分类： Selection Guides

TERMINAL ZONES

Berth, Yard, Gate and Rail Interface

CORE CRANES

STS, RTG, RMG and Straddle Carrier

CONTAINER DUTY

20 ft, 40 ft and 45 ft Containers

SYSTEM PRIORITY

Balanced Berth and Yard Throughput

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

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

1. Vessel Interface

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

2. Horizontal Transport

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

3. Yard Stacking

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

4. Landside Exchange

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

Vessel and Berth Profile

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

Throughput and Peak Demand

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

Yard Layout and Density

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

Container and Spreader Duty

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

Power and Automation

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

Marine Environment

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

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

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

Berth Crane Demand

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

Yard Block Demand

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

Transfer Fleet Demand

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

Maintenance Reserve

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

Future Expansion

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

Performance Acceptance

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

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

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

Single and Twin Lift

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

Anti-Sway and Positioning

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

Load and Twistlock Status

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

Skew, Trim and List

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

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

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

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

Grid-Electric RMG and STS

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

RTG Power Options

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

Total Cost of Ownership

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

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

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

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

Protective Functions

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

Factory Acceptance Test

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

Site Acceptance Test

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

Operational Acceptance

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

Taicang Port International Hub

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

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

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

View the Published RMG Project →

Design Basis

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

General Arrangement

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

Civil and Electrical Loads

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

Interface Control Document

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

Inspection and Test Plan

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

Commercial Schedule

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

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

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

Which yard crane provides the highest flexibility?

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

How is STS outreach selected?

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

Can existing terminal cranes be automated later?

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

What is included in a turnkey terminal crane quotation?

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

What determines delivery time?

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

01 · Yard Layout

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

02 · Load Basis

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

03 · Stack Height

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

04 · Operating Demand

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

05 · Power Supply

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

06 · Ground Interface

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

07 · Site Exposure

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

08 · Control Interface

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

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

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

Equipment Supply

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

Terminal Infrastructure

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

Delivery and Commissioning

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

What is a container gantry crane used for?

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

What is the difference between RMG and RTG?

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

Is an RMG suitable for rail intermodal terminals?

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

Can an RTG move between yard blocks?

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

How is container crane lifting capacity defined?

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

Can the crane handle 20 ft and 40 ft containers?

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

How many container tiers can it stack?

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

Is an electric RTG available?

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

Does the price include rails and installation?

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

What determines the delivery schedule?

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

Rail-Mounted Gantry Crane (RMG)

Fixed-track stacking for container yards and intermodal facilities.

Rubber-Tyred Gantry Crane (RTG)

Mobile tyre-mounted container stacking across designed yard blocks.

Container Straddle Carrier

Alternative equipment for container transfer and yard stacking.

Ship-to-Shore Crane (STS)

Quayside vessel handling upstream of container yard operations.

Portal Harbor Crane

Berth-side equipment for multipurpose cargo handling.

Port Crane Product Range

Explore the full terminal and cargo-handling equipment portfolio.

ATTACHMENT OPTIONS

C-Hook, Tong & Magnet

TYPICAL COIL WEIGHT

5 t – 25 t

CRANE CAPACITY CLASS

5 t – 50 t

COIL SERVICE DUTY

A5 – A7 Continuous

Coil Storage and Rack Handling

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

Blanking Line Feed

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

Press Shop Decoiler Service

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

Coil Transfer Between Bays

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

Return and Residual Coil Handling

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

Scrap and Skeleton Handling

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

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

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

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

01 · Coil Schedule and Weight

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

02 · Material and Surface Class

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

03 · Eye Orientation and Rotation

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

04 · Cycle Rate and Duty Class

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

05 · Storage Geometry

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

06 · Magnet Power and Control

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

07 · Automation and Line Integration

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

08 · Attachment Certification and Boundary

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

Classified Surface Handling

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

Duty Class From the Cycle

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

Controlled Set-Down

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

Attachment and Documentation

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

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

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

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

TYPICAL AUTO COIL WEIGHT

5 t – 25 t

ATTACHMENT OPTIONS

C-Hook, Tong, Magnet

STANDARD DELIVERY

30 – 45 Days

ENGINEERED DUTY RANGE

A5 – A7 Coil Service

Coil and Material Data

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

Storage and Line Geometry

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

Cycle and Duty Data

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

Attachment and Commercial Data

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

What crane handles coils in an automotive plant?

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

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

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

Does the C-hook weight count towards crane capacity?

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

How much does an automotive coil handling crane cost?

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

What duty class does coil service need?

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

Can coil handling cranes be automated?

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

01 · Overhead Crane with C-Hook

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

02 · Crane with Coil Tongs

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

03 · Magnetic Coil Handling Crane

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

04 · Rotating Coil Crane

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

05 · Automated Coil Handling Crane

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

06 · Hook Crane with Coil Rigging

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

Crane Motion Protection

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

Attachment-State Interlocks

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

Magnetic Safety Strategy

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

Product Protection

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

Automated Area Control

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

Identification and Inspection

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

Design basis

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

Attachment engineering

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

Manufacturing records

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

Factory acceptance

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

Before Manufacture

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

Erection and Commissioning

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

Planned Maintenance

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

What is the best crane attachment for steel coils?

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

Can one C-hook handle different coil sizes?

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

Can magnets lift every steel coil?

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

How are aluminum and copper coils handled?

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

How is coil handling crane capacity calculated?

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

Can a coil handling crane be automated?

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

How are finished coil surfaces protected?

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

What crane duty is required for coil service?

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

How much does a coil handling crane cost?

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

What information is needed for a coil crane quotation?

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

PRIMARY ARCHITECTURE

Top-Running Double Girder

COIL ATTACHMENTS

C-Hook, Tong, Mandrel or Magnet

OPERATING PROFILE

Process-Defined Duty

CONTROL OPTIONS

Cabin, Radio, PLC & Automation

Receiving and Unloading

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

Pickling, Rolling and Annealing

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

Slitting and Processing Lines

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

Finished-Coil Warehouse

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

Truck and Rail Dispatch

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

Outdoor Coil Yard

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

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

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

Bridge and End Carriages

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

Process-Duty Hoist

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

Coil Attachment

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

Engagement Confirmation

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

Variable-Speed Drives

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

Positioning and Data

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

Coil Geometry

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

Material Condition

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

Duty and Throughput

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

Pickup and Placement

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

Building and Runway

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

Control and Integration

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

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

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

C-Hook Design

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

Coil Tong Design

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

Inside-Diameter Lifter

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

Magnetic Attachment

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

Coil Identification

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

Positioning and Anti-Sway

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

Inventory Integration

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

Possible Design Routes

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

Engineering Deliverables

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

Manufacturing Inspection

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

FAT and Site Acceptance

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

Coil Data

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

Process and Duty

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

Building and Runway

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

Controls and Commercial Scope

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

How is coil handling crane capacity calculated?

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

Is a C-hook or coil tong better?

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

Can magnets safely lift steel coils?

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

Can one attachment handle the full coil range?

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

How much does a coil handling crane cost?

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

Can an existing runway be reused?

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

Can the crane connect to WMS or MES?

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

What should be tested before handover?

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

01 · Intelligent Grab Overhead Crane

A double-girder, four-rope grab system for repeated handling of limestone, clay, gypsum, slag, clinker, coal or other approved bulk materials. PLC control, pile scanning, anti-sway, positioning and plant-system interfaces can support semi-automatic or unmanned operation.

02 · Grab-and-Hook Dual-Purpose Crane

A practical mixed-duty solution where one bay handles both bulk material and unit loads. The design must define attachment changeover, rated load in each operating mode, storage position and controls that prevent an invalid configuration.

03 · Double-Girder Maintenance Crane

A hook crane for heavy process-equipment maintenance in kiln, cooler, crusher, fan, raw-mill and cement-mill buildings. Main and auxiliary hooks, low-speed positioning and maintenance access can be configured around the overhaul method.

04 · Single-Girder Service Crane

An economical option for lighter maintenance, workshop, packing-line and utility-building loads where the verified capacity, span, headroom and operating frequency remain within the selected hoist and runway design.

05 · Double-Girder Gantry Crane

A rail-mounted outdoor crane for equipment yards, maintenance laydown areas and construction or shutdown support where the building cannot provide an overhead-crane runway. Wind, rails, foundations and storm parking are integral design requirements.

06 · Hazardous-Area Crane or Hoist

A certified configuration for a documented combustible-dust or gas classification, such as a defined coal or alternative-fuel zone. Motors, brakes, electrics, controls, cable systems and mechanical interfaces must match the approved classification.

Dust-Resistant Design

Protected electrical enclosures, sealed or guarded components, suitable bearings, cable systems and accessible cleaning points are selected from the actual dust exposure and maintenance regime.

Heat Assessment

Equipment near kiln or clinker areas may require thermal shielding, heat-resistant components, cooling or derating after ambient and radiant temperatures are established.

Hazardous-Area Compliance

Explosion-protected equipment is applied only to a documented classified zone. The complete crane, not merely the hoist motor, must match the agreed protection concept.

Intelligent Bulk Control

Pile scanning, automatic path planning, anti-sway, target-zone control, collision avoidance and hopper interlocks can reduce manual exposure and support repeatable material flow.

Mechanical Protection

Overload protection, motion limits, service and emergency braking, buffers, rail sweeps, anti-derailment measures and maintenance isolators are defined for the selected design.

Operator and Process Interface

Cabin, radio remote or control-room operation is selected from visibility and exposure. Warning systems, cameras, exclusion zones and process interlocks support the site’s operating method.

Design Definition

General arrangement, hook or grab coverage, wheel loads, clearances, cycle calculation, power demand, control philosophy and process interfaces.

Manufacturing Control

Material traceability, dimensional inspection, welding procedures and non-destructive examination records can be included as required by the contract.

Testing and Handover

Factory tests, control simulations, electrical records, installation instructions, site tests, manuals, training and critical-spares recommendations.

Plant and Civil Readiness

Confirm runway alignment, rails, foundations, wheel-load capacity, building clearances, power, earthing, access, erection zone and shutdown interfaces before delivery.

Functional Acceptance

Define no-load and load tests, grab cycles, throughput demonstration, automation modes, interlocks, communication interfaces and operator training in the contract.

Lifecycle Availability

Plan inspection of ropes, grabs, sheaves, brakes, wheels, rails, gearboxes, motors and electrical systems around production and shutdown schedules; stock critical spares before handover.

What type of crane is used in a cement plant?

Grab overhead cranes serve defined bulk-material stores and feed points. Single- or double-girder hook cranes serve kiln, crusher, mill, cooler, fan and workshop maintenance. Gantry cranes can cover outdoor equipment or laydown yards.

How is grab-crane capacity calculated?

Crane capacity must cover the grab self-weight plus the material payload. Payload and grab volume are checked from bulk density, fill factor, particle characteristics and the required operating cycle.

Can one crane handle limestone, clinker, gypsum and coal?

Only after each material is evaluated. Density, abrasion, moisture, particle size, flow behavior, contamination limits and hazardous-area classification may require different grabs, operating modes or separate equipment.

Does every cement plant crane need explosion protection?

No. Explosion protection is required only where the plant has defined a hazardous gas or combustible-dust area. Coal, petcoke or alternative-fuel zones must be checked against the site’s formal classification.

What crane duty class is suitable for cement service?

Duty follows actual cycles and load spectrum. Occasional maintenance may use a lighter class, while continuous grab handling generally requires a higher-duty design. The class must be calculated rather than selected from the industry name.

Can a cement grab crane operate automatically?

Yes. Options include pile scanning, automatic target selection, path planning, anti-sway, collision avoidance, hopper interlocks and DCS or MES communication. Functional boundaries and manual fallback modes must be defined.

What protection is required near a kiln or clinker cooler?

Protection depends on measured ambient and radiant heat. The design may require shielding, high-temperature components, ventilation, cooling, derating, protected cables and an inspection plan suited to thermal cycling.

Can an existing cement-plant runway be reused?

Reuse is possible only after the rails, beams, columns, connections, alignment and allowable reactions are verified for the new crane wheel loads, duty, braking forces and local requirements.

How much does a cement plant crane cost?

Preliminary equipment-only market bands extend from about US$5,000 for simple maintenance cranes to US$120,000+ for conventional larger systems. Automated grab, hazardous-area and plantwide packages require a project quotation.

What information is needed for a cement crane quotation?

Provide the task, material data, throughput, maintenance-load schedule, layout, span, height, travel length, cycles, environment, area classification, runway data, power, controls, destination, code and required supply scope.

SUPPORT OPTIONS

Roof, Runway or Columns

CRANE OPTIONS

Underhung & Top Running

COVERAGE OPTIONS

Bridge, Monorail & Workstation

QUOTE BASIS

Crane + Building Interface

01 · Single-Girder Underhung Crane

A compact bridge suspended below two runways. Electric wire-rope or chain hoists provide three-axis load movement while preserving floor access and useful side approach.

02 · Low-Headroom Underhung Crane

A compact hoist and optimized girder connection increase usable hook height where roof clearance is limited. Rail elevation, beam depth and hook dimension require coordinated checking.

03 · Multi-Point Suspension Crane

Three or more runway support lines distribute loads across a wider building area and extend coverage for long-span or multi-bay workshops. Support synchronization and alignment are central design requirements.

04 · Multi-Support Double-Girder Crane

A suspended double-girder arrangement provides greater rigidity, higher capacity potential and a stable platform for large-span assembly, maintenance and aircraft-hangar applications.

05 · Top-Running Bridge Crane

The bridge runs above runway rails and transfers loads through runway beams and columns. This configuration is normally considered when capacity, span, duty or trolley requirements exceed a practical suspended arrangement.

06 · Workstation Crane or Monorail

Light-duty workstation bridges cover defined cells, while monorails move loads along a fixed route. Both can reduce manual handling when full-bay industrial crane coverage is unnecessary.

Structural Load Path

Runway beams, hangers, connections, trusses, columns and foundations require defined reactions, approved materials and traceable installation details.

Hoisting Protection

Overload limitation, upper and lower limits, emergency stop, brake control, rope or chain guidance and hook-latch requirements follow the selected hoist and service.

Bridge and Trolley Retention

End stops, buffers, wheel engagement, anti-drop or anti-derailment provisions and controlled travel address suspended running equipment.

Travel and Collision Control

End limits, warning devices, restricted zones and anti-collision functions protect multiple cranes, walls, equipment and maintenance areas.

Electrical Protection

Isolation, short-circuit and overload protection, protective grounding, control voltage, conductor guarding and enclosure selection support safe operation and servicing.

Operator Visibility

Pendant travel, radio control, lighting, alarms and camera options are arranged around load path, aisle traffic and blind areas.

Inspection Access

Platforms, access points, lockout locations and component removal clearances are coordinated with roof members and adjacent utilities.

Standards Basis

ASME B30.17 covers cranes and monorails with underhung trolley or bridge; top-running arrangements may invoke ASME B30.2 or another governing standard. Local law remains controlling.

The word “ceiling” describes location rather than structural capacity. Finished ceiling panels, purlins and secondary framing should not be treated as crane supports unless the project structural design specifically assigns that function. Loads must reach engineered roof trusses, rafters, primary beams, columns or an independent support frame.

A suspended runway introduces vertical wheel loads, dynamic effects, bridge acceleration and braking forces, skew forces and local connection reactions. Multi-point cranes also require controlled load distribution across several runway lines. Building analysis should evaluate the governing crane positions and simultaneous crane combinations.

Headroom must be calculated from rail elevation through the end truck, bridge girder, hoist body, hook block, rigging and load. Underhung systems often improve side and end approach, while a low-headroom hoist can increase usable lift. Actual geometry matters more than a generic “low headroom” label.

For an existing facility, survey data should include structural drawings, field dimensions, member condition, previous alterations, roof services and allowable connection methods. Reinforcement, dedicated runway steel or a freestanding system may provide a safer commercial route when the existing roof cannot accept crane reactions.

Henan Mine Crane documents a multi-support double-girder underhung configuration for aircraft manufacturing plants, maintenance hangars and large assembly workshops. The published product family covers 3–40 t capacity, 10–80 m span, 6–30 m lifting height and A3–A5 working classes, with project-specific power and control arrangements.

The application challenge is a broad lifting area with minimal ground obstruction, substantial component dimensions and multiple pickup positions. Several ceiling-supported runway lines distribute the bridge reactions across the approved building structure, while the double-girder bridge provides rigidity for long-span movement and controlled positioning.

A project package should include the hangar structural model, runway-reaction schedule, door and roof clearances, lifting zones, aircraft and tooling envelopes, permitted crane combinations, control philosophy, inspection access and phased installation method. Published ranges identify engineering capability but do not replace project calculations or structural approval.

View Multi-Support Ceiling Crane →

Building Survey and Approval

Verify drawings, member sizes, support locations, connection restrictions, roof services, access and existing structural condition before final design.

Runway and Hanger Fabrication

Manufacture runway beams, hangers, brackets and connections from approved details with traceable materials, dimensions and inspection points.

Installation Method

Plan delivery sequence, work-at-height controls, lifting equipment, temporary support, assembly zones and production shutdown requirements.

Rail and Runway Alignment

Check elevation, straightness, span, support spacing, flange condition, end stops and transitions before bridge installation and powered travel.

Electrification

Install conductors, festoons, isolators, grounding, control stations and communication equipment with protected access for inspection.

Functional Commissioning

Verify drives, brakes, limits, buffers, warning devices, anti-collision, radio or pendant control and emergency functions without load.

Load and Site Acceptance

Complete required proof, rated-load and operational tests under the approved procedure with documented results and assigned responsibilities.

Preventive Maintenance

Establish inspection intervals for supports, connections, rails, end trucks, wheels, brakes, ropes or chains, conductors and controls from actual service.

Load Data

Maximum and typical mass, dimensions, center of gravity, pickup points, rigging or attachment weight and any future lifting requirement.

Coverage and Geometry

Required travel area, runway length, span, rail elevation, lowest pickup, highest placement, hook approach and overhead obstructions.

Building Structure

Roof truss, rafter, beam, column and foundation drawings; support spacing; allowable reactions; connection restrictions and structural condition.

Duty and Throughput

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

Motion and Control

Required hoist, trolley and bridge speeds, low-speed range, pendant or radio control, cabin, automation and positioning tolerance.

Power and Environment

Voltage, frequency, phase, indoor temperature, dust, humidity, corrosion, washdown, clean-area or hazardous classification.

Installation Conditions

Site access, delivery opening, available lifting equipment, work-at-height rules, shutdown window, power readiness and test weights.

Commercial Boundary

Trade term, runway and support steel, reinforcement, installation, statutory inspection, training, spare parts, documentation language and schedule.

Is a ceiling crane the same as an overhead crane?

Ceiling crane is a broad commercial term. It can describe an underhung bridge, suspended monorail, workstation crane or conventional overhead bridge crane installed near the roof. The support arrangement determines the correct technical name.

Can a crane be attached directly to a building roof?

Only approved structural members and connections may carry crane loads. Finished ceiling panels and unverified secondary members are not crane supports. A qualified structural assessment is required before installation.

What is the difference between underhung and top-running cranes?

An underhung bridge runs below suspended runway beams and preserves floor space. A top-running bridge runs above runway rails and generally provides a stronger route for higher capacities, wider spans or heavier duty.

What capacity is practical for an underhung ceiling crane?

Many conventional underhung systems are applied at 10 t or below, although engineered multi-point and double-girder systems can cover higher capacities. Building reactions, span and duty determine practical limits.

Does an underhung crane improve hook coverage?

Underhung end trucks and cantilever options can improve bridge end approach, and the hoist may travel closer to runway limits. Final coverage depends on end-truck length, girder connection, hoist geometry and structural clearances.

Can a ceiling crane be installed in an existing workshop?

Yes, subject to survey and structural verification. Reinforcement, dedicated runway steel or an independent support frame may be necessary when existing roof members or connections cannot accept crane reactions.

Which data controls usable lifting height?

Rail elevation, end-truck depth, bridge girder depth, hoist headroom, hook block, rigging, attachment and load height jointly define usable lift. Roof height alone is insufficient.

How much does a ceiling crane cost?

Total cost depends on capacity, span, duty, runway, hangers, reinforcement, power, controls, freight, installation and testing. General bridge benchmarks support early budgeting, while a ceiling-supported system requires a project quotation.

Which safety standard applies to an underhung crane?

ASME B30.17 addresses cranes and monorails with an underhung trolley or bridge in applicable projects. Other jurisdictions may require EN, ISO, national or statutory rules. The governing basis must be stated in the contract.

What should be included in the final quotation?

The proposal should identify crane and hoist parameters, runway and support scope, reactions, controls, safety devices, documents, tests, packing, freight, erection, commissioning, training, spare parts, exclusions and schedule.

SYSTEM FAMILY

Overhead, Gantry or Portal

PRIMARY ATTACHMENT

Mechanical or Powered Grab

OUTPUT BASIS

Net Payload and Actual Cycle

PRICE BASIS

Project-Specific Quotation

Production Feeding

Transfer from storage pits or stockpiles into hoppers, furnaces, crushers, mixers and process lines.

Stockyard Transfer

Loading, unloading, sorting and stockpile management across indoor or outdoor storage areas.

Waste and Recycling

High-cycle movement, blending and feeding of municipal, industrial or recyclable material.

Port Cargo Handling

Ship-to-shore or terminal transfer where outreach, luffing, slewing and grab duty are required.

01 / MATERIAL

Material Characteristics

Bulk density, particle range, moisture, flowability, compaction, abrasion, corrosion and temperature determine the grab.

02 / PAYLOAD

Capacity and Grab Weight

The specification must state whether capacity means total suspended mass or net material capacity below the grab.

03 / OUTPUT

Throughput and Cycle

Required tonnes per hour, pick and discharge points, travel distances and operating availability establish performance.

04 / GEOMETRY

Pickup and Discharge Layout

Stockpile, pit, bunker, vessel and hopper geometry determine span, lift, travel, outreach and clearance.

05 / CONFIGURATION

Overhead, Gantry or Portal

Coverage, supporting structure, outdoor exposure, floor traffic and vessel interface govern the system type.

06 / DUTY

Service and Reliability

Cycles per hour, operating hours, load spectrum, starts and production criticality establish the required duty.

07 / ENVIRONMENT

Dust, Corrosion and Hazard

Airborne dust, combustible material, corrosion, humidity, wind, rain and classified areas require formal review.

08 / SCOPE

Controls and Project Boundary

Cabin, radio or automation plus rails, power, civil work, freight, erection, testing and training must be defined.

Four-Rope Mechanical Grab

A four-rope clamshell grab uses dedicated holding and closing ropes and is commonly selected for repeated high-cycle handling of free-flowing material. Winches, drums, ropes and grab are engineered together.

Electro-Hydraulic or Motor Grab

A powered grab supports detachable or mixed-use duties. Attachment power, cable management, maintenance access and achievable cycle performance require inclusion in the crane design.

Orange-Peel or Special Grab

Irregular scrap, rock and mixed waste may require an orange-peel or purpose-designed attachment. Tine shape, penetration, closing force and retention are matched to the feed.

Grab and Hook Combination

A detachable grab and hook configuration supports mixed bulk and unit-load work. Conversion frequency, connection method and attachment storage form part of the specification.

STEP 1

Material per Cycle

Effective grab volume, bulk density and realistic fill factor establish net material mass. Grab and rigging mass are checked against capacity.

STEP 2

Complete Cycle Time

Closing, hoisting, trolley and bridge travel, lowering, opening, return travel and positioning form the complete cycle.

STEP 3

Operating Availability

Pile shape, digging resistance, hopper waiting, spillage, control response, inspection and process delays reduce practical output.

Grab Overhead Crane

An overhead crane provides full-bay coverage without crane legs occupying the floor. It is suitable above storage pits, bunkers and process buildings with an adequate runway structure.

Single- or Double-Girder Design

Single-girder construction can suit moderate capacity and intermittent service. Double-girder construction is evaluated for higher duty, larger grabs, wider spans, open-winch machinery and maintenance access.

Dedicated or Dual-Purpose

A dedicated grab crane supports repeated process duty. A grab-and-hook crane covers more task types but requires defined conversion procedures and may not match a dedicated high-cycle system.

Control Method

Cabin operation supports process supervision; radio control supports selected manual duties; automated operation supports repeatable routes and plant integration.

Grab Gantry Crane

A gantry crane transfers reactions through crane legs to rails and foundations. It can cover outdoor stockpiles or buildings without an elevated overhead-crane runway.

Rails and Foundations

Wheel loads, rail alignment, foundation stiffness, drainage and settlement criteria affect reliable travel. Vehicle and pedestrian crossings require coordinated protection.

Outdoor Protection

Wind limits, storm anchoring, rail clamps, corrosion protection, rain covers, drainage and cable management form part of an outdoor design.

Vessel and Quay Interface

Working radius, vessel hatch position, water-level range, quay elevation and portal clearance establish the operating envelope.

Luffing, Slewing and Travel

Coordinated hoisting, luffing, slewing and portal travel determine cargo cycle time. Drives and controls reflect duty, wind and terminal procedures.

Quay Infrastructure

Rail gauge, wheel loads, power, storm anchoring, cable routes, access and maintenance zones must suit the quay structure.

Cargo Route

Grab discharge may feed a hopper, conveyor, truck or storage system. Dust containment, spillage control and traffic coordination affect the terminal solution.

Motion and Position

Variable-frequency drives, position feedback and anti-sway functions can support controlled cycles and accurate discharge.

Automatic Routes

Defined pick, transfer and discharge paths can include pile scanning, restricted zones and hopper selection.

Dust and Wear

Controlled discharge, protected enclosures, suitable coating and replaceable grab wear parts reflect the material and atmosphere.

Hazardous Areas

Zone classification, ignition data, equipment category, surface temperature, earthing and all ignition sources require formal review.

STEEL INDUSTRY · AUTOMATED BULK TRANSFER

Unmanned Grab Bucket Overhead Crane for Baowu Group Shaoguan Steel Plant

The project serves a bulk-material process associated with rotary-hearth-furnace steelmaking. Crane configuration and automatic control were developed for repeated material pickup, transfer and discharge within the designated production area.

ENGINEERING

Application Review

Material, output, cycle, capacity, geometry, duty, wheel loads, controls and site interfaces are reviewed before design.

MANUFACTURING

Controlled Production

Fabrication, machining, assembly, coating and component installation follow approved drawings and agreed processes.

VERIFICATION

Inspection and Testing

Dimensions, welds, mechanisms, electrics, protection devices and factory functions are checked under the contract plan.

DOCUMENTATION

Project Document Package

Approved drawings, data sheets, electrical diagrams, manuals, certificates, inspection records and test documents are supplied as specified.

Pre-Installation Verification

Runway or rail geometry, foundations, clearances, power, access, lifting plan, storage area and responsibilities are confirmed before erection.

Commissioning and Acceptance

Alignment, electrical checks, limits, brakes, protective functions, load tests, grab operation and process interfaces follow the agreed plan.

Duty-Based Maintenance

Ropes, drums, sheaves, brakes, wheels, rails, grab pins, bushes, shells, cutting edges, hydraulics and electrics require documented inspection.

Crane Equipment

Structure, trolley, drives, ropes, drums, brakes, wheels, electrics, controls and safety functions.

Grab and Process

Grab type, volume, wear materials, attachment power, automation, sensors and process interfaces.

Infrastructure

Runways, columns, rails, foundations, power, cable routes, dust control and access platforms.

Delivery and Site Work

Packing, freight, import charges, erection, commissioning, tests, training and spares.

What materials can a bulk handling crane move?

Typical applications include coal, ore, coke, slag, lime, sand, aggregates, biomass, waste and selected grain products. Material data determine suitability.

Which grab is suitable for bulk material?

Free-flowing material commonly uses a clamshell grab. Irregular scrap or waste may require an orange-peel or special-purpose grab. Geometry, force, wear and power arrangements are material-specific.

Does crane capacity include the grab?

Capacity terminology must be stated in the contract. It may describe total suspended mass including the grab or net material capacity below the grab.

How is throughput calculated?

Net material per cycle comes from effective grab volume, density and fill factor. Hourly output then depends on the complete operating cycle and availability.

When is a gantry crane preferable?

A gantry crane is commonly evaluated for outdoor yards or sites without an elevated runway. Coverage, foundations, traffic and environmental exposure govern the choice.

Can bulk handling cranes operate automatically?

Automation can include position feedback, pile scanning, anti-sway, defined routes, hopper selection, restricted zones and plant-control communication.

Can a grab crane handle combustible dust?

Suitability depends on formal hazard classification. The complete crane, grab, electrical system, mechanical ignition risks, earthing and dust controls must comply.

Is a grab crane suitable for fine powder?

An enclosed grab and extraction can be evaluated, but conveyor, screw or pneumatic transfer may be more suitable where containment and continuous flow govern.

How much does a bulk handling crane cost?

Price depends on capacity, grab, duty, output, span, automation, infrastructure, protection, freight and site services. Supply boundaries must be normalized before comparison.

What is required for a quotation?

Material, throughput, layout, capacity basis, span, lift, travel, duty, controls, environment, power, infrastructure, country and required project scope are required.

Single-Girder Grab Crane

Economical overhead configuration for intermittent light- and medium-duty bulk transfer.

Intelligent Double-Girder Grab Crane

High-duty system for demanding cycles, automation and process integration.

Grab and Hook Overhead Crane

Dual-purpose system for bulk material and conventional hook loads.

Grab and Hook Gantry Crane

Ground-supported solution for stockyards and sites without an overhead runway.

Portal Harbor Crane

Luffing and slewing terminal crane for vessel-to-quay bulk cargo transfer.

Unmanned Grab Bucket Crane

Automated process-crane application for repeatable bulk transfer.

BRIDGE STRUCTURE

Single or Double Girder

RUNWAY ARRANGEMENT

Top Running or Underhung

LIFTING SYSTEM

Hoist or Winch Trolley

PROJECT INPUTS

Load, Span, Lift and Duty

Workshop and Assembly

Transfer components between machining, fabrication and assembly stations. Define the load orientation and positioning needs at each station.

Warehouse and Maintenance

Serve storage lanes and equipment repair areas within the crane bay. Check hook access around racks, machines, doors and overhead services.

Process Material Handling

Match the lifting attachment and operating duty to bulk materials, steel products or specialised production tasks.

01 / LOAD

Load and Handling Route

List the heaviest load, typical load, dimensions, centre of gravity and lifting attachment. Mark pickup and placement points so the hook can reach each position without obstruction.

02 / BUILDING

Building and Runway

Provide a plan and cross-section showing runway levels, roof steelwork, columns and services. Existing supports require a structural assessment using the proposed crane reactions.

03 / OPERATION

Production Cycle

Describe lifts per hour, travel distances, operating shifts and the proportion of lifts near rated load. These inputs affect mechanism selection and duty classification.

04 / SITE

Environment and Access

Identify heat, dust, moisture, corrosion or explosive atmospheres. Reserve access for inspection, lubrication and removal of components during maintenance.

Hoisting: Vertical Movement

The lifting mechanism raises and lowers the suspended load. Select rope travel, hook arrangement, braking and speed control around the lift and placement requirements.

Trolley Travel: Across the Bay

The trolley or travelling hoist moves along the bridge. Trolley dimensions and end clearances affect how closely the hook can approach either side.

Bridge Travel: Along the Bay

End carriages move the bridge along the runways. Wheel arrangement, drive selection and runway alignment must work together over the travel length.

Load and Motion Protection

Specify overload protection, hoisting and travel limits, braking arrangements, emergency stops and relevant electrical protections. Confirm how each function will be demonstrated at acceptance.

Operator Control

Choose pendant, radio remote or cabin operation around visibility and operator access. For multiple control stations, define selection priority and the response to a lost command signal.

Shared Runways and Automation

Where cranes share a bay, assess collision prevention and operating separation. Anti-sway, positioning and process interfaces require a defined performance target and acceptance method.

Installation Interfaces

Agree who supplies the crane, runway beams, rails, conductors, supporting steelwork and foundations. Provide unloading access, assembly space and the planned installation window.

Acceptance and Documentation

Agree drawing approvals, inspection records, electrical diagrams, manuals and the factory and site test scope before ordering. Define the responsibilities for site commissioning and operator familiarisation.

Maintenance Access

Plan access to the hoist, trolley, wheels, drives and power supply. Identify replacement clearances and the spare parts needed for the operating schedule.

Equipment

Bridge, end carriages, hoist or trolley and controls.

Site Interfaces

Runway, electrical feed, supports and installation scope.

Project Delivery

Documentation, testing, packing, transport and commissioning.

Single-Girder Bridge Crane

Explore a single-girder electric-hoist arrangement.

Double-Girder Bridge Crane

Review the double-girder electric-hoist configuration.

Multi-Support Underhung Crane

Review a suspended design with multiple supports.

Double-Trolley Bridge Crane

Explore independent and coordinated lifting arrangements.

Explosion-Proof Bridge Crane

Review equipment for a specified hazardous environment.

5 Ton Overhead Crane

Compare configurations for a metric 5-ton requirement.

EQUIPMENT CONDITION

New · Project Configured

BRIDGE STRUCTURE

Single or Double Girder

RUNWAY ARRANGEMENT

Top Running or Underhung

CONTROL OPTIONS

Pendant · Radio · Cabin · Automation

Manufacturing and Assembly

Machinery components, fabrications, tooling, molds and assemblies moving between production stations.

Warehousing and Maintenance

Inbound materials, stored equipment, maintenance assemblies and controlled loading operations.

Steel and Metallurgy

Coils, plates, billets, ladles, scrap, process equipment and high-temperature production materials.

Power and Process Industry

Generators, turbines, pumps, production equipment and planned maintenance loads.

Bulk Material Handling

Grab-crane systems for coal, ore, aggregate, biomass, waste and process feedstock.

Hazardous and Special Areas

Classified, corrosive, dusty, high-temperature or cleanliness-controlled operating environments.

01 / LOAD

Maximum Load and Attachment

Rated capacity includes the lifted item and below-the-hook equipment. Load geometry and centre of gravity affect the handling arrangement.

02 / COVERAGE

Working Area and Hook Envelope

Span, runway length, hook approaches, lift and obstructions determine usable coverage inside the crane bay.

03 / DUTY

Load Spectrum and Operating Cycle

Working class and mechanism ratings are aligned with operating hours, starts, travel and the proportion of heavy lifts.

04 / BUILDING

Runway and Structural Capacity

Wheel loads, lateral forces, rail size, support spacing and allowable clearances must be coordinated with the supporting structure.

05 / OPERATION

Control and Motion Performance

Control position, speeds, variable-frequency drives, anti-sway and positioning functions are selected for the handling process.

06 / PROJECT SCOPE

Delivery and Site Responsibility

Runway, power distribution, freight, erection, commissioning, testing and documentation require defined responsibility.

New-Build Facility

Early coordination permits the crane envelope, runway elevation, support spacing, electrical feed and maintenance access to be incorporated into the building design.

Existing Runway

An existing runway requires dimensional and structural assessment. Rail condition, alignment, span, support spacing and permissible reactions are evaluated against the proposed crane.

Freestanding Runway

Independent runway columns can separate crane reactions from the main building where space, foundations and operating routes permit a freestanding support structure.

Hoisting Mechanism

Wire-rope electric hoists provide a compact mechanism for many general-purpose single- and double-girder cranes. Winch trolleys permit alternative reeving, machinery layouts, access provisions and redundancy for demanding service. The selected mechanism is matched to capacity, lift, speed, duty, headroom and maintenance strategy.

Bridge and Trolley Travel

Motor, brake, wheel and drive arrangements are developed for the travel distance, acceleration, operating frequency and required positioning performance. Variable-frequency control can provide smoother acceleration and deceleration where the process requires controlled motion.

Control Options

• Pendant control: local control for conventional workshop service.
• Radio remote control: flexible operating position with the specified control functions.
• Operator cabin: elevated control position for process cranes, long travel routes or defined visibility requirements.
• Remote station: control from a fixed operating room or protected station.
• Automated operation: positioning, interlocks and process communication developed from a defined functional specification.

Load and Hoist Protection

Upper and lower travel limits, overload protection, braking and other mechanism safeguards are specified for the lifting arrangement.

Travel Protection

Travel limits, end stops, buffers, audible or visual warnings and anti-collision functions are applied for the operating layout.

Electrical Protection

Isolation, emergency stopping, short-circuit, phase and motor protection are coordinated with the electrical design and site supply.

Access and Maintenance

Platforms, walkways, guards, access points and maintenance clearances are defined where required by the crane arrangement.

Hazardous Areas

Gas or dust classification, temperature class, zone information and material properties are required before an explosion-protected configuration can be established.

Outdoor or Corrosive Service

Weather exposure, wind, ambient temperature, humidity, chemicals and coating requirements determine environmental protection measures.

Capacity, Span and Lift

Structural size, hoisting equipment, rope capacity and building interface change with the lifting geometry.

Duty and Motion Control

Operating cycle, speeds, variable-frequency drives, positioning functions and redundancy affect equipment selection.

Environment and Compliance

Hazard protection, temperature, corrosion, outdoor exposure and project documentation add specific engineering requirements.

Runway and Site Scope

Runway steelwork, freight, unloading, installation, commissioning and site testing can materially change total project cost.

Henan Mine Crane develops the manufacturing package from the approved technical agreement and general arrangement. Production and inspection requirements are connected to the selected crane structure, mechanisms, electrical system and contracted documentation scope.

• Approved general arrangement and interface dimensions before production release
• Material, fabrication and component controls defined by the manufacturing plan
• Electrical and mechanism checks performed against the agreed configuration
• Inspection points, test activities and records aligned with the contract
• Packing and shipment planning coordinated with crane dimensions and destination

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

01

Engineering Approval

Project drawings, interfaces, components and commercial scope are approved before manufacturing release.

02

Production and Inspection

Manufacturing, assembly checks and agreed inspection activities follow the approved project package.

03

Packing and Delivery

Shipment preparation reflects component protection, lifting points, package dimensions and the contracted delivery term.

04

Site Installation

Runway readiness, lifting access, electrical services and installation responsibilities are confirmed before site work.

05

Commissioning and Handover

Functional checks, agreed testing, records and operating documentation support formal project handover.

Load and Operation

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

Building and Coverage

• Runway span and travel length
• Required lifting height and hook positions
• Runway and support information
• Roof, wall and service clearances

Environment and Supply

• Indoor or outdoor operating conditions
• Temperature, dust, corrosion or hazard data
• Electrical power supply
• Project location, delivery term and required services

Single-Girder Overhead Crane

Electric-hoist bridge crane for general production, warehousing and maintenance service.

Double-Girder Overhead Crane

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

Multi-Support Underhung Crane

Suspended multi-support arrangement for compatible building and runway conditions.

Double-Trolley Overhead Crane

Two lifting mechanisms for defined two-point handling and long-load operations.

Explosion-Proof Overhead Crane

Purpose-configured lifting equipment for specified hazardous operating areas.

5 Ton Overhead Crane

Five-ton bridge crane configurations for industrial facilities and defined operating duties.