分类： Selection Guides

PROCESS AREAS

Pretreatment, Zinc Kettle, Cooling & Finishing

HANDLING DUTIES

Transfer, Immersion, Tilting, Drainage & Maintenance

DESIGN CONDITIONS

Corrosive Fumes, Heat, Moisture & Cyclic Duty

PRICE BASIS

Engineered Project Quotation

01 · Single-Girder Process Crane

A compact bridge with one or two hoists for moderate suspended loads, shorter spans and defined production cycles. Hoist synchronization, service access, corrosion protection and the required duty class must be verified before selecting this lower-self-weight arrangement.

02 · Double-Girder Process Crane

A robust platform for longer spans, frequent cycles, higher suspended loads, service walkways and process-specific trolley arrangements. It provides greater flexibility for automation, redundant positioning feedback and maintainable component layouts.

03 · Twin-Hoist or Twin-Trolley Crane

Two lifting points stabilize long workpieces and support controlled entry, withdrawal and drainage angles. The control system defines synchronized lifting, permitted differential height, restricted independent motion and fault recovery.

04 · Automated Galvanizing Transport System

One or more cranes execute recipe-based routes using position feedback, tank handshakes, inter-crane zoning, production tracking and controlled recovery modes. The crane, line PLC and supervisory-system boundaries are defined before quotation.

05 · Cantilever Zinc-Pot Crane

A project-defined cantilever extends hook coverage beyond the normal bridge envelope for empty-pot handling, furnace-area service and equipment maintenance. It is not automatically a substitute for the production transport crane.

06 · Loading, Finishing and Maintenance Crane

A single- or double-girder overhead crane for racking, unloading, inspection, component removal and workshop service. Environmental protection is selected for its actual zone, while process-crane features are included only when the duty requires them.

Match the Crane to the Galvanizing Process Area

A plant-wide handling study records every pickup point, tank coordinate, dwell time, travel route, attachment, restricted zone and line interface. It also separates loading, production and maintenance duties that cannot share one machine because of environmental exposure, incompatible working envelopes or required availability.

For the pretreatment tanks, the study addresses corrosive vapor, liquid carryover, drainage, tank-rim clearance and fume-extraction interfaces. For molten-zinc immersion, it defines slow process speed, load angle, withdrawal profile, drip route, heat exposure, cover permissions and the safe position for abnormal recovery.

Loading, cooling and unloading areas require stable handover, product identification and safe interaction with operators. Pot replacement and furnace maintenance require a separate component-weight schedule, removal route, outreach, shutdown plan and verified set-down points.

Controlled Immersion and Drainage

Variable-frequency hoisting, slow process speed, position feedback and defined approach zones support controlled entry and withdrawal. Twin lifting points require permitted differential height, maximum angle and a documented recovery sequence.

Chemical and Corrosion Protection

Coating systems, protected cavities, corrosion-resistant hardware, sealed bearings, suitable ropes or chains, cable materials and maintainable inspection points are selected from the measured exposure in each process zone.

Heat and Fume Exposure

Heat shields, equipment separation, protected cable routing, ventilation and component temperature ratings are coordinated with the dryer, kettle, enclosure and extraction system rather than assigned from a generic ambient temperature.

Electrical and Control Protection

Enclosures, anti-condensation heating, protected electrification, control cabinets and network hardware are located and rated for the verified humidity, vapor and temperature. Explosion protection is supplied only where formal area classification requires it.

Load, Motion and Collision Safety

Overload limiting, brakes, operating and final limits, attachment confirmation, buffers, anti-derailment measures, fixed-obstacle zones, inter-crane separation and tank-occupancy logic form one coordinated protection architecture.

Access, Isolation and Acceptance

Guarded access, maintenance platforms, isolators, lockout provisions, emergency stops, safe-state logic and manual recovery are verified through functional tests, load tests, interlock trials and fault-recovery demonstrations.

Galvanizing Line Crane Automation and Process Integration

Manual, assisted, semi-automatic and fully automatic operating concepts are available. The correct level depends on product variety, route stability, required throughput, tank demand, operator-access restrictions, traceability and the production consequence of a crane becoming unavailable.

An automated system can manage product identification, recipe association, station sequence, dwell time, approach speed, immersion and withdrawal profiles, drain position, crane separation, buffer priority and alarm history. Tank-ready signals, covers, extraction status, doors and attachment confirmation can be used as process permissions.

The quotation should define the boundary between crane PLC, line PLC, supervisory system, tank equipment, extraction system and production database. Signal lists, network protocols, safe states, manual overrides and restart procedures must be agreed before software development and factory testing.

Design Basis

Approved load schedule, process route, duty calculations, general arrangement, lifting-device envelope, wheel loads, exposure zones, code matrix and responsibility boundary.

Control Documentation

Electrical diagrams, PLC and network architecture, operating modes, I/O schedule, interlock matrix, alarms, safe states, recovery logic and plant communications.

Manufacturing Records

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

Factory Acceptance

Drive, brake, limit, overload, alarm and interlock tests; synchronized-hoist functions; control modes; communications; simulated recipes and purchaser witness points.

Site Readiness

Confirm runway survey, rail elevation, building reserve, erection route, tank and kettle coordinates, extraction interfaces, power, network, access controls and shutdown windows.

Installation

Bridge and trolley assembly, rail and conductor checks, lifting-device integration, sensor alignment, control cabinets, utilities and line-network connections follow approved method statements.

Commissioning

Testing progresses from no-load motion and safety devices to proof testing, positioning calibration, synchronized lifting, signal checks, dry recipe simulation and controlled process trials.

Lifecycle Support

Training covers operation, attachment handling, isolation, alarms and recovery. Preventive maintenance addresses mechanisms, controls, electrification, coatings, enclosures and sensors exposed to the process environment.

Crane Equipment

Bridge, trolleys, hoists, motors, brakes, wheels, platforms, access and power collection.

Process Handling

Crossbeams, racks, baskets, chains, synchronized lifting, tilting and attachment confirmation.

Protection and Controls

Coatings, sealed components, VFDs, PLC, positioning, interlocks, sensors and plant communications.

Project Services

Engineering, documents, FAT, packing, freight, installation, commissioning, trials and training.

01 · Plant and process scope

New line, expansion or modernization; loading, pretreatment, kettle, cooling, finishing or maintenance duty; required throughput and crane role.

02 · Building and runway

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

03 · Loads and attachments

Workpiece range, racks, baskets, crossbeams, chains and hooks; maximum suspended mass, dimensions, center of gravity and lifting points.

04 · Tank line and handling route

Tank and kettle coordinates, covers, ducts, pickup and discharge points, route variants, buffers, obstacles and restricted zones.

05 · Process performance

Immersion and withdrawal profile, drain angle, dwell times, speeds, positioning accuracy, cycles, shifts and availability target.

06 · Environmental conditions

Chemicals, concentrations, vapor, humidity, condensation, temperatures, fumes, wash-down, altitude and area classification.

07 · Controls and interfaces

Manual or automatic modes, recipes, line PLC, supervisory system, network protocol, covers, doors, extraction and station sensors.

08 · Power, standards and acceptance

Voltage, frequency, destination, governing crane and electrical standards, inspection authority, FAT, load test and process trials.

09 · Delivery and site scope

Destination, trade term, packing, freight, runway, electrification, installation, commissioning, local labor, training and production support.

10 · Schedule and lifecycle

Required delivery date, shutdown window, documentation language, recommended spares, maintenance capability and service expectations.

Can a standard overhead crane be used on a galvanizing line?

A general crane may serve a clean loading or maintenance area after verification, but a process crane requires protection and controls selected for chemicals, humidity, heat, fumes, cycle frequency, attachments and immersion movements.

How is the required crane capacity calculated?

Use the maximum combined mass of the workpiece, rack or crossbeam, chains, hooks, lifting devices and retained process liquid or zinc, then apply the required engineering and regulatory allowances.

Why are two hoists used on some galvanizing cranes?

Two lifting points can stabilize long loads and permit a controlled entry, withdrawal and drainage angle. The controls must define synchronized operation, permitted differential height and fault response.

Is full automation necessary?

No. Manual control suits flexible or lower-output plants, semi-automation provides controlled station movements, and full automation is appropriate where repeatable recipes, throughput and restricted access justify the integration.

What corrosion protection is required?

The protection system depends on measured exposure by zone. It may include specialized coatings, sealed components, corrosion-resistant hardware, protected electrification, anti-condensation measures and remote control cabinets.

Does a galvanizing line crane need explosion protection?

Only where a formal hazardous-area classification and applicable local standard require it. The process and chemicals should be reviewed by the plant designer before electrical equipment is specified.

Can the crane communicate with the galvanizing line PLC?

Yes. The project can include station requests, tank-ready signals, cover and extraction status, job identification, recipe data, alarm exchange and production tracking through an agreed protocol.

What determines the number of cranes?

The answer depends on route timing, dwell times, simultaneous tank demand, crane travel distances, queues, maintenance strategy and the production impact of one crane becoming unavailable.

Why do galvanizing line crane quotations vary widely?

The supply may range from a bridge and hoist to a complete process system with synchronized lifting, attachments, corrosion protection, PLC control, line interfaces, documents, freight and site services.

What should be demonstrated before final acceptance?

Verify safety devices, load performance, positioning, synchronization, line interlocks, recipe sequences, alarms, manual recovery, fault recovery, documentation and operator-maintenance training.

SUPPORT ARRANGEMENT

Independent Floor-Mounted Runway

WORKING COVERAGE

Rectangular Crane Bay

BRIDGE OPTIONS

Single or Double Girder

COMMERCIAL BASIS

Project-Configured Quotation

Production and Assembly Cells

Dedicated lifting over machining, fabrication, assembly, testing and packing stations without transferring crane reactions into the building roof.

Existing Industrial Buildings

Facilities without an approved crane runway or with building steel that cannot accept the required vertical and horizontal crane loads.

Warehousing and Maintenance

Controlled handling of machinery, dies, components, maintenance assemblies and stored equipment across a rectangular service area.

Leased or Adaptable Facilities

Independent support can limit modifications to the main building, subject to permission for anchors, foundations, services and the complete installed structure.

Crane Bays Inside Larger Workshops

A defined lifting zone can operate below or beside other facility equipment when elevations, interferences and operating boundaries are coordinated.

New Process Areas

Independent runway systems for new production lines where crane coverage, column spacing and material flow can be planned together.

01 / LOAD

Capacity and Load Geometry

Rated capacity includes the lifted item and below-the-hook attachment. Load dimensions, centre of gravity, pickup method and potential side loading affect system design.

02 / COVERAGE

Hook Envelope and Approaches

Runway gauge, bridge travel, hook approaches, lifting height and obstructions determine usable coverage rather than the outside steel dimensions alone.

03 / STRUCTURE

Columns, Bracing and Foundations

Column spacing must suit equipment routes and floor activity. Base plates, anchors, bracing and concrete support are verified from crane reactions and site conditions.

04 / DUTY

Operating Cycle and Motion

Lifts per hour, shifts, load spectrum, travel distance, positioning tolerance and process criticality establish mechanism duty and motion-control requirements.

05 / CLEARANCE

Headroom and Building Interfaces

Roof steel, lights, ducts, doors, sprinklers, conveyors, racks and other cranes must remain outside the required structural and operating envelope.

06 / ENVIRONMENT

Site Conditions and Compliance

Indoor or outdoor exposure, temperature, dust, corrosion, hazard classification, seismic conditions and applicable rules must be defined before configuration.

Runway Columns, Bracing and Foundations

The support structure controls crane alignment, stability and load transfer. Runway beams and rails must maintain the geometry required by the bridge end carriages. Columns and bracing must resist vertical wheel reactions and the horizontal forces produced by travel, acceleration, braking, skewing and operating conditions.

Column positions are coordinated with machines, aisles, vehicle routes, doors, storage and emergency access. Bracing locations must remain compatible with the working floor. Where cross-bracing would interfere with operations, an alternative structural arrangement may be evaluated within the applicable design limits.

Foundation responsibility must be stated in the quotation. Existing slab thickness alone does not confirm adequacy. Concrete strength, reinforcement, slab condition, subgrade, anchor edge distances and calculated reactions must be reviewed by the responsible structural parties.

Usable Hook Coverage

End approaches, trolley limits, conductor arrangements and physical end stops reduce hook coverage from the outside runway footprint. Required pickup and deposit points must be plotted before final sizing.

Available Headroom

Column height, runway elevation, bridge depth, hoist headroom and upper clearances establish the highest hook position. A low-headroom arrangement may require a different bridge or trolley configuration.

Overhead and Floor Interfaces

The crane envelope is coordinated with roof trusses, lights, sprinklers and services, while independent columns are coordinated with production equipment, racks, forklifts and pedestrian routes.

Hoisting Mechanism

Electric chain hoists can suit selected light workstation duties. Wire-rope electric hoists or engineered trolley mechanisms are evaluated for industrial capacities, longer lifts, higher duty and process requirements.

Bridge and Trolley Travel

Manual movement may suit certain light enclosed-track systems. Motorized travel is configured where load, span, runway length, duty, production rate or positioning requirements make powered motion appropriate.

Controls and Variable Speed

Pendant or radio control can be specified. Variable-frequency control may support smoother acceleration, controlled approach, reduced load swing and more consistent positioning where the application requires it.

Crane Protection

• Upper and lower hoisting limits as specified
• Overload protection for the selected hoisting arrangement
• Travel end stops and buffers appropriate to the system
• Emergency stop and electrical protective functions

Runway and Support Control

• Defined wheel reactions and horizontal design forces
• Rail alignment, elevation and span tolerances
• Column, bracing, base-plate and anchor verification
• Foundation and concrete responsibility established by contract

Operating Area

• Clear separation from doors, racks and moving vehicles
• Accessible inspection and maintenance positions
• Control visibility matched to the load route
• Site procedures for operation, isolation and inspection

Crane Equipment

• Bridge girder or girders and end carriages
• Hoist, trolley and selected controls
• Crane electrification and travel components
• Specified protection, limits, buffers and accessories

Independent Runway System

• Runway beams, rails and rail attachments
• Columns, base plates and agreed bracing
• Anchor bolts when included in the supply
• Main power feed along the runway when specified

Site and Project Services

• Foundation design and construction as contractually assigned
• Freight, unloading, erection and access equipment
• Incoming electrical supply and site connections
• Commissioning, testing and operator instruction as agreed

Manufacturing, Inspection and Documentation

Manufacturing begins after approval of the technical configuration, interfaces and commercial scope. Bridge and runway components are produced against the agreed drawing package, with material, fabrication, dimensional, mechanical and electrical controls assigned through the manufacturing plan.

• General arrangement drawings and principal interface dimensions
• Calculated crane reactions for structural coordination
• Electrical diagrams and equipment information within the agreed package
• Inspection and test records required by the contract
• Operating and maintenance documentation for the supplied equipment

Manufacturing facilities and production scenes are available in the Henan Mine Crane factory display.

01

Site Verification

Floor plan, elevations, concrete conditions, access routes, electrical services and obstructions are confirmed before installation.

02

Support Erection

Columns, bracing, runway beams and rails are erected, aligned and secured to the approved foundation or concrete arrangement.

03

Crane Installation

Bridge, hoist, power feed, controls and safety components are installed after runway geometry and access conditions are accepted.

04

Commissioning

Functional checks, agreed tests, control verification and documentation support formal handover of the installed system.

05

Lifecycle Maintenance

Inspection access, lubrication points, wearing parts, rail condition, anchors and structural connections are included in the maintenance plan.

Load and Operation

• Maximum and typical lifted loads
• Load dimensions and attachment weight
• Lifts per hour and operating shifts
• Required speeds and positioning performance

Coverage and Structure

• Required span, runway length and hook positions
• Lifting height and available overhead clearance
• Permitted column and bracing locations
• Concrete, foundation or soil information

Site and Commercial Scope

• Power supply and control preference
• Environment and destination requirements
• Project location and delivery term
• Required freight, installation and commissioning services

Single-Girder Overhead Crane

Electric-hoist bridge crane for general manufacturing, warehousing and maintenance duties.

Double-Girder Overhead Crane

Two-girder structure for demanding duty, alternative trolley layouts and defined lifting envelopes.

LX Suspension Overhead Crane

Underhung single-girder arrangement for compatible runway and support conditions.

Frequency-Conversion Overhead Crane

Electric-hoist crane with controlled travel characteristics for industrial material handling.

5 Ton Overhead Crane

Five-ton bridge crane configurations for defined spans, duties and operating environments.

All Overhead Crane Products

Compare general-purpose and special-purpose overhead crane configurations from Henan Mine Crane.

CONFIGURATIONS

Double or Four Girder

LISTED PRODUCT RANGE

5–500 t, Model-Dependent

WORKING CLASS

A6–A8, Model-Dependent

PRIMARY APPLICATION

Ladle Transfer and Pouring

Ladle Transfer

Carry molten-metal ladles between furnace, refining, treatment, pouring and casting stations along a defined process route.

Controlled Pouring

Coordinate main and auxiliary hooks for ladle tilting where the pouring method, attachment and operating procedure permit.

Furnace and Charge Handling

Support furnace charging, material-box handling and selected hot-process operations with the correct attachment and protection package.

Foundry Maintenance

Handle moulds, furnace components and production equipment when the selected crane and attachment are approved for the additional load cases.

01 / RATED LOAD

Complete Suspended Load

Include liquid metal, ladle and refractory lining, ladle beam or gantry hook, rigging and all allowances required by the selected design basis.

02 / LADLE INTERFACE

Trunnions and Attachment

Define trunnion diameter, centre distance, ladle envelope, pickup clearance, allowable rotation and the geometry of the plate hook or lifting beam.

03 / PROCESS ROUTE

Furnace-to-Pour Path

Establish pickup and placement elevations, transfer distance, obstacles, restricted zones, ladle-car interfaces, pouring points and emergency set-down positions.

04 / DUTY

Load Spectrum and Cycle

State heat schedule, lifts per hour, percentage of lifts near rated load, travel distances, operating hours, production criticality and required design life.

05 / ENVIRONMENT

Heat, Dust and Splash

Record ambient and radiant temperatures, exposure duration, dust concentration, corrosive fumes, splash risk and required enclosure and insulation levels.

06 / SAFETY BASIS

Defined Failure Response

Specify the required response to power loss, motor or gearbox fault, brake fault, overspeed, overload, upper-limit activation and control-system interruption.

07 / RUNWAY

Building and Rail Interface

Verify wheel loads, horizontal reactions, rail section and alignment, column and bracket capacity, thermal environment, clearances and erection access.

08 / CONTROL AND SCOPE

Operation and Project Boundary

Define cabin, remote or automatic control, sightlines, speed ranges, process interlocks, power supply, governing standard, inspection plan and installation responsibility.

1. Secure Ladle Engagement

The gantry-type plate hook or ladle beam engages both trunnions within the defined clearance envelope. Attachment geometry must control seating, disengagement risk, side loading and inspection access.

2. Stable Vertical Lift

The main hoist raises the complete suspended load with controlled acceleration. Reeving symmetry, drum arrangement, brake control and low-speed capability influence ladle stability.

3. Controlled Cross and Long Travel

Trolley and bridge drives transport the ladle through the approved route. Variable-frequency control, defined approach speeds and interlocks can reduce abrupt motion near furnaces, ladle cars and pouring stations.

4. Pouring or Safe Placement

Where the process requires crane-assisted pouring, the auxiliary hook and ladle arrangement are evaluated as one system. Normal placement and emergency set-down locations are defined before controls and operating procedures are finalized.

Operator Cabin

An enclosed, thermally protected cabin provides a stable operating position for long travel and continuous foundry duty. Sightlines, glazing, access, ventilation and emergency egress require project review.

Remote or Automatic Control

Radio remote, remote station or automatic operation can be evaluated when visibility, exclusion zones, communications, risk assessment and process interlocks support the selected method.

Drive and Motion Control

Variable-frequency drives, low-speed approach, controlled acceleration and coordinated bridge drives support stable transfer. Required speeds follow cycle-time and ladle-stability calculations.

Condition and Safety Monitoring

Load, brake state, motor temperature, cabinet temperature, limits, travel position and selected drivetrain conditions can be monitored, alarmed and recorded within the agreed control scope.

Engineering Package

• Design criteria and duty classification basis
• General arrangement, hook coverage and clearance drawings
• Wheel loads and runway reaction schedule
• Safety-function and control-system narrative

Manufacturing Controls

• Material identification and agreed certificate review
• Welding procedure, inspection and dimensional verification
• Drum, sheave, rope, brake and wheel alignment checks
• Heat shielding, cab and electrical enclosure inspection

Testing and Handover

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

Shipment and Site Readiness

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

Erection and Alignment

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

Commissioning and Acceptance

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

Lifecycle Maintenance

Inspection plans address ropes, sheaves, drums, hooks, ladle attachments, brakes, wheels, rails, heat shields, cabins, electrical equipment and safety functions based on duty and condition.

Double-Girder Casting Crane

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

Four-Girder Casting Crane

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

Metallurgical Bridge Crane

High-duty overhead crane family for project-specific hot-metal and metallurgical operations.

YX Metallurgical Bin Crane

Material-box crane for furnace charging, bin lifting and controlled tipping in smelting plants.

Quenching Crane

Fast-response process crane for immersing and withdrawing hot components during heat treatment.

Slab Handling Crane

Special metallurgical crane for solid slab, billet, stacking and steel-product handling.

SYSTEM FAMILY

Overhead, Underhung or Gantry

RATED CAPACITY

Defined by Maximum Lifted Load

LAYOUT BASIS

Bay, Runway and Process Route

PRICE BASIS

Project-Specific Quotation

Production Handling

Movement of workpieces between machining, welding, assembly, inspection and dispatch stations.

Equipment Assembly

Controlled positioning of frames, modules, molds, fixtures, engines and large machine components.

Plant Maintenance

Planned removal and replacement of motors, pumps, dies, rollers and production-line equipment.

Internal Logistics

Transfer between receiving, buffer storage, process cells and outbound staging without occupying floor aisles.

01 / LOAD

Maximum Load and Attachment

Record the heaviest regular and occasional loads, dimensions, center of gravity, pick points and the mass of hooks, beams, magnets, grabs or fixtures.

02 / PROCESS

Travel Path and Coverage

Map loading points, machines, assembly positions, storage areas, obstructions, restricted zones and required hook approaches throughout the bay.

03 / DUTY

Cycles and Load Spectrum

Define lifts per hour, operating hours, typical load distribution, travel distances, starts, inching demand and expected service life.

04 / GEOMETRY

Span, Lift and Headroom

Confirm rail span, highest load position, floor-to-rail elevation, roof clearance, end approaches and hook side-approach requirements.

05 / STRUCTURE

Building and Runway Capacity

Verify column spacing, brackets, roof steel, runway beams, rail condition, wheel-load limits, deflection criteria and foundation capacity.

06 / ENVIRONMENT

Indoor Operating Conditions

State temperature, humidity, dust, fumes, corrosive agents, hazardous-area classification, washdown exposure and any hot-material duty.

07 / MOTION

Speed, Control and Accuracy

Specify required lifting and travel speeds, positioning tolerance, anti-sway needs, radio control, cabin operation and automation interfaces.

08 / SCOPE

Standards and Project Boundary

Define applicable standards, runway responsibility, power supply, freight terms, erection, commissioning, load testing, training, spares and documentation.

Machining and Fabrication

Cranes transfer plate, structural sections, fixtures and workpieces between cutting, machining, welding and inspection areas. Hook approaches and travel routes are coordinated with machine envelopes and safe access zones.

Assembly and Positioning

Variable-speed drives, low-speed hoisting and suitable below-the-hook devices support controlled alignment of frames, modules, dies and mechanical assemblies.

Maintenance and Tool Change

Maintenance coverage can include production machinery, utilities and service pits. Occasional heavy lifts still govern rated capacity, even when daily loads are lighter.

Receiving and Dispatch

End approaches, building doors and loading areas are considered so material can move efficiently between transport, staging and production without unsafe cross-traffic.

Wire-Rope Hoist or Open-Winch Trolley

Compact electric wire-rope hoists suit many general workshop duties. Open-winch trolleys support heavier capacity, higher duty, greater lifting height, redundant arrangements and specialized process requirements.

Variable-Frequency Motion

Variable-frequency drives can provide controlled acceleration and deceleration, low-speed positioning and reduced load swing. Speed ranges are selected from process cycle and control requirements.

Operator Interface

Pendant control supports close-range handling; radio remote control improves mobility and viewing position; a cabin can suit intensive or elevated operations. Control mode follows the risk assessment and operating procedure.

Monitoring and Automation

Available functions can include load display, operating-hour records, fault diagnostics, restricted zones, position feedback, anti-sway logic and data exchange with plant control or manufacturing systems.

Lifting Protection

Upper and lower travel limits, overload protection, brake monitoring where specified and rope-guidance provisions.

Travel Protection

End limits, buffers, rail sweeps, audible or visual warnings and anti-collision functions for multiple cranes.

Electrical Protection

Main isolation, emergency stop, phase and circuit protection, earthing and enclosure ratings matched to the site.

Maintenance Access

Service platforms, guarded access, lighting, inspection points and maintainable component arrangement where required.

ENGINEERING

Design Input Review

Load cases, classification, crane geometry, wheel reactions, power, controls and building interfaces are reviewed before detailed design.

FABRICATION

Controlled Manufacturing

Material traceability, cutting, welding, dimensional inspection, machining, assembly and coating follow the approved manufacturing plan.

TESTING

Inspection and Functional Checks

Dimensional checks, electrical inspection, mechanism operation, limit functions and specified factory tests are recorded before dispatch.

DOCUMENTATION

Project Document Package

Approved drawings, data sheets, component information, manuals, certificates and test records are supplied as defined by the contract.

Pre-Installation Verification

Runway span, rail alignment, elevation, clearances, power availability, erection access and lifting resources are confirmed before assembly begins.

Erection and Commissioning

The agreed scope can cover assembly guidance, mechanical alignment, electrical connection, functional checks, commissioning, load testing and operator or maintenance training.

Planned Maintenance

Inspection intervals reflect operating duty, local regulations and component instructions. Brakes, ropes, hooks, wheels, rails, fasteners, lubrication, electrical protection and limit devices require documented attention.

Lifecycle Support

Recommended commissioning spares and operating spares can be quoted with the crane. Accurate equipment identification supports future parts supply and technical service.

Crane Equipment

Bridge or gantry structure, hoist or trolley, end carriages, drives, electrical equipment, controls and selected safety functions.

Supporting Infrastructure

Runway beams, columns, rails, foundations, conductor system, access platforms, building modifications and plant power interfaces.

Delivery and Site Work

Packing, inland transport, ocean freight, insurance, import charges, erection resources, commissioning, testing and training.

Which crane type is most suitable for a general workshop?

A single-girder top-running overhead crane is often suitable for general light and medium production duties. Capacity, span, duty and building support must still be verified. Double-girder, underhung or gantry designs may be more appropriate under different conditions.

How is factory crane capacity selected?

Rated capacity must cover the maximum lifted load and any lifting attachment included in the suspended mass. Load geometry, center of gravity, dynamic effects and occasional maintenance lifts also require consideration.

Can an overhead crane be installed in an existing factory?

Installation is possible when dimensions, clearances, runway condition and structural capacity are verified. If the building cannot support the calculated reactions, an independent runway or gantry arrangement can be evaluated.

What information is needed to confirm crane span?

Crane span is normally based on the verified center-to-center distance between runway rails. Building width alone is insufficient. Rail geometry, end clearance and hook approaches are also required.

When is a double-girder workshop crane required?

Double-girder construction is commonly evaluated for heavier loads, wider spans, higher operating duty, greater lifting height, maintenance platforms or specialized trolley and attachment arrangements.

What is the difference between an underhung crane and a top-running crane?

An underhung crane travels on the lower flange of a suspended runway, while a top-running crane travels on rails above the runway beams. Capacity, span, approach, building reactions and headroom differ between the systems.

Can one crane serve several production machines?

One overhead crane can serve multiple stations within its hook coverage when travel routes, machine clearances, cycle demand and scheduling are compatible. Overlapping cranes or local lifting devices may be required for simultaneous operations.

Does a crane quotation include the runway and installation?

Not automatically. Crane equipment, runway steel, rails, electrification, freight, erection, commissioning and load testing can be separate scope items. The commercial schedule should state every inclusion, exclusion and interface.

Can workshop cranes use radio remote control?

Radio remote control can be specified for many workshop cranes. The final control concept considers operator visibility, emergency controls, interference management, backup operation and site safety rules.

How can comparable factory crane quotations be evaluated?

Compare rated load, span, duty, speeds, motor and brake data, structural weights, wheel loads, electrical brands, safety functions, runway scope, documentation, testing, freight terms, installation and lifecycle parts support.

Single-Girder Bridge Crane

Economical full-bay handling for general manufacturing, fabrication and maintenance duties.

Electric Single-Girder Overhead Crane

Compact electric-hoist configuration for workshops requiring efficient headroom and smooth handling.

Double-Girder Bridge Crane

Higher-capacity and higher-duty solution for demanding production and maintenance operations.

Multi-Support Underhung Crane

Suspended runway arrangement for wide workshop coverage with reduced floor obstruction.

Intelligent Electric Hoist Overhead Crane

Controlled-motion crane platform for production monitoring, positioning and plant integration requirements.

Double-Trolley Electric Hoist Crane

Two-point lifting solution for long assemblies, coordinated handling and controlled load orientation.

FULL NAME

Electric Overhead Travelling

POWERED MOTIONS

Hoist, Cross Travel and Long Travel

BRIDGE OPTIONS

Single or Double Girder

SELECTION INPUTS

Capacity, Span, Lift and Duty

Hoisting: Raise and Lower

The hoist motor, transmission, rope drum and hook system lift the suspended load. Required hook travel and handling accuracy guide the hoist arrangement and speed selection.

Cross Travel: Across the Bay

The trolley or travelling hoist moves along the bridge. This motion reaches pickup and placement points across the span, within the hook’s side approaches.

Long Travel: Along the Bay

Powered end carriages move the bridge along its runways. Runway length, end stops and crane dimensions determine the usable longitudinal coverage.

01 / LOAD

Define the Lift

Provide the maximum load, typical load, dimensions and lifting points. Include the weight and arrangement of slings, lifting beams or other attachments when defining the required lifting capacity.

02 / SPACE

Check the Building

Supply a plan and cross-section showing runway spacing, runway elevation, roof members, columns and services. For existing facilities, identify obstructions and the condition of the supporting structure.

03 / DUTY

Describe the Work Cycle

List lifts per hour, travel distances and operating shifts. An assembly crane making occasional heavy lifts and a production crane handling loads repeatedly can require different mechanisms despite the same rated capacity.

04 / CONDITIONS

Define the Environment

State indoor or outdoor operation, temperature, dust, humidity and corrosion exposure. Hazardous atmospheres, hot loads and process attachments need their own equipment and protection requirements.

Load Spectrum

Record how often loads are light, intermediate or close to rated capacity. Repeated near-capacity lifts create a different service requirement from occasional maximum lifts.

Mechanism Operating Time

Separate time spent hoisting, cross travelling and long travelling from the shift duration. Include repeated positioning movements, starts and any simultaneous motion required by the process.

Classification and Design Basis

Identify the applicable standard and the proposed duty for the crane and its mechanisms. Codes from different classification systems need an engineering assessment before they can be treated as equivalent.

Span and Hook Coverage

Crane span follows the runway centreline spacing. The hook cannot normally reach those centrelines because the trolley and bridge have approach limits. Check every machine, loading point and storage position on the plan.

Headroom and Lifting Height

Show the highest required hook level relative to the floor and runway. Load depth, lifting gear, crane height, roof clearance and maintenance space all affect the usable lift.

Runway Loads and Supports

Provide the proposed wheel loads, wheel spacing and applicable horizontal reactions for structural review. Existing runway beams, rails, connections and supporting columns must suit the selected crane.

Henan Mine Crane manufactures overhead lifting equipment for industrial material handling. The company’s factory facilities page shows its manufacturing workshops and crane structures.

For your EOT crane order, define the documents and inspections needed to connect the agreed specification with the delivered equipment:

• General arrangement drawing with capacity, span, hook levels, crane dimensions and runway interfaces.
• Component schedule and electrical diagrams identifying the supplied hoist, drives, controls and protection functions.
• Agreed material, fabrication and inspection records, including any specified weld examinations.
• Factory and site acceptance scope, operation and maintenance manuals, and a spare-parts list.

Agree witness points and acceptance criteria before manufacture. Any conformity documents must correspond to the ordered equipment and destination requirements.

Installation Preparation

Coordinate crane delivery with runway readiness, electrical availability, unloading access and assembly space. Identify the lifting equipment and site personnel needed for installation.

Commissioning and Handover

Agree alignment checks, control verification, protection checks and the applicable load-test scope. Identify responsibility for test loads, witnessing, records and operator familiarisation.

Maintenance Planning

Provide safe access and isolation arrangements for the hoist, ropes, brakes, wheels, drives and electrical system. Base inspection and lubrication schedules on the supplied manuals and actual duty.

What is the full form of EOT crane?

EOT stands for Electric Overhead Travelling. It describes an overhead bridge crane with electrically powered lifting and travelling motions, used to move materials within the available hook coverage.

Is an EOT crane the same as an overhead crane?

EOT is a common name for an electrically powered overhead travelling crane. “Overhead crane” is a broader description, so an enquiry should still identify the bridge arrangement, hoist, runway support and required motions.

Should a 5-ton or 10-ton EOT crane use one girder or two?

Both capacities can be considered within different arrangements. Compare required hook height, span, duty, runway loading and installed cost. The 5 Ton Overhead Crane page provides another starting point for a metric 5-ton requirement.

What is the difference between an EOT crane and an electric hoist?

The hoist is the lifting mechanism. A complete EOT crane also includes the bridge, travel mechanisms, controls and interfaces to the runway and electrical supply. Confirm which equipment is included when comparing prices.

Can an EOT crane operate continuously?

Continuous service requires a specification based on the actual load spectrum, operating time and work cycle. Girder count and rated capacity do not establish continuous-duty capability; crane and mechanism selection must cover the intended service.

Can the crane run on our existing runway?

Possibly, after surveying the runway and checking its structure, alignment and electrical interfaces against the proposed crane. Provide existing drawings and condition information, then compare wheel loads, wheel spacing, rail compatibility and clearances.

Does the quotation include installation and runway steelwork?

These items depend on the agreed scope. Identify crane equipment, rails, beams, columns, power supply, unloading, erection and commissioning separately, including responsibility for site tests and any local installation work.

Single-Girder Overhead Crane

Electric-hoist bridge arrangements for workshop transfer, assembly and maintenance.

Double-Girder Electric-Hoist Crane

Two bridge girders carrying a hoist trolley, with project-specific hook levels and interfaces.

Multi-Support Underhung Crane

Suspended lifting coverage across an engineered multi-runway building layout.

Frequency-Conversion Overhead Crane

Electric-hoist configurations with specified speed-control and monitoring options.

Double-Trolley Overhead Crane

Two lifting points for defined independent or coordinated handling tasks.

Explosion-Proof Overhead Crane

Equipment selection around a defined hazardous area and protection requirement.

PROCESS DUTIES

Scrap, Charging, Ladle, Slag & Maintenance

CRANE SYSTEMS

Magnet, Grab, Charging, Casting & Service

OPERATING DUTY

Process-Specific Heavy Duty, A7–A8 Available

PRICE BASIS

Engineered Project Quotation

01 · Scrap Yard Magnet or Grab Crane

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

02 · Scrap Charging Crane

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

03 · Ladle Transfer or Casting Crane

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

04 · Slag Pot Handling Crane

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

05 · Furnace Maintenance Crane

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

06 · Automated EAF Crane System

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

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

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

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

Double-Girder Casting Crane Range

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

Four-Girder Casting Crane Range

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

Load Path and Attachment Verification

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

Hoisting Brakes and Protective Functions

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

Furnace Charging Permissions

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

Thermal, Dust and Fume Protection

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

Controlled Motion and Collision Management

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

Emergency Set-Down and Recovery

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

Scrap Charging, Ladle Transfer and Process Automation

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

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

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

Design Basis Package

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

Safety and Control Documents

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

Manufacturing Quality Records

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

Factory and Site Acceptance

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

Runway and Site Readiness

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

Installation and Assembly

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

Commissioning and Process Trials

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

Inspection and Maintenance Strategy

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

Crane Equipment

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

Process Attachments

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

Safety and Automation

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

Project Services

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

01 · Melt-Shop Process

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

02 · Crane Responsibilities

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

03 · Maximum Gross Loads

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

04 · Load Drawings

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

05 · Building and Runway

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

06 · Stations and Clearances

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

07 · Duty and Performance

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

08 · Environment and Protection

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

09 · Controls and Compliance

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

10 · Commercial Scope

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

Is an EAF crane one specific crane type?

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

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

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

How is scrap charging crane capacity calculated?

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

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

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

When is a four-girder casting crane considered?

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

What data is needed to check furnace clearances?

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

Can EAF crane operation be automated?

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

Which standards apply to an EAF crane?

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

What determines EAF crane price?

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

Can an existing runway be reused?

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

PROCESS AREAS

Smelter, Anode Plant, Tankhouse & Maintenance

HANDLING DUTIES

Vessels, Anodes, Cathodes, Bulk Materials & Equipment

DESIGN CONDITIONS

Heat, Dust, Fumes, Corrosion & Intensive Duty

PRICE BASIS

Engineered Project Quotation

01 · Molten Copper and Vessel Handling Crane

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

02 · Charging and Bulk-Material Crane

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

03 · Anode Handling Crane

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

04 · Electrolytic Copper Tankhouse Crane

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

05 · Insulated or Special-Environment Crane

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

06 · Maintenance and Auxiliary Crane

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

Match the Crane to the Copper Process Area

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

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

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

High-Consequence Suspended Loads

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

Heat and Thermal Exposure

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

Fumes, Acid Mist and Corrosion

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

Dust and Material Containment

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

Stable Motion and Positioning

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

Operator and Maintenance Access

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

Electrolytic Copper Crane and Tankhouse Automation

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

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

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

Relevant Heavy-Metallurgy Project Reference

360-Ton Four-Girder Foundry Crane Project

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

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

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

View the 360-Ton Metallurgical Crane Project →

Design Basis

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

Control Documentation

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

Manufacturing Records

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

Factory Acceptance

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

Site Readiness

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

Installation

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

Commissioning

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

Lifecycle Support

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

Crane and Lifting Device

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

Controls and Protection

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

Delivery and Services

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

Plant Interfaces

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

01 · Plant and process area

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

02 · Building and runway

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

03 · Loads and attachments

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

04 · Process route and coverage

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

05 · Performance

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

06 · Environment

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

07 · Controls and utilities

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

08 · Compliance and acceptance

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

09 · Delivery and site scope

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

10 · Schedule and lifecycle

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

Is a copper smelter crane one standard crane model?

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

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

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

How is the crane capacity selected?

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

Can a general double-girder crane handle molten copper?

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

How is tankhouse corrosion addressed?

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

Can an electrolytic copper crane be automated?

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

Can an existing runway be retained?

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

Does every copper plant need an insulated crane?

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

Why do advertised copper smelter crane prices vary widely?

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

What should final acceptance include?

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

PROCESS AREAS

Feed, Smelting, Casting & Refining

CRANE TYPES

Grab, Bin, Casting & Maintenance

PRIMARY EXPOSURES

Heat, Dust, Fumes & Corrosion

PROJECT BASIS

Process, Load, Duty, Route & Risk

Concentrate and Flux Handling

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

Furnace Charging and Bin Transfer

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

Matte and Slag Pot Transfer

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

Blister Copper and Anode Refining

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

Anode Casting and Product Handling

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

Electrorefinery Tankhouse

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

Acid Plant and Off-Gas Systems

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

Shutdown and Major Maintenance

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

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

Process and Load Matrix

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

Production Duty

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

Load Path and Interfaces

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

Environmental Data

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

Building and Runway

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

Safety and Acceptance

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

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

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

Thermal Protection

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

Dust Management

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

Fume Exposure

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

Corrosion System

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

Tankhouse Electrical Interface

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

Hazardous Areas

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

Wheel Loads and Fatigue

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

Process Clearances

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

Runway Survey

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

Maintenance Access

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

Critical Spares Strategy

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

Erection and Outage Plan

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

Design Review

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

Manufacturing Records

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

Factory Acceptance

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

Site Acceptance

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

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

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

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

Design Basis

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

Calculation Package

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

Interface Drawings

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

Inspection and Test Plan

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

Operating Documentation

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

Commercial Schedule

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

Process and Load Data

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

Vessel and Attachment Drawings

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

Duty and Production Cycle

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

Plant Layout and Runway

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

Environment and Controls

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

Compliance and Commercial Scope

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

Which crane is used in a copper smelter?

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

Can an electromagnetic crane lift copper?

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

How is casting-crane capacity calculated?

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

Is every copper smelter crane explosion-proof?

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

What duty class is required?

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

Can an existing runway be reused?

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

How much does a copper smelter crane cost?

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

What should be tested before handover?

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

01 · Rail-Mounted Gantry Crane

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

02 · Rubber-Tyred Gantry Crane

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

03 · Container Straddle Carrier

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

04 · Container Overhead Crane

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

05 · Automated RMG or RTG System

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

06 · Intermodal and Rail Yard Crane

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

Electric and Mobile Power

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

Spreader and Load Confirmation

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

Anti-Sway and Positioning

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

TOS, RCMS and Remote Operation

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

Collision and Traffic Protection

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

Wind and Outdoor Protection

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

Design basis

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

Interface engineering

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

Manufacturing records

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

Factory acceptance

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

Before Manufacture

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

Erection and Integration

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

Commissioning and Support

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

What is a container yard crane?

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

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

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

How is container yard crane capacity specified?

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

How many container rows and tiers can one crane cover?

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

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

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

Can an RMG or RTG be automated?

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

What power options are available?

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

How is yard crane throughput calculated?

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

How much does a container yard crane cost?

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

What information is needed for a container yard crane quotation?

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

CORE CONFIGURATIONS

RTG, RMG, Straddle and Fixed Crane

CONTAINER DUTY

20 ft, 40 ft and 45 ft Containers

YARD INTERFACES

Stack, Truck, Rail and Transfer Lane

PROJECT PRIORITY

Throughput, Density and Lifecycle Cost

Annual and Peak Throughput

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

Block Geometry

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

Container and Spreader Duty

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

Mobility and Layout Stability

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

Civil and Power Infrastructure

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

Automation and TOS Interfaces

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

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

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

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

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

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

Demand Profile

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

Cycle Components

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

Operational Allowance

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

Redundancy

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

Diesel-Electric RTG

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

Hybrid or Battery RTG

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

Cable-Reel or Busbar E-RTG

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

Grid-Powered RMG

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

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

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

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

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

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

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

Load and Motion Protection

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

Collision and Traffic Control

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

Wind Management

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

Corrosion Protection

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

Access and Maintenance

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

Contract Codes

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

Taicang Port International Hub

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

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

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

View the Published Project

Technical Proposal

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

Civil Interface Data

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

Electrical and Controls

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

Quality Documentation

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

Site and Acceptance Scope

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

Lifecycle Support

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

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

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

Which crane suits a flexible or expanding yard?

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

Which crane suits a fixed high-density block?

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

How are span and lifting height selected?

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

Can a manual yard crane be prepared for later automation?

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

What belongs in a turnkey yard-crane contract?

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