.

Hangar geometry is developed in plan and elevation using the aircraft envelope, towing route, maintenance docks, tail position, wing-tip clearance, hangar doors, roof trusses and all overhead services. The crane must reach the maintenance point without creating a conflict elsewhere in the bay.

The structural interface schedule states maximum and minimum vertical reactions, transverse and longitudinal forces, buffer loads, simultaneous crane positions, fatigue cycles, support tolerances, runway or roof deflection, seismic actions where applicable, and erection loads. Existing hangars require verified drawings and a condition assessment before support capacity is accepted.

Lighting, sprinklers, smoke extraction, ventilation ducts, door drives, antennas and maintenance walkways are included in the coordinated model. Isolation access and component-removal routes remain available after the aircraft and docking system occupy the bay.

Protective Functions

Overload and overtravel protection, emergency stop, motion limits, anti-collision, restricted zones, warning devices, brake supervision where specified and safe electrical isolation.

Aircraft Surface Protection

Low-sway travel, padded or approved attachments, controlled approach speed, protected hooks, positive fixture locking and exclusion of loose objects from lifting equipment.

Factory Acceptance Test

Mechanisms, controls, alarms, limits, interfaces, simulated faults, load-monitoring functions, synchronized motion and contracted document hold points.

Site Acceptance Test

Runway geometry, travel clearances, electrification, rated and proof loads, zone functions, representative routes, accuracy, recovery, training and handover records.

Maintenance-Task Validation

Approved fixture engagement, engine or component clearance, low-speed placement, route access and defined abnormal-state recovery are verified with a representative load.

Lifecycle Records

Inspection schedules, lifting-accessory records, calibration where required, rope and brake checks, critical spares, software backups, maintenance logs and change control.

A general maintenance hangar does not automatically require explosion-protected construction. Paint, solvent, fuel-system or battery work may create a classified zone only after the facility’s hazardous-area study defines the substance, zone or division, gas or vapor group, temperature class, ventilation basis and equipment category.

Where classification is confirmed, motors, brakes, enclosures, controls, cable systems, limit devices and operating procedures are selected for the declared environment. A crane crossing classified and unclassified bays requires clear equipment boundaries and an approved operating philosophy.

Wash areas and humid coastal hangars can require higher enclosure protection, corrosion-resistant components, compatible coatings, drainage control and a revised inspection schedule. Ambient temperature, altitude and outdoor exposure at the hangar door are included in the equipment data sheet.

24 Equipment Sets for an Aerospace Research Institute

Henan Mine Crane reports delivering 24 equipment sets to an aerospace research institute, including six lower-rotating girder bridge cranes placed into operation. The published application covers precision transfer of aerospace power components and structural parts.

The equipment uses PLC and inverter closed-loop vector control, remote, manual and tablet operating modes, and a servo-controlled attachment with extension and rotation. Published performance includes positioning accuracy of ±2 mm and attachment rotation accuracy of ±0.5° for the project configuration.

The delivery passed acceptance by the Xi’an Institute of Special Equipment Inspection and Testing. This record demonstrates adjacent aerospace precision-handling capability; an aircraft MRO hangar system is engineered from its separate fleet, building and maintenance requirements.

View Published Aerospace Project →

Design Basis

Aircraft fleet, maintenance tasks, loads, fixtures, duty, environment, standards, operating modes and supply exclusions.

General Arrangement

Plan, elevation, aircraft envelope, hook approaches, transfer routes, parking positions, maintenance access and electrification.

Structural Interface

Support coordinates, vertical and horizontal reactions, buffers, simultaneous positions, tolerances, deflection and erection loads.

Control Description

Speed modes, interlocks, zones, anti-collision, bridge transfer, load monitoring, alarms, communications and recovery logic.

Inspection and Test Plan

Manufacturing records, mechanism tests, load tests, safety-function checks, transfer tests, task validation and document hold points.

Commercial Schedule

Price, Incoterm, milestones, delivery, site services, acceptance, documentation, training, spares, warranty and exclusions.

Which crane type is suitable for a large clear-floor hangar?

A multi-support underhung crane is frequently considered where roof or runway support can carry the required load and floor columns would obstruct aircraft or maintenance traffic. A top-running bridge crane remains practical when dedicated columns and runways are available.

Can one crane serve several hangar bays?

Yes. Interlocking suspension bridges can transfer compatible service trolleys or platforms between bays. Bridge alignment, locking, power continuity, transfer interlocks and route clearances must be engineered as one system.

How is capacity selected for aircraft engine handling?

Capacity includes the heaviest approved engine or component, cradle, spreader, slings, attachments and applicable dynamic or eccentric load conditions. The maintenance method also defines hook approach, low speed and required orientation.

Can an aircraft hangar crane carry personnel?

Only a purpose-engineered personnel-access system should perform that duty. A teleplatform requires its own rated load, fall protection, control hierarchy, collision prevention, emergency lowering, rescue plan and compliance assessment. A standard cargo hook does not establish personnel-lifting suitability.

Can a crane be installed in an existing aircraft hangar?

Yes, subject to verified building geometry and structural capacity. Retrofit engineering covers roof or column condition, reactions, reinforcement, access for erection, electrical supply, fire systems and continuing hangar operations.

Does every hangar require an explosion-proof crane?

No. Explosion-protected equipment is selected from the formal hazardous-area classification for a specific paint, solvent, fuel or process zone. The general aviation application alone does not determine explosion-protection requirements.

What determines aircraft hangar crane lead time?

Engineering approval, structural coordination, customized steelwork, hoists and controls, teleplatform or transfer equipment, conformity documentation, factory testing, ocean freight, site readiness and commissioning all affect the schedule.

PRIMARY SCOPE

Industrial Rail-Mounted Gantry

POWERED MOTIONS

Hoist · Trolley · Long Travel

STRUCTURES

Full or Semi · Single or Double

QUOTE INPUTS

Load · Span · Lift · Duty · Site

Fabrication and Assembly

Suitable for transferring frames, machinery, plate assemblies and long fabrications between production, inspection and dispatch positions. Hook coverage and travel clearance are configured for the load orientation throughout the handling route.

Outdoor Storage Yards

Provides powered coverage for stock rows, loading lanes and transfer points without imposing crane loads on the building structure. Wind protection, drainage, rail alignment and parking restraints are incorporated into the project design.

Precast and Construction Areas

Supports the handling of molds, reinforcement cages, precast components and project modules within a defined working corridor. Access conditions, foundation interfaces and changing site restrictions form part of the selection basis.

Maintenance and Service Bays

Provides lifting coverage where elevated building runways are unavailable or unsuitable. A semi-gantry arrangement can also serve a dedicated working strip adjacent to an existing support structure.

01 / LOAD

Payload and Attachment

Required load data comprise the maximum and typical suspended loads, dimensions, center of gravity, lifting points and the mass of slings, lifting beams, grabs, magnets or other attachments.

02 / COVERAGE

Span, Lift and Hook Reach

Required layout data comprise pickup and placement positions, clear width between the legs, rail gauge, travel length, lifting height, hook approaches and cantilever outreach.

03 / MOTION

Travel, Speed and Positioning

Motion requirements include operating speeds, travel distances, stopping accuracy, inching, load-swing control and any requirement for synchronized or variable-frequency travel.

04 / DUTY

Cycles and Load Spectrum

Crane and mechanism duty are selected from lifts per hour, operating shifts, load distribution and total travel. Rated capacity alone does not establish the required duty classification.

05 / SITE

Rails, Ground and Obstacles

Site information should identify the layout, ground or foundation conditions, rail data, obstacles and vehicle or pedestrian routes throughout the moving-leg envelope.

06 / ENVIRONMENT

Weather and Process Conditions

Environmental data should identify wind, rain, temperature, dust, humidity, corrosion and any hazardous-area or hot-material classification. Special operating environments require dedicated protection and compliance measures.

VERTICAL AXIS

Electric Hoisting

The hoist or winch raises and lowers the load through the specified lifting medium and hook or attachment. Capacity, lift, duty, speed, reeving and braking are selected together.

CROSS AXIS

Powered Trolley Travel

The trolley moves the suspended load across the bridge. End approaches, acceleration and positioning affect usable coverage and load control near the legs and cantilevers.

LONG AXIS

Motorized Gantry Travel

Powered end carriages move the complete structure along rails or an approved floor path. Drive coordination, wheel guidance, braking and skew control are essential system decisions.

Runway Geometry

Rail gauge, straightness, level, elevation difference and end alignment affect wheel contact and skew. Inspection and acceptance criteria should be agreed before crane erection.

Civil and Structural Interface

Foundation design requires the selected crane’s wheel loads, wheel spacing and horizontal or exceptional forces. Generic capacity alone is not enough for civil design.

Drive Coordination

The long-travel design coordinates driven wheels, brakes, acceleration and feedback or correction as required. The aim is controlled travel without excessive skew or flange forces.

End and Parking Positions

Define buffers, end stops, travel limits, service access and the normal parking location. Outdoor systems may require rail clamps, anchors or other wind restraints.

Define the Electrical Boundary

Record the site voltage, frequency, phases, earthing arrangement and available fault information. The contract should state who supplies the incoming isolator, feeder, runway electrification, trailing cable management and connections.

• Cable reel, festoon or conductor system selected for travel length and environment.
• Pendant, radio control, cab or combined operating stations.
• Single-speed, two-speed or variable-frequency motion as specified.
• Required enclosure, heating, cooling or corrosion protection.

Safety and Protective Functions

• Overload protection and hoisting upper and lower limits as applicable.
• Service and holding brakes for the selected mechanisms.
• Trolley and gantry travel limits, buffers and end stops.
• Emergency stops, isolating provisions and electrical protections.
• Audible or visual travel warnings and anti-collision functions where required by the risk assessment.

Operating and Out-of-Service Wind

The project specification defines design wind data, operating limits, monitoring, shutdown actions and the secured out-of-service condition.

Parking and Restraint

Travel brakes, rail clamps, storm anchors or other restraints are selected from the design and site. Civil interfaces must be coordinated with the foundation scope.

Weather and Corrosion

The protection package may include a specified coating system, weather-rated enclosures, drainage, covers and heaters based on rain, dust, humidity, coastal exposure or process chemicals.

Crane Equipment

Bridge, legs, hoist or trolley, travel drives, controls and specified protection.

Rails and Foundations

Runway steel, civil work, end stops, anchors, alignment and drainage.

Electrical Interface

Incoming feeder, isolator, conductor or cable reel, earthing and site connections.

Delivery and Site Work

Packing, freight, insurance, duties, unloading, erection, testing and handover.

1. Load: maximum and typical payload, attachment mass, dimensions and lifting points.
2. Geometry: span or clear width, lifting height, travel length, approaches and cantilevers.
3. Operation: lifts per hour, shifts, travel distances, speeds and positioning needs.
4. Site: layout, rail or floor information, obstacles, traffic, ground and foundations.

1. Environment: indoor or outdoor, wind, temperature, rain, dust, corrosion and classifications.
2. Power: voltage, phases, frequency and preferred supply route and controls.
3. Destination: country, applicable requirements, documentation and inspection plan.
4. Commercial scope: Incoterm, freight, rails, erection, commissioning, training and spares.

Henan Mine Crane manufactures the structural assemblies and integrates the hoisting, travel, control and electrical systems in accordance with the approved project specification. The documentation package can include the following records within the agreed supply scope. Henan Mine Crane Manufacturing Facilities.

• General arrangement drawing with dimensions, clearances, hook coverage and service access.
• Wheel loads, wheel spacing and rail-interface data for civil and structural coordination.
• Motor and component schedule plus electrical diagrams and control description.
• Agreed material, welding, inspection, factory test and site acceptance records.
• Operating, inspection and maintenance manuals with spare-parts identification.

Site Preparation

Site preparation includes approved foundations, rails, end stops, power routing, earthing and drainage, together with verification of geometry and installation readiness before equipment delivery.

Erection and Commissioning

The installation plan defines unloading and assembly areas, erection equipment, inspection stages, functional checks, applicable load tests, training and handover responsibilities.

Lifecycle Maintenance

Safe maintenance access is required for the hoist, trolley, wheels, drives, brakes and electrification. Inspection intervals are established from operating duty, environment, supplied manuals and local requirements.

European Single-Girder Gantry Crane

Powered electric-hoist full-gantry configuration for general industrial material handling.

Double-Girder Electric-Hoist Gantry Crane

Two-girder electric-hoist arrangement for increased rigidity and alternative hook geometry.

MG Double-Girder Gantry Crane

Heavy-duty double-girder configuration with a project-selected winch trolley.

Single-Girder Semi-Gantry Crane

Semi-gantry configuration using one ground runway and one elevated runway.

L-Type Gantry Crane

Offset leg geometry providing additional passage clearance for long materials.

Double-Girder Truss Gantry Crane

Truss construction configured for the specified span, environment and transport conditions.

PRIMARY SERVICE

Scrap Receiving, Sorting and Feeding

CRANE ARCHITECTURE

Overhead or Gantry Crane

LIFTING DEVICES

Magnet, Orange-Peel Grab or Hook

CONTROL LEVELS

Cabin, Radio, Assisted or Automatic

1. Receiving and Inspection

Unload trucks, rail wagons, containers or transfer bins into an inspection area. The receiving plan covers vehicle clearances, unloading sequence, traffic separation and quarantine of closed vessels, batteries, cylinders, hot material or other rejected items.

2. Sorting and Segregation

Separate ferrous and nonferrous grades, oversize pieces, turnings, plate offcuts, castings and contaminants. Magnetic pickup can support ferrous segregation; mixed or nonmagnetic streams normally require a suitable mechanical grab.

3. Stockpile and Reclaim

Build controlled piles and reclaim material without exceeding floor, retaining-wall, bin or crane-envelope limits. Pile height, slope, buried dense pieces and interlocked scrap affect penetration, pickup stability and cycle time.

4. Process-Line Feeding

Feed a shear, shredder, baler, crusher, sorting line, conveyor hopper or furnace charge system at a controlled rate. Equipment-ready signals, hopper level, gates, safe approach and release permissives are included in the control sequence.

5. Processed-Metal Transfer

Move shredded scrap, cut scrap, compacted bales, bundles or chips to inspection, storage or blending positions. Product form may require a closed grab, magnet, bale clamp, lifting beam or conventional hook rigging.

6. Dispatch and Maintenance

Load outbound vehicles and support planned maintenance of magnets, grabs, shredders, balers and conveyors. Production handling and maintenance lifts are documented separately, with defined attachment changeover and parking arrangements.

Bridge or Gantry Structure

Top-running double-girder cranes suit fixed indoor bays. Gantry cranes serve open yards where a building runway is unavailable. Structure, wheels and drives are calculated from span, fatigue spectrum, skewing, wind and maximum wheel reactions.

Process-Duty Hoisting Machinery

Drum, ropes, sheaves, reducer, motor, brakes and controls are sized for gross suspended load, lifting height, starts per hour, load spectrum, shock and required availability rather than rated tonnage alone.

Scrap Attachment

An electromagnet, orange-peel grab, closed multi-tine grab, bale device, lifting beam or hook is matched to representative material. Attachment mass and service connections remain part of the rated suspended load.

Attachment Power and Protection

Magnet rectifiers, cable reels and retention provisions, or hydraulic power packs, hoses and rotators, are guarded against sharp scrap, impact, abrasion, heat, dust, rain and accidental snagging.

Operator and Control System

Cabin, radio control, assisted functions or automatic operation can include cameras, load display, anti-sway, position tracking, pile profiling, destination confirmation and process-line handshakes.

Access and Maintainability

Walkways, service platforms, guarded access, isolation stations, attachment stands and component-removal paths reduce maintenance exposure above stockpiles and operating equipment.

Scrap Composition

Ferrous percentage, nonferrous grades, piece dimensions, shape, entanglement, density, coatings, contamination, temperature and seasonal variation are recorded from representative loads.

Attachment and Net Payload

Magnet, grab, rotator, hook block, beam, cables and hoses consume part of the crane rating. Net scrap payload is calculated after every suspended component is included.

Production Throughput

Required tonnes per hour, average verified pickup, full travel path, hoisting heights, destination queues, attachment closing time and operating availability establish the real cycle requirement.

Duty and Load Spectrum

Lifts per hour, shifts, annual hours, average and maximum loads, starts, reversing, impact and production consequence of downtime determine mechanism and structural classification.

Site and Environment

Indoor or outdoor location, temperature, wind, rain, snow, dust, metal fines, salt, fumes, washdown, fire exposure and corrosive contaminants determine protection and component placement.

Layout and Interfaces

Span, lift, runway length, pile limits, vehicle lanes, process openings, attachment envelope, power supply, plant PLC and maintenance access are verified on coordinated drawings.

Hook, Beam or Bale Device

Compacted bales, bundled stock, bins and maintenance loads may require certified slings, a lifting beam, tongs, clamps or a conventional hook. Defined lifting points and stable load geometry remain essential.

Standard Bulk Grab Boundary

A clamshell or four-rope bulk grab designed for ore, coal, slag or other free-flowing material is not presumed suitable for tangled scrap. Structural loads, closure method and shell geometry require separate confirmation.

Multiple Attachments

A dual-purpose crane is practical where attachment exchange frequency, connection safety, parked-attachment location, production interruption and loss of net payload are acceptable within the operating plan.

Gross Suspended Load

Crane rated capacity must cover the maximum net scrap mass plus the complete suspended attachment, hook block, rotator, beam, cables and other equipment below the hoist. A crane labeled 20 t does not provide a 20 t scrap payload when a heavy grab or magnet is installed.

Volumetric Grab Check

Expected scrap mass per grab is estimated from usable grab volume multiplied by representative bulk density and a verified filling factor, then limited by crane and attachment ratings. Density can change sharply between light-gauge tangled scrap, shredded material, cast pieces and compacted feed.

Production Cycle Check

Throughput is calculated from the complete cycle: approach, penetration or magnet placement, closure or energization, hoist, travel, destination wait, lowering, release and return. Average production pickup and availability—not only theoretical maximum load—control tonnes per hour.

Capacity Data Required

• Maximum and typical piece mass and dimensions
• Representative loose bulk density by scrap family
• Attachment self-weight, services and rotating equipment
• Measured or trial-based magnet pickup or grab filling factor
• Source and destination coordinates and lift heights
• Required tonnes per hour and peak queue condition
• Daily shifts, annual hours and production availability target

Load Spectrum and Starts

Frequent reversals, high starts per hour, variable loads, impact, grab closure and abrupt magnet release create a fatigue profile different from occasional workshop lifting. ISO, FEM or CMAA classification is selected from the declared service.

Operator Visibility

A cabin, radio station or remote control room is arranged around pile height, dust, glare and blind spots. Cameras can cover the attachment, hopper, vehicles and travel path but do not replace defined exclusion controls.

Assisted Functions

Anti-sway, slow zones, protected travel corridors, height limits, load weighing, position display, grab or magnet status and destination confirmation support repeatable operation.

Automatic Stockpile Handling

Position tracking and pile profiling can generate source coordinates and prevent excessive pile height. Automatic release remains inhibited until the destination and process state are confirmed.

Process-Line Interface

Signals with shears, shredders, balers, conveyors, bunkers and gates define ready, hold, fault, occupancy, level, release and task-complete states. Ownership of every safety permissive is documented.

Recovery and Diagnostics

Safe manual recovery covers failed sensors, incomplete closure, lost magnet feedback, blocked destinations, communications loss and interrupted power. Diagnostics retain events, loads, cycles, alarms and maintenance counters.

Dropped-Material Zone

Suspended scrap can shift, detach or project beyond the attachment. Personnel routes, vehicle routes, operating stations and maintenance access are separated from the defined load path and release zone.

Incoming-Scrap Hazards

Batteries, sealed containers, cylinders, residual fluids, hot pieces, radioactive sources and unknown chemicals require receiving inspection, rejection and quarantine procedures. Crane selection does not replace material acceptance controls.

Fire and Emergency State

Fire detection, evacuation, emergency stops, safe parking and response to a retained suspended load are coordinated with the site emergency plan. Battery-containing scrap and hot loads receive specific controls.

Dust, Fines and Abrasion

Sealed enclosures, filtered or pressurized electrical rooms, guarded cables, abrasion-resistant liners, protected sensors and accessible cleaning points are selected from the measured environment.

Outdoor Operation

Wind monitoring, operating and out-of-service wind limits, rail clamps or storm anchors, drainage, low-temperature provisions, lightning protection and corrosion systems are established for the site.

Hazardous-Area Boundary

Explosion-protected equipment is specified only where a formal area classification identifies combustible gas or dust zones. General metal dust or a recycling application name alone does not establish an ATEX or IECEx scope.

Existing Runway Verification

Reuse requires condition and geometry checks of rails, beams, brackets, columns, connections and foundations. Maximum and minimum wheel loads, lateral and longitudinal forces, buffer reactions and fatigue demand are issued for structural review.

Stockpile and Clearance Model

The model includes maximum pile contours, protruding pieces, attachment swing or rotation, hopper edges, vehicle envelopes, lighting, ductwork, columns and adjacent cranes. Storage rules prevent stockpiles from entering a protected motion envelope.

Wear and Service Access

High-wear tines, shells, magnet chains, cable outlets, hoses, sheaves, wheels and brakes remain inspectable. Attachment stands, safe parking, washdown or cleaning provisions and component-removal paths are defined before fabrication.

Site Documents

• Verified bay, runway and yard drawings
• Allowable wheel reactions and foundation information
• Pile, bin, hopper, building and vehicle envelopes
• Rail condition, elevation, span and alignment survey
• Power, grounding, communications and fire-system interfaces
• Erection opening, laydown area and shutdown window
• Environmental and hazardous-area assessments

Design Review

Confirm load cases, classification, gross and net capacities, wheel loads, attachment envelope, material assumptions, protection package, safety functions, interfaces and inspection access.

Factory Acceptance Test

Verify assemblies, drives, brakes, limits, load protection, magnet or grab logic, alarms, safety functions, interface simulation, documentation and contracted quality records before shipment.

Site and Production Acceptance

Test proof loads, representative scrap, pickup retention and release, grab closure, cycle time, hopper interfaces, collision zones, power-loss response, cameras, positioning and abnormal recovery.

Automatic Rotating Electromagnetic Beam Platform

Henan Mine Crane publishes an electromagnetic beam platform with automatic handling functions for steel products and describes a 5–50 t configurable capacity range for the solution family. Positioning, magnetic control and plant interfaces provide relevant engineering experience for ferrous-material handling.

Evidence boundary: the published benchmark project is identified as slab transfer at a steel base, not as a delivered metal recycling yard crane. Random scrap requires a different magnet arrangement, load model, retention assessment, pile strategy and production test.

View Published Magnetic-Handling Solution →

Primary Price Drivers

Gross capacity and net payload; span and lift; duty classification and speeds; magnet or grab type and size; rotation; gantry or runway; outdoor and corrosion package; cabin; automation; safety zoning; plant interfaces; local code, documentation and certification.

Commercial Scope to Reconcile

Runway rails and structural work; gantry foundations; electrification; freight and insurance; duties and taxes; erection equipment; mechanical and electrical installation; supervision; commissioning; test loads or scrap; training; spares, warranty and production acceptance.

Technical Proposal

Design basis, crane arrangement, capacities, duty class, speeds, attachment concept, expected pickup assumptions, environmental protection, control level and deviations.

Interface Schedule

Wheel reactions, power, grounding, communications, process I/O, operating zones, foundation or runway boundary, erection needs and third-party responsibilities.

Attachment Data

Deadweight, dimensions, volume or magnetic characteristics, service connections, rated limits, wear parts, inspection method, proof test and representative-material test plan.

Safety Documentation

Risk-assessment inputs, safety-function list, exclusion zones, attachment logic, power-loss behavior, isolation, emergency states and required conformity records.

Quality and O&M Records

Inspection and test plan, material and welding records as specified, coating reports, component certificates, manuals, lubrication plan, training and recommended spares.

Commercial Schedule

Price, Incoterm, milestones, packing, freight boundary, installation, commissioning, training, acceptance, warranty, exclusions, validity and optional lifecycle services.

Scrap and Attachment Data

Ferrous and nonferrous percentage; material families; piece size, maximum single piece, loose density, temperature and contaminants; photographs or samples; preferred magnet, orange-peel grab, bale device or hook.

Process and Duty Data

Receiving, pile, shear, shredder, baler, hopper and dispatch routes; tonnes per hour; average pickup; lifts per hour; shifts; annual hours; load spectrum; travel paths and availability target.

Site and Environment Data

Indoor or outdoor location; span, lift and runway length; drawings; wheel-load limits; pile and vehicle envelopes; temperature, wind, dust, corrosion and fire conditions; power supply and project destination.

Controls and Commercial Data

Cabin, radio, assisted or automatic mode; cameras and weighing; process PLC or WMS interface; safety zones; governing standard; Incoterm; freight, installation, commissioning and testing boundary.

Which crane is suitable for a scrap yard?

A double-girder overhead crane suits a covered bay with an adequate runway. A gantry crane suits an open yard. The attachment is then selected from scrap composition: magnet for validated ferrous material, orange-peel grab for mixed or irregular scrap, and hook-based devices for defined loads.

Can one crane handle ferrous and nonferrous scrap?

Yes, when a suitable mechanical grab is used or a controlled attachment-change system is provided. An electromagnet alone cannot lift nonferrous material. Changeover time, attachment parking and retained payload must be included in the operating plan.

How is metal recycling crane capacity determined?

Rated capacity starts with the maximum gross suspended load. Net scrap payload equals the available rating after the attachment, hook block, rotator, beam and service equipment are included. Duty, dynamic effects and governing code are then applied.

Does magnet capacity equal loose-scrap lifting capacity?

No. Loose-scrap pickup depends on material, contact, air gaps, piece geometry, pile depth and temperature. Catalog test-plate values require application-specific derating and representative production trials.

What grab is used for irregular scrap?

A multi-tine orange-peel grab is commonly selected. Open, semi-closed or closed tine geometry is matched to bulky scrap, mixed or sheared scrap, or smaller pieces and chips. Volume, deadweight, penetration, closure force and wear remain project-specific.

Can a recycling crane feed a shredder or baler automatically?

Yes. Automatic or assisted feeding can use position tracking, pile profiling, level signals and process permissives. Destination availability, safe release, collision control and manual recovery require a documented interface specification.

How much does a metal recycling crane cost?

Attachment listings can range from a few thousand dollars to much higher values, but they do not establish the installed crane cost. A project price requires capacity, span, duty, attachment, throughput, environment, runway or gantry, controls, destination and supply boundary.

Can an existing runway be reused?

Only after geometry, rail alignment, condition, fatigue history, beams, columns, connections and foundations are verified against the proposed vertical, lateral, longitudinal and buffer reactions.

PROCESS AREAS

Converter, EAF, Refining, Casting & Smelting

CRANE CONFIGURATIONS

Double Girder or Four Girder, Main & Auxiliary Trolley

OPERATING DUTY

Project-Specific Metallurgical Duty, A7–A8 Available

PRICE BASIS

Engineered Project Quotation

01 · Double-Girder Ladle Crane

A heavy-duty bridge with a metallurgical trolley and gantry-type ladle attachment for direct molten-metal transfer. Henan Mine Crane offers double-girder casting-crane configurations in the 50–150 t range, with project-specific capacity, span, lift and A7–A8 duty selection.

02 · Four-Girder Ladle Crane

A four-girder, four- or six-rail structure with separate main and auxiliary trolleys for ultra-heavy ladles, frequent production cycles and controlled pouring. Available Henan Mine Crane configurations extend from 200/50 t to 500/200 t, subject to final engineering.

03 · Main-and-Auxiliary Trolley Crane

The main trolley lifts and transports the full ladle through the gantry beam and plate hooks. The auxiliary trolley provides a separate hook for tilting, pouring, ladle-cover handling or maintenance. Controls restrict unsafe combinations and define coordinated motion.

04 · Metallurgical Bridge Crane

A project-configured metallurgical crane for molten metal, hot components or furnace-area materials. The exact lifting device, braking architecture and protection level determine whether it is suitable for direct ladle service; the product name alone is not sufficient.

05 · Automated Ladle Transfer Crane

Position feedback, variable-frequency drives, anti-sway functions, route permissions and process handshakes support repeatable transfers between furnace, refining and casting stations. Automation scope is defined with the plant control and safety systems.

06 · Auxiliary and Maintenance Crane

A separate crane can handle ladle covers, refractory equipment, furnace components and maintenance loads. Unless it is specifically engineered and accepted for molten-metal service, it must not be treated as a substitute for the production ladle crane.

The handling route should be mapped from pickup to set-down before the bridge, trolley and hoist arrangement is selected. Furnace structures, fume-extraction ducts, ladle cars, transfer aisles, refining stations, casting-machine turrets, emergency set-down positions and maintenance access can all control the crane envelope.

Each station requires verified coordinates, approach clearances and permitted motions. A workable general arrangement also considers where a loaded crane may wait, how another crane passes or shares a bay, and where a full ladle can be safely placed after a drive, brake, power or process interruption.

Production and maintenance duties should be separated where heat exposure, working envelope, attachment requirements or availability targets make one shared crane unsuitable. This avoids using the primary ladle crane for tasks that interfere with the steelmaking sequence.

Main-Hoist Braking Architecture

Service and emergency braking functions are selected from the governing standard and project risk review. Brake torque, application sequence, monitoring and safe response to drive or power failure are documented and tested.

Independent Limits and Overspeed Protection

Operating limits, final limits, overspeed detection, drum and rope supervision, load monitoring and permissive logic prevent unintended overtravel. Critical channels are arranged to avoid a single undetected failure.

Verified Load Path and Ladle Engagement

The gantry beam, plate hooks, trunnion interface, sheaves, ropes, equalization and trolley frame are engineered as one load path. Hook engagement, wear limits and inspection access are included in operating procedures.

Thermal and Splash Protection

Heat shields, protected equipment locations, suitable insulation systems, heat-resistant cables, ventilation or cooling and guarded walkways are selected from measured radiant and ambient conditions.

Controlled Motion and Collision Management

Variable-frequency drives, creep speeds, acceleration control, position feedback, anti-sway functions, inter-crane spacing and restricted zones support stable travel through congested production bays.

Emergency Set-Down and Recovery

Approved set-down positions, backup or emergency functions, manual recovery boundaries, communications and rescue access are agreed with plant operations. The response must protect personnel, the ladle and downstream production equipment.

Ladle Transfer, Tilting and Controlled Pouring

During transfer, the main trolley carries the loaded ladle through the gantry beam and paired plate hooks. Bridge and trolley motions use controlled acceleration and deceleration to limit load swing and molten-metal movement. Slow approach speeds are available at furnace, refining and casting positions where clearances are restricted.

For pouring, the main hoist supports the ladle while the auxiliary hook engages the designated tilting point. The control philosophy defines which motions are permitted, the maximum allowable tilt, communication between operator positions and the conditions that stop or inhibit a pour. Independent movement remains available only within the approved operating envelope.

Automation may include station coordinates, travel zoning, positioning feedback, anti-sway control, electronic weighing, condition monitoring and handshakes with ladle cars, furnace systems or casting equipment. Every automatic sequence requires a validated safe state and a practical recovery method for interrupted transfers.

Design Basis Package

Approved load schedule, ladle and trunnion drawings, cycle histogram, general arrangement, clearance study, duty calculations, wheel loads, runway reactions, heat zones and compliance matrix.

Safety and Control Documents

Functional description, operating modes, brake philosophy, limit and interlock matrix, PLC and network architecture, safe states, 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 contracted.

Factory and Site Acceptance

No-load and functional tests, brake and limit verification, overload functions, trolley and bridge motion, communications, fault simulation, proof-load plan, site commissioning and operator-maintenance training.

Runway and Site Readiness

Survey rail span, elevation, alignment and runway capacity; confirm building clearances, erection route, crane access, furnace and casting coordinates, electrification, control networks and shutdown windows.

Installation and Assembly

Bridge girders, end carriages, trolley, reeving, gantry beam, plate hooks, heat shields, electrification and control cabinets are assembled under approved lifting, alignment and torque procedures.

Commissioning and Process Trials

Testing progresses from no-load motion and safety functions to proof-load testing, brake verification, positioning, main/auxiliary operation, interlocks, communications, dry-route simulation and controlled production trials.

Inspection and Maintenance Strategy

Inspection intervals follow duty, environment, regulation and manufacturer instructions. The program covers ropes, drums, sheaves, brakes, hooks, ladle beam, trunnion interface, structures, wheels, heat shields, cables, sensors and controls.

Crane Equipment

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

Ladle Handling System

Gantry beam, plate hooks, auxiliary hook, engagement geometry and inspection provisions.

Safety and Controls

Brake system, limits, monitoring, VFDs, PLC, positioning, zoning and process interfaces.

Project Services

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

01 · Process and crane duty

Steelmaking, ironmaking, refining, continuous casting, foundry or non-ferrous service; production route, throughput, shifts, annual hours and required availability.

02 · Gross suspended loads

Maximum molten-metal charge, ladle shell and lining, slag, lifting beam, plate hooks, blocks, rigging and all abnormal but permitted load cases.

03 · Ladle and trunnion drawings

Ladle diameter and height, trunnion size and spacing, center of gravity, filling level, tilt point, cover, pickup tolerance and interface restrictions.

04 · Building and runway

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

05 · Stations and transfer route

Furnace, ladle car, refining, casting, set-down and maintenance coordinates; ducts, platforms, obstacles, shared crane zones and exclusion areas.

06 · Motion and performance

Main and auxiliary speeds, creep speed, travel speeds, positioning tolerance, maximum acceleration, cycle times, load-sway limits and pour sequence.

07 · Thermal and environmental data

Ambient and radiant temperatures by zone, exposure duration, dust, fumes, molten splash, corrosion, altitude, indoor ventilation and operator environment.

08 · Controls and plant interfaces

Cabin, radio or remote station; manual, assisted or automatic modes; PLC, network protocol, ladle car, furnace, refining and casting handshakes.

09 · Standards and acceptance

Destination, governing crane/electrical standards, inspection authority, document language, witness points, FAT, proof-load test and process trials.

10 · Commercial and site scope

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

How is ladle crane capacity calculated?

Use the maximum combined mass of the filled ladle, refractory lining, molten metal, slag, gantry beam, plate hooks, blocks and all suspended tooling. Apply the design and regulatory factors required by the governing engineering basis.

When is a four-girder ladle crane required?

Four-girder multi-rail designs are considered for ultra-heavy capacities, intensive duty, separate main and auxiliary trolleys, high structural stiffness and critical availability. Runway capacity, maintenance access and lifecycle cost must also support the choice.

Can a standard double-girder overhead crane carry a steel ladle?

Not by default. Direct molten-metal service requires a suitable load path, ladle attachment, braking and limit architecture, thermal protection, operating duty, controls, inspection plan and acceptance procedure.

What is the function of the auxiliary hook?

The auxiliary hook may tilt the ladle for pouring, handle covers or support maintenance. Its capacity, position, reeving and permissible simultaneous operation with the main hoist are defined from the process and ladle geometry.

Is A7 or A8 duty always necessary?

The required duty follows the actual cycle and load spectrum. Henan Mine Crane offers A7–A8 casting-crane configurations, but final classification must be calculated from lifts per hour, operating hours, load distribution and production criticality.

What safety functions are required for molten-metal handling?

The final set depends on the governing standard and risk assessment. Typical subjects include braking, independent limits, overload and overspeed monitoring, emergency response, secure ladle engagement, heat protection, collision control and safe set-down.

Can ladle transfer be automated?

Yes. Position feedback, VFD motion, anti-sway, route zoning and plant handshakes can support assisted or automatic transfer. Safe states, manual recovery, communications and process ownership must be agreed before software development.

What determines ladle handling crane price?

Gross load, span, lift, duty, bridge and trolley structure, ladle attachment, brake and safety architecture, thermal protection, controls, runway interface, documentation, shipping and site services are the main cost drivers.

Can an existing crane or runway be reused?

Reuse is possible only after structural, mechanical, electrical and fatigue assessment. The review must confirm runway reactions, rail condition, clearances, load path, duty, heat exposure, compliance and the practical modernization boundary.

What should be demonstrated before acceptance?

Verify documentation, safety functions, brakes, limits, load performance, main and auxiliary motion, position control, plant interlocks, alarms, emergency response, proof testing, dry process routes, operator training and agreed production trials.

PRIMARY SYSTEM

Overhead Bridge Crane

SUPPORT OPTIONS

Building or Freestanding

COVERAGE OPTIONS

Bay, Line or Workstation

CONTROL OPTIONS

Pendant, Radio, Cabin & PLC

Top-Running Overhead Crane

Bridge wheels travel on rails above runway beams. Single- and double-girder arrangements provide full-bay coverage for manufacturing, fabrication, assembly, warehousing and maintenance.

Underhung Overhead Crane

Bridge end carriages travel beneath compatible runway beams. This arrangement can improve side approach and preserve floor area, but the suspended support structure requires engineering verification.

Freestanding Bridge Crane

Independent columns and runways transfer crane reactions into dedicated foundations. It is used where the existing building cannot accept crane loads or where a self-contained system is preferred.

Workstation Crane

Light enclosed-track or profile systems provide low rolling resistance and precise movement over a defined work cell. They are suited to repetitive ergonomic handling rather than heavy production loads.

Monorail and Jib Crane

A monorail follows a fixed linear or curved route, while a jib serves a circular or sector-shaped area. Both suit localized transfer, machine loading and maintenance tasks.

Indoor Gantry Crane

A portable or rail-mounted gantry stands on floor-running legs. It can serve leased buildings, maintenance areas or production zones without relying on elevated runway beams.

A powered indoor bridge crane combines the load-handling mechanism, moving bridge, end carriages, electrification and controls. The hoist lifts vertically, the trolley moves across the bridge and the bridge travels along parallel runways. The structure transfers operating forces into the building or independent support system.

A complete specification identifies every interface. The crane package does not automatically include runway beams, rails, columns, foundations, incoming plant power, installation, test weights or statutory inspection. These items are assigned before quotations are compared.

Bridge Structure

One or two girders carry the moving hoist or trolley. Capacity, span, wheel loads, deflection, fatigue and available headroom determine the bridge form.

Hoist or Trolley

Electric chain hoists serve lighter compact handling, wire-rope hoists cover broader industrial duties and open-winch trolleys support demanding process applications.

End Carriages

Wheel assemblies support the bridge and provide long travel. Wheel spacing, rail profile, drive arrangement and alignment affect travel quality and runway reactions.

Electrification

Conductor bars or festoon systems feed the moving bridge, while festoon cable, cable track or energy chain serves the hoist trolley.

Controls and Protection

Pendant, radio, cabin or PLC controls operate the motions with emergency stop, brakes, motion limits, overload protection and specified alarms or interlocks.

Runway Interface

Rails, beams, brackets, columns and foundations receive crane forces. Structural responsibility and allowable reactions are stated in the technical offer.

01 · Gross Suspended Load

Include the payload, lifting beam, slings, clamps, magnets, grabs and every component below the hook. State normal and maximum load distributions.

02 · Required Coverage

Map pickup and placement points, travel route, machine interference, aisles and future expansion. Match the coverage shape to a bridge, monorail, jib or workstation system.

03 · Span, Lift and Headroom

Provide runway rail centers, lowest pickup, highest placement, rail elevation, roof clearance, load height and rigging depth.

04 · Working Duty

Define lifts per hour, full-load frequency, load spectrum, shifts, travel distance and annual operating hours. These values establish mechanism and structural service requirements.

05 · Building Structure

Confirm whether the facility can support top-running or suspended runway reactions. Existing beams and columns require calculation, condition and alignment review.

06 · Motion and Positioning

State required speeds, low-speed range, acceleration, stopping, anti-sway, synchronized lifting, positioning tolerance and automation interfaces.

07 · Indoor Environment

Temperature, dust, humidity, corrosion, washdown, cleanroom class, hazardous-area classification and electromagnetic or thermal exposure affect equipment selection.

08 · Project Boundary

Assign runway, rails, columns, foundations, plant power, freight, unloading, installation, commissioning, load testing, permits and inspection.

Runway Type

Top-running rails sit above runway beams; underhung end carriages travel beneath compatible beams. These arrangements are not interchangeable without structural review.

Rail Geometry

Gauge, straightness, elevation, joints, rail section and end stops influence wheel contact, skewing, vibration and component wear.

Wheel Loads

Maximum and minimum reactions are assessed with the trolley or hoist in governing positions, including applicable impact, braking and lateral forces.

Vertical Envelope

Roof bracing, ducts, sprinklers, lights and cable trays must remain clear throughout bridge and trolley travel. Highest hook position is checked on a dimensioned drawing.

Hook Approaches

End and side approaches determine access to machines, racks, truck lanes and walls. Nominal span alone does not establish usable floor coverage.

Freestanding Structure

Independent columns avoid building loads but require foundation reactions, floor-layout control, bracing, column spacing and an erection plan.

Variable-Frequency Motion

VFD control provides smooth acceleration, controlled deceleration and selectable low speed. It can reduce load swing and mechanical shock when correctly tuned.

Overload and Motion Limits

Overload protection, upper and lower hoist limits, travel limits, buffers and end stops restrict foreseeable overtravel and overload conditions.

Braking and Emergency Stop

Service brakes hold and stop each powered motion within the design basis. Emergency-stop circuits remove commanded motion based on the control architecture.

Anti-Collision and Zoning

Multiple cranes, restricted areas and fixed obstacles can require distance monitoring, slowdown zones, stop zones and interlocked access.

Positioning and Anti-Sway

Encoders, laser or other position feedback, closed-loop drives and anti-sway logic support repetitive placement and controlled automated cycles.

Inspection Access

Platforms, walkways, access points, lighting and isolation provisions are included where required for safe inspection and maintenance of the selected configuration.

Fabrication and Machining

Transfers plate, profiles, fixtures, tools, machine parts and welded assemblies between cutting, welding, machining, inspection and dispatch stations.

Assembly and Production

Positions components and subassemblies where smooth motion, controlled low speed and accurate hook approach support cycle time and product quality.

Warehouse and Logistics

Moves machinery, dies, steel products, pallets and unit loads while preserving floor lanes for production, storage and vehicle traffic.

Maintenance Facilities

Provides controlled removal and installation of motors, pumps, gearboxes, dies, vehicle components and plant machinery.

Heavy Manufacturing

Double-girder and process cranes handle large weldments, transformers, turbines, construction machinery and other high-value assemblies.

Controlled Environments

Cleanroom, explosion-proof, dust-controlled, corrosion-resistant or insulated cranes require declared environmental classification and dedicated components.

Henan Mine Crane reports the successive supply of more than 300 intelligent cranes of various types for XCMG manufacturing operations. The equipment supports assembly and structural-component movement across engineering-machinery production processes.

A multi-bay manufacturing program can require different capacities, spans, duties and controls while preserving consistent operator interfaces, documentation, maintenance principles and spare-parts planning. High-precision positioning, digital controls, remote monitoring and production-system integration are applied to suit the process task.

For a comparable indoor crane program, each bay requires an individual load and building assessment. A coordinated fleet specification can then standardize controls, safety functions, component preferences, inspection records and training without forcing every process into one crane model.

View Manufacturing Project →

Project control connects approved operating data to design, fabrication, inspection, packing, erection and handover. General arrangement drawings, wheel loads, electrical data and building interfaces are approved before bridge dimensions or runway connections are finalized.

Site acceptance begins with runway or support verification, then proceeds through assembly, alignment, electrical checks, protective-device settings, no-load operation, specified load testing, training and handover documentation.

Load and Process Data

Maximum and routine loads, attachment mass, dimensions, center of gravity, lifting points, cycles, travel route and production consequence.

Building and Coverage Data

Bay dimensions, span, travel length, rail elevation, hook approaches, roof obstacles, columns and existing runway details.

Operating and Control Data

Working shifts, load spectrum, speeds, low-speed positioning, pendant, radio, cabin, PLC, anti-sway and system integration.

Commercial and Site Data

Destination, voltage, Incoterm, installation resources, permits, test weights, inspection authority and requested documentation.

Which crane type is suitable for an indoor workshop?

A top-running single-girder electric-hoist crane is a common starting point for general workshop handling. Underhung, freestanding, double-girder, workstation, monorail or jib systems can be more suitable after coverage, structure, duty and headroom are assessed.

What is the difference between an indoor crane and an overhead crane?

Indoor crane describes the operating environment. Overhead crane identifies a bridge moving along elevated runways. Most industrial indoor cranes are overhead bridge systems, but indoor equipment also includes monorails, jibs, workstation cranes and gantries.

How much does an indoor crane cost?

Current public North American positions extend from approximately US$10,000–25,000 for selected jibs and monorails to about US$40,000 for a conventional 5 t single-girder bridge and around US$60,000 for a 5 t double-girder bridge. Scope and region govern final value.

Can an indoor crane use the existing building structure?

Building-supported installation is possible after runway beams, columns, roof framing, connections and foundations are verified for crane reactions, fatigue, alignment and clearances.

When is a freestanding crane required?

Independent columns are considered when the building cannot accept crane loads, when structural information is unavailable, or when a self-contained runway provides better project control. Foundations and floor use become part of the project.

How is the required crane capacity calculated?

Capacity is based on the maximum gross suspended load, including payload, lifting beam, slings, clamps, magnets, grabs and every below-hook component. Dynamic, duty and applicable design factors are then applied.

Are runway and installation included in the quotation?

Runway steel, rails, columns, foundations, plant power, freight, erection, test weights and local inspection are included only when expressly listed in the commercial scope.

What documents support final acceptance?

The handover package can include approved drawings, wheel-load data, electrical diagrams, manuals, component information, inspection results, factory test documents, commissioning settings and site load-test records.

01 · Powerhouse Overhead Crane

A double-girder bridge crane for generating-unit erection, rotor and stator handling, turbine disassembly and scheduled maintenance across the powerhouse bay.

02 · Pumped-Storage Powerhouse Crane

A high-capacity, frequently low-headroom arrangement for underground caverns, with project-defined synchronized lifting, precision motion and monitoring functions.

03 · Dam-Crest Gantry Crane

A rail-mounted outdoor crane serving multiple gate or stoplog positions, engineered for long travel, wind exposure, drainage, corrosion protection and safe parking.

04 · Intake Gate and Stoplog Crane

A lifting system with a purpose-designed spreader or engagement device for intake gates, emergency gates, stoplogs and trash racks at specified slots.

05 · Tailrace or Draft-Tube Service Crane

A separate crane or hoist for downstream gates, draft-tube stoplogs and maintenance tasks where access, water level and lifting depth differ from the dam crest.

06 · Auxiliary Maintenance Crane

An appropriately rated bridge crane, monorail or electric-hoist system for valve, pump, workshop and service-bay loads that do not require the main crane.

Controlled Low-Speed Motion

Variable-frequency drives can provide smooth acceleration, reduced mechanical shock and a specified slow-speed range for alignment over the turbine pit or gate slot.

Hook Synchronization

Where the approved lift uses two hooks or lifting points, feedback and control functions are configured to maintain the project-defined relationship and stop on unacceptable deviation.

Braking and Limits

Hoisting brakes, upper and lower limits, overload protection, travel limits, buffers and emergency functions are selected to the risk assessment and applicable contract standard.

Anti-Sway and Monitoring

Project-defined anti-sway, position feedback, fault recording and operating-data monitoring can support repeatable heavy lifts and maintenance planning.

Crane and Runway Interface

Wheel loads, skew control, rail tolerances, end stops and structural deflection criteria are coordinated with the powerhouse or dam civil design.

Maintenance Access

Service platforms, guarded access, inspection points, lighting and maintainable component placement are incorporated according to the approved arrangement.

Design Package

General arrangement, wheel loads, hook approaches, mechanism data, electrical architecture and agreed calculation documents.

Manufacturing Control

Material traceability, welding and inspection records, dimensional control, mechanism checks and agreed witness points.

Testing and Handover

Factory tests, site commissioning, protection verification, load testing, manuals, spare-parts documentation and training records.

Early Civil Coordination

Confirm runway elevation, support reactions, rails, embedded items, access openings and crane assembly sequence before the structure is closed.

Site Execution

Coordinate transport dimensions, underground access, erection equipment, electrical supply, installation supervision and commissioning resources.

Long-Term Availability

Establish inspection intervals, lubrication points, rope and brake checks, critical spares and outage support before operational handover.

What type of crane is used in a hydropower powerhouse?

A double-girder overhead crane is commonly selected for turbine-generator erection and major overhaul. Capacity, hook arrangement, span, lift height and duty are established from the station’s approved lift study.

How is hydropower plant crane capacity calculated?

Use the governing component weight plus the complete below-the-hook equipment and rigging, then verify the handling method and load path. The plant’s MW output is not the crane’s rated lifting capacity.

Why may a pumped-storage crane need a low-headroom design?

Many pumped-storage units are located in underground caverns where roof elevation and installation access are constrained. A low-headroom arrangement can improve hook elevation, subject to structural and maintenance-clearance checks.

When are synchronized double hooks required?

They may be specified when the approved lifting method uses two lifting points on a large component. Required load sharing, permitted deviation, feedback and stopping logic must be defined by engineering.

What does a dam gantry crane handle?

Depending on the project, it can handle intake or spillway gates, stoplogs, trash racks and maintenance equipment at multiple positions along a rail. The spreader and lifting sequence are matched to the gate design.

Is a gate hoist the same as a gantry crane?

No. A fixed gate hoist normally serves a defined gate position, while a gantry crane travels along rails and can serve multiple slots or maintenance points. The correct choice follows the operating philosophy.

What protection is needed for an outdoor hydropower crane?

The specification may include a suitable coating system, weather-resistant electrics, drainage, wind monitoring, rail clamps or anchoring, lightning protection and low-temperature measures based on actual site conditions.

Can an existing hydropower crane be replaced or modernized?

A retrofit is possible after checking the existing runway, wheel loads, clearances, electrical supply, access route and outage window. The retained structure and new equipment require a documented interface assessment.

How much does a hydropower plant crane cost?

There is no reliable unit price without capacity, span, lift height, hook or gate-spreader arrangement, controls, environmental protection and supply boundary. An itemized quotation is required for a valid comparison.

What information is needed for a fast quotation?

Provide drawings, the critical lift or gate data, span, lift height or depth, runway details, duty, environment, site power, destination, required standard, schedule and installation or commissioning scope.

PROCESS COVERAGE

Slab to Finished Product

CRANE FAMILY

Production & Service Cranes

ATTACHMENT OPTIONS

Hook, Beam, Clamp & Magnet

CONTROL OPTIONS

Cabin, PLC & Automation

01 · Slab Transfer Crane

Moves hot or ambient slabs between continuous casting, cooling, storage and reheating-furnace preparation. Mechanical clamps, magnet beams or approved lifting beams are selected from slab temperature, geometry and stack access.

02 · Rolling-Line Production Crane

Supports mill-line material movement, tooling exchange and production interventions. High duty, controlled acceleration, protected electrical equipment and clear operating visibility address the heat, scale and production rhythm.

03 · Roll-Shop and Roll-Change Crane

Handles work rolls, backup rolls, chocks, cassettes and roll-changing equipment. Multi-point beams, auxiliary hoists, precise low-speed control and accurate hook approach support alignment and workshop safety.

04 · Plate Handling Crane

Uses magnets, clamps or lifting beams for plates and long products after rolling, cooling and finishing. Load flatness, plate temperature, surface quality and multi-magnet control determine the attachment system.

05 · Coil Handling Crane

Transfers coils with C-hooks, coil grabs, magnets or engineered beams. Coil eye orientation, width, outside diameter, mass, storage saddles and emergency lowering requirements govern configuration.

06 · Maintenance and Service Crane

Provides intermittent access to drives, stands, motors, gearboxes and production equipment. Useful hook approach, low-speed positioning, rigging clearance and shutdown installation access are more important than production throughput.

Hoisting Protection

Overload limitation, upper and lower limits, brake monitoring, rope guidance, slack-rope protection and low-speed positioning are selected for the load and duty.

Heat and Electrical Protection

Heat shields, protected cabinets, temperature-rated cables, cooling or ventilation and suitable lubrication reduce radiant-heat and scale exposure.

Long-Load and Attachment Control

Synchronized lifting, attachment status, magnet monitoring, clamp locks and controlled release prevent skew, unequal loading and unintended load loss.

Travel and Collision Protection

End limits, buffers, rail sweeps, anti-collision, restricted zones and crane-separation logic address adjacent cranes and fixed production equipment.

Operator Visibility

Cabin position, cameras, lighting, warning devices and communication systems provide visibility around mills, stacks, vehicles and maintenance teams.

Automation and Recovery

Position feedback, anti-sway, permissive logic, safe stop, fault diagnosis, controlled restart and manual recovery govern automated cycles.

Maintenance Isolation

Accessible isolators, lockout points, platforms, walkways and component-removal zones support planned work above active production areas.

Emergency Operating Plan

Load retention, controlled lowering, alternate power, emergency braking and production shutdown responsibilities are documented for credible failures.

Top-running double-girder bridges are widely applied in rolling mills because the structure supports higher capacities, open-winch trolleys, main and auxiliary hoists, service platforms and process attachments. Box-girder design, trolley arrangement and wheel distribution are selected from the span, fatigue duty, headroom and building reactions.

Production cranes require motion profiles that combine efficient clear travel with controlled approach near the mill, stack or vehicle. Variable-frequency drives, encoders and suitable braking provide low-speed positioning without abrupt acceleration of long slabs, rolls, plates or coils. Maximum speed alone does not determine throughput; pickup, alignment and safe release often control the cycle.

Fleet planning assigns a unique equipment number, bay, runway, load family and duty to every crane. Common operator interfaces, drive families, brakes, electrical components and documentation can reduce training and spare-parts complexity where ratings remain compatible. Process-specific attachments and protection stay unique to the workstation.

Runway reactions, rail alignment, conductor location, maintenance platforms, mobile-crane access and removal paths should be coordinated with building and process-equipment design before fabrication. Late interface changes can affect hook coverage, wheel loads and installation cost.

Henan Mine Crane supplied 34 double-girder overhead cranes for Chongqing Panhua Plate’s intelligent hot-rolling project. The documented fleet ranges from 10 t to 100 t and supports a steel-plate production base with an annual capacity of 4.5 million tonnes.

The cranes serve production, roll handling, tooling, equipment service and maintenance positions. Capacity and duty were assigned by workstation, while compatible controls, documentation and spare-parts planning were coordinated across the fleet. This prevents a 10 t maintenance crane and a similarly rated production crane from being treated as identical equipment.

Phased engineering, manufacturing and delivery aligned crane availability with workshop construction and commissioning. The case demonstrates the procurement value of one fleet schedule: every crane retains the required span, lift, duty, attachment and environmental protection while project-wide interfaces remain controlled.

View Hot Rolling Crane Case →

Fleet Engineering Schedule

List every crane by bay, quantity, capacity, span, lift, duty, attachment, power, control mode and required drawing, manufacturing and delivery date.

Runway and Site Verification

Confirm rail centers, elevation, alignment, support capacity, conductor arrangement, crane separation, end stops and installation access before shipment.

Phased Packing and Delivery

Match bridge sections, trolleys, panels, attachments and loose parts to the equipment number and destination bay. Delivery batches follow site readiness.

Erection and Alignment

Plan mobile-equipment access, assembly areas, lifting method, rail checks, conductor installation, attachment assembly and work near process equipment.

Commissioning and Acceptance

Verify brakes, limits, drives, synchronization, controls, alarms, communications and attachment functions before load and process trials.

Operator and Maintenance Training

Cover operating modes, warning responses, daily checks, isolation, fault recovery, attachment inspection and crane-specific limitations.

Preventive Maintenance

Inspection intervals reflect load cycles, heat, scale, dust and production consequence. Brakes, ropes, wheels, rails, cables and attachments receive defined wear limits.

Fleet Spare-Parts Planning

Standardize compatible brake, drive, contactor, encoder, sensor, limit, rope and seal families while retaining crane-specific critical spares.

Crane Schedule

Quantity, equipment number, bay, capacity, span, lifting height, runway length, headroom, hook approach and required delivery sequence.

Load and Attachment

Load name, maximum and typical mass, dimensions, center of gravity, pickup points, temperature, attachment type and attachment mass.

Duty and Throughput

Moves per hour, load spectrum, shifts, annual hours, full-load frequency, travel distance, target cycle and production consequence.

Motion and Control

Hoist, trolley and bridge speeds, low-speed range, main and auxiliary hooks, cabin or radio control, anti-sway and positioning tolerance.

Environment

Ambient temperature, product temperature, radiant heat, distance, scale, dust, fumes, humidity, corrosion and electrical enclosure requirements.

Runway and Building

Rail section, runway beam, column spacing, rail elevation, wheel-load limits, conductor position, obstructions and installation access.

Automation and Interfaces

PLC or MES communication, I/O, equipment interlocks, stack or target coordinates, cameras, data records and manual recovery mode.

Commercial and Acceptance Scope

Trade term, packing, freight, runway, installation, load testing, third-party inspection, training, spares and schedule milestones.

Which crane types are required in a hot rolling mill?

Typical systems include slab transfer cranes, production bridge cranes, roll-handling cranes, plate or coil cranes and maintenance cranes. The exact fleet follows process layout, load families and maintenance strategy.

How is crane capacity selected?

Capacity includes the maximum load and every suspended attachment. Roll beams, clamps, magnets, C-hooks, hook blocks and rigging enter the gross-load calculation. Future lifts require defined geometry and duty.

Can one crane handle slabs, rolls and coils?

A shared crane is possible only when capacity, attachment changes, headroom, duty, heat exposure and operating routes remain compatible. Dedicated process cranes normally provide clearer safety and throughput for frequent tasks.

What duty class suits a rolling mill crane?

Duty follows load spectrum, moves per hour, shifts, travel distance and operating consequence. A production crane and an intermittent maintenance crane can require different mechanism and structural classifications at the same capacity.

How is radiant heat addressed?

Thermal design considers product surface temperature, ambient air, exposure distance and duration. Shields, protected cabinets, suitable cables, component placement, cooling and lubrication are selected from the actual heat map.

Can rolling mill cranes integrate with MES?

Yes. PLC-based systems can exchange task, permissive, status, position and fault data with plant systems. Interface ownership, protocol, I/O, cybersecurity boundary and manual recovery are defined before implementation.

What attachment is suitable for steel plate?

Magnets support fast handling of approved ferromagnetic plates, while clamps or beams may suit restricted magnetic use or specific surface requirements. Temperature, air gap, plate range and power-loss strategy govern selection.

How should roll changes be handled?

A dedicated roll beam or multi-point arrangement should match roll centers, mass, balance and storage stands. Synchronized lifting, precise low-speed motion and clear exclusion zones support controlled alignment.

Can a large crane fleet be delivered in phases?

Yes. Drawing approval, production and shipment can follow workshop readiness. Every component and document should retain the correct crane number, bay and delivery batch throughout the project.

What should a commercial quotation include?

The proposal should identify crane and attachment scope, technical parameters, runway interface, heat protection, controls, documentation, testing, packing, freight, erection, commissioning, training, spares, exclusions and schedule.

PUBLISHED CAPACITY PLATFORM

20–150 t or Custom

PUBLISHED SPAN RANGE

7.5–35 m

PROCESS MOTION

Controlled Rapid Immersion

CONTROL OPTIONS

Manual, PLC or Automatic

Vertical Shaft and Roll Quenching

Lift long shafts, rolls or rotors in a controlled vertical orientation and lower them into a tank while maintaining clearance, stability and the specified immersion profile.

Batch and Basket Quenching

Transfer loaded baskets, racks or fixtures from the furnace to water, polymer, brine or oil baths with repeatable pickup, travel, immersion and drainage positions.

Die and Mold Heat Treatment

Handle dies, mold blocks and tool steel between heating, quenching, tempering and inspection stations with an attachment matched to geometry and hot-load behavior.

Gear, Ring and Bearing Production

Move rings, gears, rollers and bearing components through controlled thermal cycles where positioning, batch traceability and repeatable transfer time are required.

Forging Heat-Treatment Bay

Transfer heavy forgings, flanges and pressure-vessel parts from furnaces to cooling or quenching stations, including single- or dual-point handling where approved.

Automatic Heat-Treatment Line

Coordinate crane movements with furnace doors, tank covers, agitation systems, recipes, tracking databases and defined safe zones through an approved signal matrix.

1. Bridge and end carriages: distribute trolley, load and dynamic reactions to the runway while maintaining the required approach to furnaces and tanks.
2. Process hoist: provides normal lifting, rapid or controlled immersion, recovery and low-speed positioning through a motion profile matched to the treatment recipe.
3. Brakes and monitoring: use the project-defined service, holding and emergency functions, with overspeed, position, limit and load supervision where required.
4. Below-hook equipment: may include baskets, racks, spreaders, lifting beams, tongs, clamps or vertical lifting fixtures engineered for the hot workpiece and bath.
5. Controls and interfaces: coordinate bridge, trolley and hoist motion with furnace doors, tank equipment, restricted zones, process recipes and operator commands.
6. Environmental protection: addresses radiant heat, steam or vapor, splash, corrosion, scale, water drainage, oil mist, cable routing, enclosure selection and maintenance access.

Load and Orientation

Minimum, typical and maximum gross load; dimensions; center-of-gravity range; vertical or horizontal orientation; single or multiple pickup points; fixture mass and retained liquid.

Transfer and Immersion Time

Furnace-door release to bath entry, travel distance, required lowering profile, entry depth, dwell, agitation interaction, withdrawal speed and drainage time.

Temperature and Exposure

Workpiece temperature at pickup, furnace opening duration, radiant-heat map, steam or vapor plume, splash envelope and measured temperatures at ropes, brakes, motors, sensors and panels.

Bath and Medium

Tank length, width, depth and freeboard; water, polymer, brine or oil; operating temperature; agitation; covers; overflow; ventilation; fire strategy; drainage and contamination controls.

Duty and Availability

Lifts per hour, starts and reversals, shifts, annual hours, load spectrum, required production availability, maintenance windows and the consequence of an interrupted batch.

Power Loss and Recovery

Safe load state, controlled lowering or lifting, emergency power source, brake behavior, manual recovery, tank access and the permitted response at each point in the process cycle.

Building and Runway

Rail-center span, runway length and elevation, available headroom, hook approaches, wheel-load limits, furnace and tank obstructions, ventilation ducts and installation access.

Controls and Acceptance

Cabin, radio or automatic operation; positioning tolerance; anti-sway; recipe signals; traceability; safe zones; FAT, SAT and representative-load test criteria.

A useful performance specification describes the entire motion from furnace pickup to bath exit. It states when timing begins, the path and acceleration limits, the liquid-entry point, the required immersion depth, permitted swing, dwell time, withdrawal profile and the condition in which the load may travel again. A single maximum hoist speed does not prove that the cycle can be achieved.

1. Pickup and confirmation: verify fixture engagement, gross load and permission to leave the furnace zone.
2. Transfer: use the approved bridge, trolley and hoist profile while controlling sway and clearance.
3. Immersion: transition to the specified lowering mode and reach the defined depth within the treatment window.
4. Bath dwell: hold or move the load only as permitted by the recipe, tank agitation and fixture design.
5. Withdrawal and drainage: recover at the defined speed, stop at the drainage position and contain liquid before travel.
6. Completion and traceability: release the route only after the load, tank and downstream station meet the agreed conditions.

Oil Quenching Requires a Site-Specific Fire Review

Oil type, flash characteristics, bath temperature, vapor control, ignition sources, fire detection, suppression, ventilation and emergency procedures are defined by the process owner and applicable local requirements. Electrical-area classification and equipment selection follow that review; they should not be assumed from the word “oil” alone.

The crane supply boundary should state who provides the tank cover, ventilation, fire system, process sensors, emergency power, cable interfaces, containment and final integrated test.

Baskets and Racks

Define empty and loaded mass, support points, deformation limits, liquid flow, drainage, center of gravity, maximum temperature and positive engagement.

Lifting Beams and Spreaders

Confirm hook spacing, headroom, load equalization, hot-zone exposure, proof testing, storage position and compatibility with every approved load family.

Tongs and Clamps

Establish the gripping principle, acceptable surface contact, engagement confirmation, loss-of-force response and behavior at process temperature.

Vertical Lifting Fixtures

Control long-load alignment, lateral stability, tank clearance and pickup verification through the full lift and immersion depth.

Dual-Point Suspension

Specify capacity split, permitted tilt, synchronization tolerance, load sharing, reeving behavior and the response to unequal motion or sensor loss.

Attachment Changeover

Plan storage, identification, mechanical and electrical connections, interlocks, inspection status and the process for preventing the wrong attachment selection.

Interface Matrix

Every exchange with the furnace, door, tank cover, agitation system, ventilation, process controller and plant network should identify the signal owner, permissive condition, timeout, fault reaction, reset authority and safe state. Automatic travel should be blocked when equipment is not in the agreed position.

Remote access, event records, user permissions and network segregation are agreed with the plant’s operational technology policy. Automation scope includes the practical means to recover a load after a sensor, communication or drive fault.

Design Review

Approved load cases, mechanism classification, fatigue basis, runway reactions, motion profile, attachment, heat and environmental map, failure analysis and interface schedule.

Factory Testing

Material and fabrication records, dimensional checks, mechanism and brake tests, panel and software checks, simulated I/O, alarms, limits and document review under the agreed inspection plan.

Site Acceptance

Installation and alignment checks, proof and functional tests, representative fixture or load trials, process sequence, emergency response, interfaces, recovery, training and handover documents.

Workpiece and Fixture

Minimum, normal and maximum mass and dimensions; material; temperature at pickup; center of gravity; orientation; basket, rack, spreader or clamp data; drawings and photographs.

Treatment Cycle

Furnace pickup point, route, maximum transfer time, immersion depth and profile, dwell, agitation, withdrawal, drainage, destination, cycles per hour and load spectrum.

Tank and Environment

Bath medium and temperature; tank dimensions and freeboard; covers and agitation; vapor, splash and ventilation; furnace and ambient heat data; corrosion and fire strategy.

Workshop and Runway

Rail-center span, runway length and elevation; required lift; headroom; approaches; rail and beam data; wheel-load limits; cross-section, equipment layout and installation access.

Controls and Emergency Strategy

Manual, assisted or automatic mode; positions and tolerances; interface signals; cameras; anti-sway; power-loss response; emergency source; recovery access and safe states.

Commercial and Compliance Scope

Destination, power supply, standards, inspection route, Incoterm, freight, installation, electrification, commissioning, testing, training, spares, documentation and warranty requirements.

Is a heat treatment crane the same as a quenching crane?

A quenching crane is one type of heat treatment crane. It is specifically engineered for timed immersion and recovery. Heat-treatment handling can also include furnace transfer, tempering, annealing and cooling operations without rapid immersion.

How is heat treatment crane capacity calculated?

Start with the heaviest workpiece and add the basket, fixture, beam, rigging, hook block, retained liquid and every suspended accessory. Then evaluate eccentric loading, multi-point load sharing, dynamic motion and abnormal cases.

Can a standard overhead crane perform quenching?

Only if a dedicated engineering review confirms the complete process. Immersion time, hoist profile, brakes, power-loss response, thermal exposure, vapor, splash, corrosion, fixture, clearance and duty can require a purpose-built system.

Which quenching media can the crane serve?

Water, polymer solution, brine and oil can be considered. Each medium creates different vapor, splash, corrosion, contamination, ventilation and fire conditions, so the bath data and site risk assessment are required.

How much does a heat treatment crane cost?

Specialist suppliers normally quote by project, and the September 2026 public review found no dependable like-for-like numeric price. Capacity, immersion performance, attachment, environment, redundancy, automation, runway and installed scope must be defined first.

What happens if power fails during quenching?

The required response is defined for every cycle stage. Depending on the risk assessment, the solution may use emergency power, selected redundant functions, controlled recovery and a documented manual procedure.

Can the crane integrate with furnaces and tank controls?

Yes. Integration can include door, cover and agitation interlocks, route permissions, load identification, recipe selection, position confirmation, event records and plant-system communication under an approved functional specification.

What should be tested before handover?

Tests cover rated and proof loads, brakes, limits, overspeed and overload functions, process motion, positioning, attachment, interfaces, safe states, emergency response, manual recovery and representative treatment sequences.

Quenching Crane
Heat-Treatment Process System