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PRIMARY ARCHITECTURE

Top-Running Double Girder

LOAD FORM

Straight Rebar Bundles & Long Steel

LIFTING SYSTEMS

Magnet, Spreader, Sling or Clamp

CONTROL OPTIONS

Cabin, Radio, PLC & Automation

Rolling-Mill Finishing Bay

Transfer cut-to-length bars from collection beds to inspection, bundling, weighing, storage and dispatch positions.

Finished-Rebar Warehouse

Stack, retrieve and sequence bundles by heat, diameter, length, grade, customer order or vehicle-loading plan.

Rebar Fabrication Plant

Feed straight bars to cutting and bending equipment and move prepared reinforcement assemblies within defined handling zones.

Steel Service Center

Handle mixed long-steel inventories where rebar, round bar, sections and fabricated bundles require controlled segregation.

Truck and Rail Loading

Load or unload bundles while respecting vehicle geometry, exclusion zones, trailer support points and secured-load procedures.

Outdoor Rebar Yard

Serve covered or open storage with project-specific wind, rain, corrosion, temperature and electrification provisions.

1. Bridge and end carriages: carry the trolley and distribute vertical, longitudinal and transverse reactions to the runway.
2. Hoisting and trolley mechanisms: provide main and creep speeds selected from cycle time, placement tolerance and load control.
3. Lifting beam: establishes the pickup-point spacing needed to control long bundles and may be fixed, rotating or telescopic.
4. Load-engagement system: uses purpose-selected magnets, sling points, protected hooks, clamps or a combination arrangement.
5. Power and controls: coordinate crane motions, magnet circuits, attachment status, limits, alarms and optional WMS/MES communication.
6. Safety and feedback: monitor overload, position, travel limits, skew or anti-collision functions, magnet state and permitted release conditions.

Bundle Matrix

Minimum and maximum mass, bar length and diameter, bundle diameter or width, bars per bundle, number of bundles per lift and center-of-gravity variation.

Material and Surface

Steel grade and magnetic response; black, galvanized, epoxy-coated or stainless surface; temperature, scale, oil, moisture and acceptable contact marks.

Bundle Integrity

Tie type, quantity and position; loose or nested bars; permitted sag; overhang; separation method; damaged-bundle and partial-bundle handling procedure.

Duty and Throughput

Lifts per hour, shifts, annual hours, load spectrum, travel distances, required cycle time, peak dispatch rate and production consequence of downtime.

Storage and Vehicle Interface

Rack or dunnage geometry, stack height, aisle width, truck or rail-car profile, pickup clearance, release height, exclusion zones and required rotation.

Building and Integration

Rail-center span, runway length and elevation, wheel-load limits, headroom, approaches, power supply, cabin visibility, positioning tolerance and WMS/MES protocol.

Long bundles need several support or pickup points. Magnet quantity and spacing, sling separation or clamp location are established from the maximum length, minimum bundle stiffness, permissible sag and center-of-gravity range. The outer pickup points must control end droop without overstressing individual bars or bundle ties.

Representative-load trials are required when lifting performance depends on magnetic contact, friction, coating, bar nesting, tie condition or automated bundle recognition. A solid test weight does not reproduce the air gaps and bar-to-bar movement of a real rebar bundle.

Magnet Array

Magnet type, pole geometry, grouped excitation, current control and spacing follow bar diameter, bundle profile, air gaps, temperature and required pickup combinations.

Spreader and Sling Geometry

Beam length, sling angles, rated components, protective sleeves and pickup spacing prevent excessive bending and coating damage.

Rotation and Telescoping

Rotation is justified by the rack and vehicle approach; telescoping is justified by a wide length range. Both functions require mechanical limits, interlocks and maintenance access.

Bundle Identification

Barcode, RFID, production data or machine vision associates each bundle with heat, grade, diameter, length, mass, order and storage position.

Positioning and Anti-Sway

Absolute position feedback, rotation sensing and load-dependent motion control support repeatable pickup and placement.

Inventory Integration

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

Possible Design Routes

A project may use ISO crane-classification principles with applicable crane and electrical standards; EN 13001 with EN 15011 and EN 13155 where applicable; or a North American route using CMAA specifications with applicable ASME B30.2, B30.20 and ASME BTH-1 requirements. A Chinese-standard route may reference the applicable bridge-crane and lifting-magnet standards. The contract states the selected basis.

Engineering Deliverables

General arrangement, wheel loads, duty calculation, rebar matrix, beam and attachment data, magnetic study where applicable, clearance study, electrical drawings, control narrative, interface list, inspection plan and maintenance-access arrangement.

Manufacturing Inspection

Material traceability, welding procedures and welder qualification, specified NDT, dimensional checks, machinery alignment, beam and attachment inspection, electrical-panel inspection, cable management, coating and documentation records.

FAT and Site Acceptance

Functional tests verify motions, brakes, limits, overload protection, rotation, attachment engagement, alarms and available automation. Site tests then cover runway, erection, load testing, representative rebar bundles, power-loss response, placement tolerance, interfaces, training and handover.

Rebar and Bundle Data

Grade and magnetic properties; black, galvanized, epoxy-coated or stainless condition; minimum/maximum bundle mass, length and diameter; bar diameter; bars and bundles per lift; tie details; temperature; drawings and photographs.

Process and Throughput

Pickup and placement stations; storage sequence; lifts per hour; shifts; annual hours; load spectrum; travel distances; target cycle time; peak vehicle loading; production consequence of an outage.

Building and Storage Layout

Span, runway length, rail section and elevation; required lift; approaches; headroom; rack, dunnage, truck and rail-car drawings; existing wheel-load limits; installation access and site survey.

Controls and Commercial Scope

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

How is rebar handling crane capacity calculated?

Capacity begins with the maximum total rebar payload and adds the lifting beam, magnets or clamps, rigging, hook block and all other suspended equipment. Duty, unbalanced loading and dynamic effects are then applied under the selected design standard.

Can magnets safely lift rebar bundles?

Only after validating steel grade, bar diameter, rib profile, bundle shape, air gaps, surface condition, temperature and retention of every bar. Representative bundles must be tested across the approved operating envelope.

Is a fixed or rotating beam more suitable?

A fixed beam is simpler where pickup and placement share one orientation. Rotation is justified where racks, lines or vehicles require different angles, but it adds headroom, machinery, controls and inspection requirements.

How should epoxy-coated rebar be handled?

The lifting system should use protected contact faces, padded spreaders or suitable synthetic slings under the applicable coating specification. Unprotected chains, sharp edges, dragging and uncontrolled impact should be excluded.

How much does a rebar handling crane cost?

Public information reviewed in September 2026 ranged from US$10,500–12,000 for one nominal 10 t rotating magnetic-beam listing, to US$26,000 for a published 10 t steel-bar crane, and US$135,100 for a large-span 5+5 t steel-mill magnetic-beam project. A final price requires a fully reconciled technical and commercial scope.

Can an existing runway be reused?

Only after rails, beams, brackets, columns, connections and foundations are checked for condition, alignment, fatigue and the new crane reactions. The magnetic beam and long-span load distribution can change wheel loads materially.

Can the crane connect to WMS or MES?

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

What should be tested before handover?

Testing covers crane motions, brakes, limits, overload protection, rotation, attachment engagement and release, representative bundles, emergency power response, placement tolerance, safety zones, interfaces and manual recovery under agreed criteria.

01 · Single-Girder Overhead Crane

An economical indoor option for lighter precast elements, molds, reinforcement assemblies and general production handling where the capacity, span and duty remain within the selected hoist system.

02 · Double-Girder Overhead Crane

A production-bay solution for heavier elements, higher duty, greater hook height or project-defined dual-hook and double-trolley handling inside a precast factory.

03 · Single-Girder Rail Gantry Crane

A practical yard crane for smaller and medium precast products along defined storage or loading lanes, subject to wind, rail, wheel-load and duty verification.

04 · Double-Girder Rail Gantry Crane

The principal configuration for heavy beams, bridge girders, large wall panels and repeated outdoor loading where stability, span, hook coverage and long-load control are decisive.

05 · Truss Gantry Crane

A rail-mounted alternative for selected outdoor spans and transport constraints. Its open structure, connection details, corrosion protection and inspection access must suit the site environment.

06 · Rubber-Tyred Gantry Crane

A self-propelled solution for serving multiple production or storage lanes without fixed travel rails. Ground bearing, steering, braking, power source and traffic management become major design inputs.

Controlled Motion

Variable-frequency drives, suitable low-speed operation and controlled acceleration reduce shock loading and help position fragile or long elements at molds, racks and vehicles.

Load Protection

Overload protection, upper and lower limits, travel limits, service brakes, emergency stop and hook safety devices are specified for the selected crane and local requirements.

Long-Load Management

Where required, synchronized controls, load feedback, skew monitoring, anti-sway functions and defined fault responses support the approved multiple-point lifting method.

Wind and Parking

Outdoor cranes may require wind indication, operating limits, rail clamps, storm anchors, parking procedures, weather protection, drainage and lightning measures based on site data.

Operator Visibility

Pendant, radio remote or cabin control is selected from the travel route and sightlines. Cameras, lighting, warning devices and communication systems can support restricted-visibility areas.

Restricted Lift Zone

Traffic separation, exclusion zones, defined signaling and an approved lift plan remain essential. Crane controls do not replace the site’s safe system of work.

Design Definition

General arrangement, hook coverage, wheel loads, clearances, power demand, control philosophy and below-the-hook interfaces.

Manufacturing Control

Material traceability, dimensional inspection, welding and non-destructive examination records can be defined where required by the contract.

Testing and Handover

Factory test records, electrical documentation, installation instructions, site-test procedures, manuals, spare-parts list and training scope.

Civil Readiness

Confirm runway alignment, rail level, foundations, wheel-load capacity, drainage, earthing, access and erection areas before crane delivery.

Site Acceptance

Define installation inspection, no-load and functional tests, proof-load arrangements, synchronized-mode checks and operator training in the contract.

Lifecycle Availability

Plan brake, rope, hook, wheel, rail, gearbox and electrical inspections around production shifts; establish critical spares before handover.

What crane is used in a precast concrete plant?

Indoor production commonly uses single- or double-girder overhead cranes. Outdoor storage and loading commonly use rail-mounted gantry cranes, while rubber-tyred cranes suit yards that require travel between multiple lanes.

How is precast crane capacity selected?

Capacity is based on the heaviest element plus the hook block, lifting beam, slings, shackles, lifting clutches and other suspended equipment. The approved lifting method and load distribution must also be verified.

Is a double-girder crane necessary for concrete beams?

It is often selected for heavy or long beams, greater spans, higher duty or multi-hook handling. A single-girder crane may remain suitable when the verified load, span, headroom and operating cycle are within its design envelope.

Can one crane handle both production and outdoor storage?

Only if the physical route and crane structure provide continuous coverage. Most facilities use separate indoor and yard cranes because buildings, weather exposure, travel paths and stacking duties differ.

When is a rubber-tyred gantry crane suitable?

It suits yards that need one machine to serve multiple lanes or changing routes without fixed rails. Ground bearing, grade, turning space, steering mode, braking and mixed-traffic controls must be assessed.

Can two cranes lift one precast beam?

A tandem lift is possible only under an engineered method that defines load sharing, crane capacities, controls, communication, travel, fault response and supervision. Independent cranes should not be paired by assumption.

What lifting device is used for precast concrete?

The device follows the product engineer’s approved lifting points and may include a spreader beam, lifting frame, slings, clutches or purpose-approved clamps. Sling angle and attachment loads require verification.

What protection is required for an outdoor precast yard crane?

The site specification may require suitable coatings, weather-protected electrics, drainage, wind monitoring, rail clamps, storm anchors, lightning protection and low-temperature measures.

How much does a precast concrete crane cost?

Conventional equipment-only public budgets may range from about US$10,000 to US$280,000+, but a valid quote requires capacity, span, height, duty, hook arrangement, rigging, runway, controls, delivery and installation scope.

What information is needed for a fast quotation?

Provide element weights and dimensions, lift points, rigging, site layout, span, height, travel length, cycle rate, environment, runway or ground details, voltage, destination, schedule and required supply boundary.

01 · Turbine-Hall Bridge Crane

A heavy-duty double-girder configuration for approved turbine-generator erection loads and major maintenance lifts.

02 · Main and Auxiliary Hooks

Two separately rated hook functions where the lift plan calls for high-capacity lifts and smaller service operations.

03 · Auxiliary-Bay Crane

An appropriately rated bridge crane or electric-hoist solution for workshop, pump, valve or other service-bay loads.

04 · Track-Switching Access

A project-specific cross-travel arrangement for designated maintenance routes between compatible track sections.

05 · Coal or Biomass Grab

A grab crane for approved loose fuel handling, sized for material properties and actual handling cycles.

06 · Ash and Slag Handling

A separate bulk-handling design for the temperature, dust, abrasiveness and operating frequency of the ash area.

07 · Hydropower Powerhouse Crane

A generating-unit lifting arrangement developed around turbine, generator and maintenance access in the powerhouse.

08 · Retrofit or Upgrade

A replacement study that checks existing runway reactions, hook reach, electrical supply and construction access.

Low-Speed Positioning

Hoist and travel drives can be specified for smooth acceleration and a defined slow-speed range as equipment approaches its final position. Acceptance criteria should state the required operating behavior rather than promising an unverified positioning tolerance.

Protection and Interlocks

Overload protection, upper and lower limits, end-of-travel controls, emergency stop, braking and safe operation near other cranes are reviewed against the actual crane design and applicable project requirements.

Dust, Heat and Humidity

Electrical enclosure protection, cable routing, paint system and service access are selected for measured conditions. Explosion-protected equipment is considered only where a documented hazardous-area classification requires it.

Henan Mine Crane supplied lifting equipment for a 2 × 350 MW cogeneration project in Jimsar, Xinjiang. During construction, the project crane supported the lift of the Unit 1 generator stator—a critical generating-unit installation task.

The crane solution incorporates full variable-frequency speed control and PLC-based control for regulated motion, with equipment selected for the site’s heat and dust. The 2 × 350 MW designation describes the plant’s generating output, not the crane’s lifting rating; the latter is defined by the approved lift plan.

This installation illustrates why the crane, rigging, generator delivery sequence and building clearances must be coordinated before the heavy lift. The project lift path and the station’s subsequent maintenance needs both belong in the original technical specification.

View the Xinjiang Power Plant Project

Building Interface

Check runway geometry, support reactions, end clearances, lifting access and the stage at which the crane can be assembled inside the turbine hall.

Testing and Handover

Agree on factory inspection, site commissioning, load tests, protection checks, manuals and operator instruction under the applicable project standard.

Lifecycle Maintenance

Specify inspectable brakes, ropes, wheels, electrics and service platforms; define spare parts and the maintenance plan before the first scheduled outage.

What crane is used in a turbine hall?

A double-girder overhead crane is commonly specified for heavy turbine and generator erection and future overhaul work. Its final ratings, hook configuration and bridge geometry depend on the approved lift plan.

How is power plant crane capacity selected?

Assess the heaviest approved component plus lifting beam and rigging, then check its handling path and site requirements. A generating unit’s MW rating is not an overhead crane capacity.

What is the auxiliary hook for?

A separately rated auxiliary hook can handle smaller components, approved rigging operations and some maintenance lifts. Its use with the main hook must be governed by the crane design and lift plan.

Can an electric-hoist bridge crane replace a turbine-hall crane?

Not automatically. An electric-hoist bridge may suit a service bay or other defined loads, while main generating-unit erection may require a different lifting mechanism, capacity, hook approach and structural rating.

Why are hook approach and lifting height important?

A crane must reach the turbine, generator and service areas while lifting the rigged component clear of foundations, platforms and pipework. A correct tonnage without sufficient reach may still be unusable.

Can two cranes lift one component together?

Only under an engineered tandem-lift arrangement that defines load sharing, coordinated control, rigging and runway reactions. Adding the two rated capacities does not establish a permitted combined load.

Is a grab crane appropriate for all power plant areas?

No. Grabs are for suitable bulk fuel, ash or other loose materials. Turbine-generator equipment requires approved hooks and rigging; a waste-to-energy feed bunker requires its own application-specific grab system.

Does every power plant crane need explosion protection?

No. Electrical protection is selected according to a documented area classification and the applicable local requirements. Heat and dust alone do not justify assigning a universal explosion-proof rating.

What determines the price of a turbine-hall crane?

Hook ratings, span, lifting height, control requirements, duty, plant environment, runway interface, testing and delivery scope. A detailed technical offer is necessary for a meaningful price comparison.

Can a crane be installed in an existing power station?

A replacement or retrofit is possible subject to runway capacity, remaining hook travel, power supply, access openings and the construction window available without disrupting operations.

Thermal Power Bridge Crane

Heavy turbine-generator installation and planned maintenance applications.

Electric-Hoist Double-Girder Crane

A separate option for appropriately rated power-station service bays.

Cross-Travel Overhead Crane

Track-switching access for engineered power-plant maintenance routes.

Single-Girder Service Crane

Smaller maintenance loads where its rating and duty are suitable.

Grab Double-Girder Overhead Crane

Bulk fuel or approved loose-material applications, not turbine lifts.

Cargo and Handling Device

Confirm container dimensions and maximum gross mass, or bulk density, grab payload, general-cargo dimensions and lifting points.

Vessel and Berth

Specify beam, container rows, deck and hatch elevations, tidal range, berth length and required front and back reach.

Quay and Ground

Confirm rail gauge, wheel-load limits, existing foundations, apron width, pavement bearing and drainage.

Throughput and Duty

Define annual and peak volumes, shifts, operating cycles, required availability and maintenance windows.

Yard Configuration

State rows, stacking height, truck lanes, turning areas, rail tracks and future block expansion.

Wind and Marine Exposure

Provide operating and storm wind criteria, salt exposure, ambient range and coating requirements.

Power and Automation

Identify utility supply, diesel or electric strategy, cable routing, TOS interfaces and control mode.

Delivery Boundary

Define crane, spreader or grab, freight, site assembly, commissioning, load testing, training and spares.

STS Container Handling

Outreach is set by vessel beam and furthest container row; lift above and below rail follows vessel and tidal extremes. Capacity must identify whether it is under spreader or includes spreader mass. Wheel loads, rail gauge, backreach and boom parking position are checked against the quay.

Portal Harbor Operations

Portal cranes require lifting capacity across a specified radius chart, not a single headline capacity. Bulk grab cycles, hook loads and container attachments impose different duty and control requirements.

Wind and Marine Conditions

Operating and out-of-service wind criteria, storm anchoring, protective coatings, access routes and maintainable electrical enclosures are included in the technical agreement.

RMG: Defined Rail Corridor

A fixed rail corridor supports repeatable container handling in high-density blocks and intermodal yards. Rail alignment, wheel reactions, span, cantilevers and truck or rail interfaces must be coordinated before civil construction.

RTG: Flexible Yard Blocks

Tyred travel permits movement between yard blocks subject to route width and ground condition. Diesel, hybrid, battery and busbar-assisted configurations differ in infrastructure, operating cost and emissions.

Shared Selection Basis

State container rows, stacking height, truck lanes, spreader specification, hoisting and travel speeds, anti-sway requirement, terminal operating system interface and desired fleet availability.

Design Evidence

General arrangement, load chart, wheel reactions, duty basis, structural calculations and wind criteria should match the tender.

Manufacturing Controls

Review the proposed inspection plan for steelwork, welding, drives, electrics, coating and factory functional tests.

Acceptance Criteria

FAT, site commissioning, load testing, spreader or grab tests and performance demonstrations need contractual pass criteria.

Lifecycle Support

Manuals, electrical drawings, parts lists, training, service access and spare-part lead times influence terminal uptime.

The 40.5 tonne inland-port RMG application sets out a rail-mounted container-handling configuration for dry ports, rail freight areas and intermodal logistics hubs.

The engineering configuration addresses container specification, handling route, rail geometry, electrical controls and spreader compatibility. Final duty, span, height, interfaces and acceptance criteria depend on terminal-specific data.

For procurement, the defining interfaces are the rail corridor, container stack envelope and connections to truck and rail handling areas. These details should be reconciled with terminal drawings before freezing the crane general arrangement.

Site Readiness

Verify quay or yard bearing capacity, rail survey, erection access, lifting plan, power interface and storm-protection foundations.

Commissioning

Electrical, brake, limit, interlock and wind-protection checks precede load testing, operating trials and operator training.

Planned Maintenance

Structural connections, ropes, brakes, wheels, tyres, spreaders, corrosion protection, cable systems and safety devices require duty-based inspection.

Crane Equipment

Structure, machinery, spreader or grab, electrical systems and controls.

Terminal Infrastructure

Rails, quay strengthening, pavement, power distribution and communications.

Delivery and Service

Freight, insurance, import costs, erection, testing, training and spares.

Which crane handles containers at the berth?

A ship-to-shore crane is designed for vessel-to-quay container transfer; reach and lift follow vessel and water-level data.

Which crane is suitable for bulk cargo?

A grab-equipped portal harbor crane can serve berth handling where outreach, grab payload and tonnes-per-hour duty are established.

What is the difference between RTG and RMG?

RTG cranes travel on tyres and may move between blocks; RMG cranes travel on fixed rails within a defined handling corridor.

How is STS outreach determined?

The furthest container row, vessel beam, mooring offset and berth layout establish minimum working outreach.

Does lifting capacity include the spreader?

Capacity basis must state whether the rating is under spreader or includes spreader and attachment mass.

Can port cranes connect to terminal software?

Control interfaces can be specified for a terminal operating system when protocols, safety permissions and acceptance tests are defined.

How is storm protection specified?

Operating and parked wind cases govern brakes, clamps, anchors, tie-downs and terminal procedures.

Does equipment price include installation?

Not automatically. Freight, civil work, rails, erection, commissioning and testing must be explicitly included or excluded.

What documents support supplier evaluation?

General arrangement, load chart, wheel reactions, duty basis, inspection plan, electrical architecture, test plan and spare-parts schedule.

What information is required for a port crane quote?

Cargo, vessel profile, berth and yard plans, required output, operating duty, wind criteria, power, destination and supply scope.

Ship-to-Shore Crane

Quayside handling for container vessels.

Portal Harbor Crane

Berth-side lifting for bulk and general cargo.

RMG Container Crane

Fixed-rail container yard and intermodal operations.

RTG Container Crane

Flexible tyre-mounted yard stacking.

Container Straddle Carrier

Terminal container transfer and stacking.

Port Crane Product Range

Compare the complete quay and yard equipment range.

PRIMARY ARCHITECTURE

Top-Running Double Girder

LOAD ATTACHMENTS

Hook, Clamp, Magnet or Beam

OPERATING PROFILE

Process-Defined Heavy Duty

CONTROL OPTIONS

Cabin, Radio, PLC & Automation

Slab Receiving and Buffer Storage

Unload, identify, stack and retrieve slabs by grade, heat or rolling schedule. Clamp, magnet or lifting-beam selection depends on slab temperature, dimensions, surface scale, stack arrangement and traceability requirements.

Furnace and Mill-Line Transfer

Move feedstock or process components near reheating and rolling equipment. Radiant heat, scale, restricted access, collision zones and production interlocks become part of the crane design basis.

Roll Change and Mill Maintenance

Lift work rolls, backup rolls, chocks, drive components and maintenance tools. Low-speed control, hook approach, lift height, rigging clearance and reliable inching are often more important than high travel speed.

Finishing and Inspection

Transfer plates between cooling, leveling, cutting, inspection, marking and repair stations. The attachment must support the plate without excessive deflection, marking or unintended multi-sheet pickup.

Finished-Plate Warehouse

Stack and retrieve individual plates or packs by order, grade and size. Position feedback, inventory interfaces, stack-height control and automated scheduling can reduce search time and handling damage.

Dispatch and Loading

Load rail wagons, trucks or internal transfer vehicles. Side approach, outdoor exposure, vehicle-clearance zoning, communication with ground personnel and the required loading sequence govern the configuration.

A process map should record every pickup point, placement point, load state, handling frequency, travel distance, traffic conflict and upstream or downstream interlock. This is the basis for deciding whether the mill needs one versatile crane, dedicated zone cranes or a coordinated fleet.

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

Bridge and End Carriages

Box girders, diaphragms, end carriages, wheels and travel drives carry vertical, lateral, acceleration and skew forces. Span, duty, fatigue spectrum, wheel loads and runway stiffness govern the structure.

Open-Winch Trolley

Drum, wire rope, sheaves, reducer, motor, service brake and specified emergency or redundant braking form the lifting mechanism. The reeving and rope fleet angle are engineered for the attachment and lift path.

Load Attachment

Hooks, slab clamps, plate clamps, fixed or rotating magnet beams, vacuum lifters and mechanical beams address different materials. Attachment mass is included in the gross suspended load.

Electrification and Protection

Runway power, trolley festoon or energy chain, panels, VFDs, motors, encoders and cables are selected for temperature, scale, dust, vibration, maintenance access and the declared enclosure level.

Control and Position Feedback

Cabin, radio or PLC control can combine encoders, anti-sway, cameras, laser or barcode identification, load measurement, zoning and production-system interfaces.

Runway Interface

Rails, clips, runway beams, columns, brackets and foundations receive crane reactions. Maximum and minimum wheel loads, transverse forces and longitudinal forces are issued for structural coordination.

01 · Gross Suspended Load

Include the heaviest slab, plate, roll or component plus clamp, magnet, beam, hook block, slings and every below-hook item. State normal and maximum load cases.

02 · Material Geometry and Stack

Provide minimum and maximum length, width, thickness, mass, flatness, center of gravity, bundle form, support points, stack height and gaps between layers.

03 · Temperature and Surface

Declare material temperature, radiant heat, scale, oil, water, paint, surface quality and permitted contact marks. These factors can change magnet, clamp and vacuum performance.

04 · Duty and Production Cycle

Define lifts per hour, shifts, annual hours, load spectrum, travel distances, acceleration, waiting time and the production effect of a crane outage.

05 · Attachment and Retention

State whether the crane lifts one plate, a plate pack, a slab, a roll or maintenance equipment. Define power-loss behavior, locking, pickup confirmation and load-release control.

06 · Geometry and Runway

Confirm span, runway length, rail elevation, lift height, hook approaches, maintenance clearances, existing rail data, building reactions and installation access.

07 · Motion and Automation

Specify full and creep speeds, acceleration, positioning tolerance, anti-sway, synchronized motion, inventory tracking, MES/WMS interface and manual recovery mode.

08 · Reliability and Project Boundary

Define required redundancy, maintainability, critical spares, runway and electrification scope, freight, erection, testing, training, local inspection and performance acceptance.

Attachment selection determines how force enters the load. Long plate can deflect, thin plate can peel from a magnetic stack, hot scale can create an air gap, and a clamp can damage edges or surfaces if its contact geometry is wrong. Testing must therefore use representative materials, temperatures and stack conditions rather than a nominal dead weight alone.

The approved design records the full range of material properties and the unacceptable conditions. Operators and automation logic need a clear permissive for correct pickup, a defined response to incomplete engagement and a controlled release sequence.

Thermal Survey

Record ambient temperature, radiant-heat intensity, exposure duration, hot-material path and ventilation. Shields, component separation, insulation and cooling are then assigned where required.

Scale and Dust Control

Enclosures, seals, filtered ventilation and accessible cleaning points protect panels, brakes, motors, encoders and bearings. Accumulation zones should not obstruct cooling or inspection.

Runway Geometry

Rail gauge, elevation, straightness, joints, clips and support settlement affect skewing and wheel wear. Existing runways require survey and structural verification before crane manufacture.

Wheel and Rail Interface

Wheel diameter, flange geometry, hardness, rail section, bearing arrangement and drive balance are coordinated with duty, wheel loads and runway alignment.

Cabin Environment

Visibility, glazing protection, filtration, cooling or heating, seat ergonomics, access, escape route and camera coverage are defined for the operator’s actual exposure and sight lines.

Outdoor and Coastal Areas

Dispatch yards may require wind monitoring, storm parking, rain protection, corrosion category, drainage, lightning protection and weather-dependent operating limits.

Possible International Design Basis

A project may specify the ISO 4301 classification framework with relevant crane standards, the EN 13001 series with EN 15011 for bridge and gantry cranes, or a North American basis using CMAA specifications and applicable ASME B30 requirements. The purchase specification states the selected route.

Engineering Deliverables

General arrangement, wheel loads and reactions, design calculations where contracted, duty classification, mechanism data, attachment calculations, electrical drawings, control narrative, interface list and maintenance-access plan.

Manufacturing Inspection

Material identification, welding procedure and welder qualification, dimensional inspection, specified nondestructive examination, wheel and rail-interface checks, assembly verification, coating records and electrical-panel inspection.

FAT and Site Acceptance

Factory testing verifies accessible functions before shipment. Site acceptance then checks runway, erection, alignment, electrical protection, no-load operation, load testing, attachment behavior, interfaces, training and handover against agreed criteria.

Material and Attachment Data

Material type and grade; individual or pack handling; minimum and maximum mass, length, width and thickness; temperature; surface condition; stack arrangement; center of gravity; attachment preference; permitted contact marks; lifting points.

Process and Duty Data

Pickup and placement stations; cycle sequence; lifts per hour; shifts; annual operating hours; load spectrum; travel distance; required speeds; creep speed; outage consequence; shared or dedicated crane; future production increase.

Building and Runway Data

Span between rail centers; runway length; rail section; rail elevation; required lift; end and side approaches; roof and machine clearances; existing wheel-load limits; runway drawings; alignment survey; erection and maintenance access.

Controls, Site and Commercial Data

Cabin, radio or automatic operation; positioning tolerance; MES/WMS protocol; anti-collision zones; voltage and frequency; ambient and radiant heat; dust; destination; design standard; Incoterm; installation scope; inspection authority; documentation language.

How is plate mill crane capacity calculated?

Capacity starts with the maximum gross suspended load: material plus magnet, clamp, vacuum lifter, lifting beam, hook block, slings and every other item below the hoist. Load distribution, dynamic effects, duty and the selected design standard are then applied.

Is a magnet or clamp better for steel plate?

Neither is universally better. Magnets offer rapid non-rigged pickup of compatible ferromagnetic material. Clamps provide mechanical engagement within an approved geometry. Steel grade, plate thickness, temperature, surface, stack count, damage limits and power-loss response determine the choice.

Can a plate mill crane handle hot slabs or plates?

Yes, when the maximum material temperature, radiant exposure and handling duration are declared. The attachment, wire ropes, cables, sensors, panels, motors, brakes, cabin and structural shielding are then selected or protected for the actual exposure.

Can one crane handle slabs, plates, rolls and maintenance loads?

A multi-purpose crane is possible when capacity, duty, attachment changeover, controls and clearance support every task. High-cycle production and precision maintenance often justify separate cranes because sharing can create scheduling conflict, unnecessary complexity and a larger outage consequence.

How much does a plate mill crane cost?

The price is project-specific. Public listings reviewed in September 2026 ranged from tens of thousands of US dollars for generic double-girder equipment to about US$208,930 for one lower-rotating electromagnetic bridge-crane listing. A contract price requires the complete process and supply scope.

Can a new crane use the existing plate mill runway?

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

Can the crane connect to MES or warehouse software?

Yes. The interface specification defines task messages, product identity, locations, status feedback, protocol, time synchronization, data ownership, safety boundaries, cybersecurity, manual override and recovery after a network or system interruption.

What documents are needed for final handover?

The agreed package can include approved drawings, wheel-load data, manuals, component schedules, electrical diagrams, software backups, settings, inspection and test records, certificates, spare-parts lists, training records and site load-test or commissioning reports.

PRIMARY SERVICE

Entry, Exit & Buffer Coils

TYPICAL ARCHITECTURE

Top-Running Double Girder

ATTACHMENT OPTIONS

C-Hook, Tong, Mandrel or Magnet

CONTROL LEVELS

Manual, Assisted or Automatic

1. Incoming Coil Receiving

Unload hot-rolled coils from trucks, rail wagons or transfer cars and place them on identified saddles. Vehicle envelope, coil eye orientation, lashing removal, edge protection and pedestrian exclusion are included in the lift plan.

2. Entry Section Feeding

Select the scheduled coil and place it on the entry saddle, coil car or pay-off reel interface. Low-speed approach, confirmed centerline, uncoiler availability and attachment-release permissives protect both coil and line equipment.

3. Process-Section Maintenance

Support planned lifting of rolls, pumps, motors, covers and other maintainable assemblies. Maintenance loads, access openings and lifting points are documented separately from routine coil-handling duty.

4. Exit Coil Removal

Remove the completed pickled coil from the exit saddle, recoiler coil car or turnstile only after the line confirms a safe transfer state. Coil bands, tail condition and stable support are verified before travel begins.

5. Buffer, Inspection and Rework

Route coils by grade, order and process status. Storage coordinates, hold areas, inspection stands and rework queues require positive identification and controlled placement on approved supports.

6. Downstream Transfer or Dispatch

Feed a tandem mill, annealing line, coating line or slitter, or load coils into road and rail transport. Order verification and stable final placement close the material-tracking transaction.

One Line Can Require More Than One Crane

Entry and exit bays can have different coil conditions, cycle requirements and environmental exposure. Independent cranes can isolate production logistics, maintenance and dispatch traffic, while overlapping coverage or an emergency transfer plan can support availability.

The handling study records crane-to-crane collision zones, shared runway sections, handover saddles, recovery positions and the production consequence of each single failure.

Bridge and End Carriages

Girders, wheels and travel drives are engineered from span, fatigue spectrum, wheel loads, lateral forces, runway stiffness and required approach. Walkways and service platforms support safe inspection.

Process-Duty Hoist

Drum, rope, sheaves, reducer, motor and brakes are sized for the gross suspended load, lift, speed, starts per hour, operating class and required redundancy or emergency lowering philosophy.

Coil Attachment

A C-hook, powered tong, inside-diameter lifter or approved magnet engages the defined coil range. Contact surfaces, engagement confirmation and attachment parking stands form part of the system.

Motion and Positioning

Variable-frequency drives provide controlled acceleration and creep speed. Encoders, laser positioning, anti-sway functions and load-height feedback support repeatable line and saddle approaches.

Electrical and Control System

Panels, PLC, drives, sensors, communications and operator stations are protected for the mapped environment. Diagnostics identify permissive status, faults, maintenance needs and task progress.

Line and Inventory Interface

Handshakes with the line PLC, coil cars, uncoiler, recoiler, turnstile, gates and storage management prevent conflicting movements and preserve coil identity.

Coil Envelope

Minimum and maximum coil mass, outside diameter, inside diameter, face width, eye orientation, center-of-gravity range, winding tightness, banding, tail condition and permitted contact areas.

Material Condition

Steel grade, surface scale before pickling, oil or residual moisture after pickling, edge sensitivity, surface-marking limits, temperature and any restrictions on magnetic lifting.

Throughput and Duty

Coils per hour, lifts per shift, loaded travel distance, average and maximum load, production schedule, queuing allowance, annual hours, maintenance windows and outage consequence.

Station Interfaces

Saddle geometry, coil-car stroke, uncoiler and recoiler centerlines, turnstile positions, truck or rail clearances, obstacles, approach distances and attachment release conditions.

Environment Map

Acid chemistry and concentration, mist distribution, chloride or sulfate exposure, temperature, humidity, condensation, washdown, ventilation, dust and the location of cleaner service zones.

Building and Utilities

Span, lift, runway elevation, rail section, wheel-load limits, end approaches, headroom, power supply, cable route, maintenance access, erection opening and future line modifications.

Architecture Selection

Top-running double-girder cranes are commonly selected when coil mass, attachment weight, span, duty or positioning equipment requires higher structural capacity and accessible machinery arrangements. Single-girder solutions can suit lighter auxiliary service where duty, headroom and maintenance needs support that choice.

A rotating hook block or powered attachment rotation may be required when coil eye orientation changes between transport, storage and line stations. The rotating envelope is verified against saddles, guards, columns and adjacent crane structures.

Gross Suspended Load

The load calculation includes maximum coil mass plus the complete attachment, hook block, rotation mechanism, cables and any permanent equipment below the hoist. Capacity margin is not a substitute for a defined coil range or controlled attachment geometry.

Operating Class and Load Spectrum

Crane classification is selected from total working cycles, distribution of light and heavy loads, motion running time, starts per hour and expected service life. A crane that feeds every production coil normally requires a different fatigue evaluation from an occasional maintenance crane of the same rated capacity.

Speeds and Cycle Time

Main speeds are balanced against travel distance, line takt time, suspended-load stability and available deceleration zones. High top speed does not guarantee a shorter safe cycle. Controlled acceleration, anti-sway and accurate final approach often produce more repeatable throughput.

Performance Data for the Specification

• Maximum gross suspended load and complete coil range
• Required hook or attachment travel and end approaches
• Hoist, trolley and bridge main and creep speeds
• Coils per hour and defined reference handling cycle
• Placement tolerance at each automatic station
• Availability target and planned maintenance allowance
• Noise, power, braking and emergency operating criteria

C-Hook

Suitable where the coil bore is accessible and the hook can enter without striking the saddle or line equipment. Throat depth, lower-arm section, counterweight, tip shape, lining and permissible coil range are engineered together.

Powered Coil Tong

Powered arms or jaws engage a defined coil range. Position feedback, load confirmation and fail-safe retention support assisted or automatic cycles, while moving parts require accessible inspection and corrosion protection.

Inside-Diameter Lifter

An expanding or positive-locking device engages the bore. ID tolerance, insertion depth, bore integrity, activation state and a mechanically secure lifting condition require verification for every coil family.

Electromagnetic System

Magnetic lifting is considered only after material, curvature, contact condition, air gap, surface oil or scale, temperature and retained-load behavior are validated. Ferromagnetic material alone does not establish a safe lifting capacity.

Hook and Spreader Package

A conventional hook, beam or maintenance attachment can support non-coil lifts. Changeover controls, dedicated stands, identification and proof-test records prevent an unapproved attachment from entering a production task.

Surface Protection

Replaceable pads, rounded contact edges and controlled contact pressure can reduce marking. Material compatibility, trapped contamination, inspection frequency and pad wear limits are specified.

Station Handshakes

The line PLC confirms station identity, coil availability, coil-car position, uncoiler or recoiler state, guards, gates and permission to enter. The crane returns approach, placement and task-complete states.

Coil Identification

Barcode, RFID, operator confirmation or production data links the physical coil with grade, order, dimensions, process status and destination. Exception rules prevent an unidentified coil from entering an automatic task.

Position and Anti-Sway

Absolute or referenced position data, controlled acceleration, sway reduction, load-height feedback and final approach logic support repeatable placement without using line equipment as a mechanical stop.

Traffic and Protected Zones

Crane-to-crane separation, vehicle lanes, restricted process areas, temporary maintenance zones and personnel access states are enforced through the agreed safety architecture.

MES or WMS Interface

Task messages define source, destination, coil identity and priority. Interface design also covers acknowledgements, duplicate commands, time synchronization, audit history, cybersecurity and network loss.

Manual Recovery

Every automatic sequence requires a controlled safe state and a documented recovery path for sensor failure, lost communications, incomplete engagement, blocked destination or interrupted power.

Overload and Motion Limits

Rated-capacity protection, normal and final motion limits, brakes, buffers, travel warnings and monitored speed zones are selected under the governing code and risk assessment.

Attachment Permissive

Hoisting begins only after the approved engagement state is confirmed. Release is inhibited until the coil is supported, the destination is correct and the release sequence is authorized.

Restricted-Area Control

Barriers, gates, scanners, warning devices and administrative controls are coordinated around line entrances, vehicles, storage aisles and automatic crane operating zones.

Collision Avoidance

Adjacent cranes, building columns, line structures, high coils and temporary maintenance equipment are included in the collision model and stopping-distance calculation.

Energy Isolation

Lockout points, stored-energy release, access platforms and local isolation are coordinated for crane maintenance and work on interfacing line equipment.

Abnormal Events

The operating concept covers power loss, retained suspended load, failed attachment sensor, displaced coil, unavailable destination, fire alarm, ventilation loss and evacuation.

Existing Runway Verification

Reuse requires verification of rail section and alignment, beams, brackets, columns, connections, foundations, fatigue history and measured condition. Maximum and minimum wheel reactions, lateral forces, buffer loads and electrification loads are issued for structural review.

Clearance and Approach Study

Hook approach, C-hook counterweight, tong arms, rotating envelope, cabin, walkways and festoon or conductor systems are checked in three dimensions against roof steel, ducts, exhaust equipment, lighting and the pickling line.

Maintenance Access

Inspection platforms, guarded access, safe parking position, component removal paths, lifting points, rope replacement space and isolation stations are defined before fabrication. Critical sensors and corrosion-prone parts remain visible and replaceable.

Site Data Required

• Building and runway drawings with verified dimensions
• Rail elevation, span, length, end stops and expansion joints
• Existing allowable vertical and horizontal reactions
• Roof, duct, tank, line and vehicle clearances
• Erection opening, laydown area and shutdown window
• Electrical supply, grounding and communication network
• Environmental survey and hazardous-area documentation

Design Review

Confirm load cases, classification, general arrangement, wheel loads, attachment envelope, corrosion schedule, electrical architecture, safety functions, interfaces and inspection access.

Factory Acceptance Test

Verify assemblies, controls, drives, braking, limits, sensors, attachment logic, alarms, interface simulation, documentation and agreed inspection records before shipment.

Site Acceptance Test

Test crane motions, load protection, representative coils, all transfer stations, placement tolerance, collision zones, line handshakes, abnormal states, manual recovery and operator procedures.

Primary Price Drivers

Capacity and span; operating class and speeds; C-hook, tong, mandrel or magnet; rotation; corrosion-control system; cabin and HVAC; positioning and anti-sway; automatic controls; safety zoning; line PLC and MES/WMS interfaces; runway electrification; documentation and local certification.

Commercial Scope to Reconcile

Runway rails and beams; structural strengthening; freight and insurance; taxes and duties; site supervision; mechanical and electrical installation; lifting equipment for erection; commissioning; load-test weights; training; spares; warranty support and production acceptance testing.

Technical Proposal

Design basis, general arrangement, main mechanisms, duty classification, speeds, attachment concept, protection package, control level and stated deviations.

Interface Schedule

Runway reactions, power and communications, line I/O, station coordinates, civil boundaries, erection needs, environmental inputs and third-party responsibilities.

Safety Documentation

Risk-assessment inputs, safety-function list, restricted zones, attachment logic, isolation concept, emergency states and required local conformity documents.

Quality Records

Material and welding records as specified, inspection and test plans, coating records, component certificates, attachment proof testing and factory test reports.

Operation and Maintenance

Manuals, lubrication plan, corrosion inspection, adjustment limits, fault recovery, spare-parts list, training scope and recommended preventive-maintenance intervals.

Commercial Schedule

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

Coil and Attachment Data

Material and grade; minimum and maximum mass, OD, ID and width; eye orientation; temperature; surface and oil condition; banding; center of gravity; contact restrictions; proposed C-hook, tong, ID lifter or magnet.

Process and Duty Data

Entry, exit, storage and dispatch sequence; station coordinates; lifts per hour; shifts; annual hours; load spectrum; travel distances; target cycle; availability target and required contingency.

Environment and Site Data

Acid chemistry, concentration and temperature; mist or corrosivity survey; humidity, condensation and washdown; ventilation; span, runway and clearances; power supply; building drawings and destination.

Controls and Commercial Data

Manual, assisted or automatic operation; placement tolerance; line PLC and MES/WMS protocols; safety zones; required code; Incoterm; freight, installation, commissioning, test and documentation boundaries.

Where does a pickling line crane operate?

Its principal production duties are usually in the incoming-coil, line-entry, line-exit, buffer, inspection and dispatch zones. It may also support planned maintenance, but the steel strip travels through the pickling tanks on the line equipment.

Does every pickling line crane need acid-resistant construction?

Protection depends on measured or specified exposure. Acid chemistry, mist, ventilation, humidity, condensation and washdown are mapped by zone. Coatings, enclosures, seals, materials and maintenance intervals are then selected for each zone.

Is a C-hook or powered coil tong more suitable?

A C-hook offers mechanical simplicity where the bore is accessible. A powered tong offers automated engagement and feedback for high-cycle service but adds mechanisms and maintenance. Coil geometry, cycle rate, access and control level determine the choice.

Can an electromagnetic crane handle pickled coils?

Only after the material grade, curved contact, air gaps, oil or moisture, banding, temperature, required holding force and power-loss behavior are validated. A mechanical attachment may be preferable where magnetic performance is uncertain.

How is rated capacity determined?

The starting value is the maximum gross suspended load: coil plus attachment, hook block and all equipment carried below the hoist. Operating class, dynamic effects, load distribution and governing code are then applied.

How much does a pickling line crane cost?

Public figures range from low-cost attachment or generic crane listings to substantially broader engineered projects. A defensible price requires coil data, span, duty, attachment, corrosion protection, automation, runway scope, destination and installation boundary.

Can the crane connect to the line PLC and MES?

Yes. The interface specification defines station states, task messages, coil identity, coordinates, acknowledgements, safety ownership, network protocol, cybersecurity, diagnostics and recovery after interrupted communications.

Can an existing runway be reused?

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

01 · Load Definition

Record heaviest reel, roll or machine component; include lifting beam, clamps, slings and other below-hook equipment in the required capacity.

02 · Handling Geometry

Confirm roll diameter, length, orientation, pickup and landing clearances, machine openings and permitted rotation.

03 · Building Envelope

Establish runway length, span, hook approach, available headroom, lifting height and existing column or runway loads.

04 · Duty Profile

Define lifts per hour, operating shifts, load distribution, travel distances and the time allowed for maintenance shutdowns.

05 · Mill Environment

Identify humidity, washdown, fibres and dust, corrosive chemicals, local temperature and any classified hazardous area.

06 · Load Attachment

Specify hooks, lifting beams, roll clamps or other approved attachments and the protection needed to prevent product damage.

07 · Control and Access

Choose pendant, radio or cabin control as appropriate; map operator visibility, access platforms and maintenance routes.

08 · Plant Integration

Coordinate crane operation with conveyors, production machines, pedestrian routes, fire protection and site electrical supply.

Henan Mine Crane’s three-trolley electric-hoist bridge crane is presented for paper-industry component handling and equipment maintenance. Three independently positioned lifting stations can be specified where a machine component has multiple approved lifting points or where different workstations need access along one bridge.

For a paper-machine maintenance lift, the engineering schedule identifies each component’s mass and centre of gravity, the lifting-point arrangement, trolley positions, combined bridge load, synchronized-motion requirement and path into the maintenance area. An approved lift plan and control philosophy govern any coordinated operation.

Technical drawings, inspection records and applicable project references can be included in the vendor-qualification discussion.

Crane Equipment

Bridge, hoist or trolleys, drives, controls, electrification and specified protective equipment.

Mill Interfaces

Runway and building works, lifting attachment, production interlocks and equipment access changes.

Delivery and Handover

Packing, freight, installation, commissioning, inspections, training and initial spare parts.

What is a paper mill crane?

An overhead lifting system configured for a specific pulp or paper production, maintenance or storage duty.

Which crane handles paper-machine components?

A properly rated hook crane or multi-trolley arrangement can be specified from the component mass, lifting points and maintenance route.

Can the same crane handle parent rolls?

Only with a qualified roll-handling attachment and a handling procedure matched to the roll and process.

When is a three-trolley crane appropriate?

Where multiple lifting stations or approved multi-point lifts justify separately controlled trolleys and engineered load sharing.

Is an A5–A6 crane required in every paper mill?

No. Working class follows actual operating cycles and load spectrum; A5–A6 describes the published three-trolley product range.

How is rated capacity calculated?

The heaviest permitted load includes the material and all below-hook lifting equipment, subject to the approved lift plan.

What protection is needed for a humid mill?

Electrical enclosure, cable and coating requirements are specified from actual moisture, washdown and chemical exposure.

Can a crane be installed in an existing mill?

Yes, subject to building and runway assessment, access for erection and a practical production shutdown plan.

Is a roll-handling attachment included in the price?

Only if included in the written equipment scope; roll clamps, beams or other devices should be itemized.

What is needed for a firm quotation?

Mill drawings, the load and lift schedule, environmental data, required attachments and the complete service scope.

Three-Trolley Electric-Hoist Crane

Multiple lifting stations for engineered component handling.

Double-Trolley Overhead Crane

Two-point handling subject to coordinated-lift design.

Single-Girder Overhead Cranes

General mill service and selected lighter maintenance lifts.

Double-Girder Overhead Cranes

Higher-capacity machine-area and maintenance configurations.

Overhead Crane Product Range

Compare available overhead crane configurations.