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PRIMARY SERVICE

Scrap Receiving, Sorting and Feeding

CRANE ARCHITECTURE

Overhead or Gantry Crane

LIFTING DEVICES

Magnet, Orange-Peel Grab or Hook

CONTROL LEVELS

Cabin, Radio, Assisted or Automatic

1. Receiving and Inspection

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

2. Sorting and Segregation

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

3. Stockpile and Reclaim

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

4. Process-Line Feeding

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

5. Processed-Metal Transfer

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

6. Dispatch and Maintenance

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

Bridge or Gantry Structure

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

Process-Duty Hoisting Machinery

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

Scrap Attachment

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

Attachment Power and Protection

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

Operator and Control System

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

Access and Maintainability

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

Scrap Composition

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

Attachment and Net Payload

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

Production Throughput

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

Duty and Load Spectrum

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

Site and Environment

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

Layout and Interfaces

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

Hook, Beam or Bale Device

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

Standard Bulk Grab Boundary

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

Multiple Attachments

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

Gross Suspended Load

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

Volumetric Grab Check

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

Production Cycle Check

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

Capacity Data Required

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

Load Spectrum and Starts

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

Operator Visibility

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

Assisted Functions

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

Automatic Stockpile Handling

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

Process-Line Interface

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

Recovery and Diagnostics

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

Dropped-Material Zone

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

Incoming-Scrap Hazards

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

Fire and Emergency State

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

Dust, Fines and Abrasion

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

Outdoor Operation

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

Hazardous-Area Boundary

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

Existing Runway Verification

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

Stockpile and Clearance Model

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

Wear and Service Access

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

Site Documents

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

Design Review

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

Factory Acceptance Test

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

Site and Production Acceptance

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

Automatic Rotating Electromagnetic Beam Platform

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

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

View Published Magnetic-Handling Solution →

Primary Price Drivers

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

Commercial Scope to Reconcile

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

Technical Proposal

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

Interface Schedule

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

Attachment Data

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

Safety Documentation

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

Quality and O&M Records

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

Commercial Schedule

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

Scrap and Attachment Data

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

Process and Duty Data

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

Site and Environment Data

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

Controls and Commercial Data

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

Which crane is suitable for a scrap yard?

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

Can one crane handle ferrous and nonferrous scrap?

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

How is metal recycling crane capacity determined?

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

Does magnet capacity equal loose-scrap lifting capacity?

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

What grab is used for irregular scrap?

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

Can a recycling crane feed a shredder or baler automatically?

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

How much does a metal recycling crane cost?

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

Can an existing runway be reused?

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

PROCESS AREAS

Converter, EAF, Refining, Casting & Smelting

CRANE CONFIGURATIONS

Double Girder or Four Girder, Main & Auxiliary Trolley

OPERATING DUTY

Project-Specific Metallurgical Duty, A7–A8 Available

PRICE BASIS

Engineered Project Quotation

01 · Double-Girder Ladle Crane

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

02 · Four-Girder Ladle Crane

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

03 · Main-and-Auxiliary Trolley Crane

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

04 · Metallurgical Bridge Crane

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

05 · Automated Ladle Transfer Crane

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

06 · Auxiliary and Maintenance Crane

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

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

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

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

Main-Hoist Braking Architecture

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

Independent Limits and Overspeed Protection

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

Verified Load Path and Ladle Engagement

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

Thermal and Splash Protection

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

Controlled Motion and Collision Management

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

Emergency Set-Down and Recovery

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

Ladle Transfer, Tilting and Controlled Pouring

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

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

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

Design Basis Package

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

Safety and Control Documents

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

Manufacturing Quality Records

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

Factory and Site Acceptance

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

Runway and Site Readiness

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

Installation and Assembly

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

Commissioning and Process Trials

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

Inspection and Maintenance Strategy

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

Crane Equipment

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

Ladle Handling System

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

Safety and Controls

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

Project Services

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

01 · Process and crane duty

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

02 · Gross suspended loads

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

03 · Ladle and trunnion drawings

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

04 · Building and runway

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

05 · Stations and transfer route

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

06 · Motion and performance

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

07 · Thermal and environmental data

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

08 · Controls and plant interfaces

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

09 · Standards and acceptance

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

10 · Commercial and site scope

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

How is ladle crane capacity calculated?

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

When is a four-girder ladle crane required?

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

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

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

What is the function of the auxiliary hook?

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

Is A7 or A8 duty always necessary?

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

What safety functions are required for molten-metal handling?

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

Can ladle transfer be automated?

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

What determines ladle handling crane price?

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

Can an existing crane or runway be reused?

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

What should be demonstrated before acceptance?

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

PRIMARY SYSTEM

Overhead Bridge Crane

SUPPORT OPTIONS

Building or Freestanding

COVERAGE OPTIONS

Bay, Line or Workstation

CONTROL OPTIONS

Pendant, Radio, Cabin & PLC

Top-Running Overhead Crane

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

Underhung Overhead Crane

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

Freestanding Bridge Crane

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

Workstation Crane

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

Monorail and Jib Crane

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

Indoor Gantry Crane

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

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

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

Bridge Structure

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

Hoist or Trolley

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

End Carriages

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

Electrification

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

Controls and Protection

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

Runway Interface

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

01 · Gross Suspended Load

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

02 · Required Coverage

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

03 · Span, Lift and Headroom

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

04 · Working Duty

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

05 · Building Structure

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

06 · Motion and Positioning

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

07 · Indoor Environment

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

08 · Project Boundary

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

Runway Type

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

Rail Geometry

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

Wheel Loads

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

Vertical Envelope

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

Hook Approaches

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

Freestanding Structure

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

Variable-Frequency Motion

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

Overload and Motion Limits

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

Braking and Emergency Stop

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

Anti-Collision and Zoning

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

Positioning and Anti-Sway

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

Inspection Access

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

Fabrication and Machining

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

Assembly and Production

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

Warehouse and Logistics

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

Maintenance Facilities

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

Heavy Manufacturing

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

Controlled Environments

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

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

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

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

View Manufacturing Project →

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

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

Load and Process Data

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

Building and Coverage Data

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

Operating and Control Data

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

Commercial and Site Data

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

Which crane type is suitable for an indoor workshop?

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

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

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

How much does an indoor crane cost?

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

Can an indoor crane use the existing building structure?

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

When is a freestanding crane required?

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

How is the required crane capacity calculated?

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

Are runway and installation included in the quotation?

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

What documents support final acceptance?

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

01 · Powerhouse Overhead Crane

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

02 · Pumped-Storage Powerhouse Crane

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

03 · Dam-Crest Gantry Crane

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

04 · Intake Gate and Stoplog Crane

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

05 · Tailrace or Draft-Tube Service Crane

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

06 · Auxiliary Maintenance Crane

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

Controlled Low-Speed Motion

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

Hook Synchronization

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

Braking and Limits

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

Anti-Sway and Monitoring

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

Crane and Runway Interface

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

Maintenance Access

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

Design Package

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

Manufacturing Control

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

Testing and Handover

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

Early Civil Coordination

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

Site Execution

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

Long-Term Availability

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

What type of crane is used in a hydropower powerhouse?

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

How is hydropower plant crane capacity calculated?

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

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

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

When are synchronized double hooks required?

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

What does a dam gantry crane handle?

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

Is a gate hoist the same as a gantry crane?

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

What protection is needed for an outdoor hydropower crane?

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

Can an existing hydropower crane be replaced or modernized?

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

How much does a hydropower plant crane cost?

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

What information is needed for a fast quotation?

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

PROCESS COVERAGE

Slab to Finished Product

CRANE FAMILY

Production & Service Cranes

ATTACHMENT OPTIONS

Hook, Beam, Clamp & Magnet

CONTROL OPTIONS

Cabin, PLC & Automation

01 · Slab Transfer Crane

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

02 · Rolling-Line Production Crane

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

03 · Roll-Shop and Roll-Change Crane

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

04 · Plate Handling Crane

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

05 · Coil Handling Crane

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

06 · Maintenance and Service Crane

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

Hoisting Protection

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

Heat and Electrical Protection

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

Long-Load and Attachment Control

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

Travel and Collision Protection

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

Operator Visibility

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

Automation and Recovery

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

Maintenance Isolation

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

Emergency Operating Plan

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

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

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

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

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

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

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

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

View Hot Rolling Crane Case →

Fleet Engineering Schedule

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

Runway and Site Verification

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

Phased Packing and Delivery

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

Erection and Alignment

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

Commissioning and Acceptance

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

Operator and Maintenance Training

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

Preventive Maintenance

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

Fleet Spare-Parts Planning

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

Crane Schedule

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

Load and Attachment

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

Duty and Throughput

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

Motion and Control

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

Environment

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

Runway and Building

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

Automation and Interfaces

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

Commercial and Acceptance Scope

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

Which crane types are required in a hot rolling mill?

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

How is crane capacity selected?

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

Can one crane handle slabs, rolls and coils?

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

What duty class suits a rolling mill crane?

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

How is radiant heat addressed?

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

Can rolling mill cranes integrate with MES?

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

What attachment is suitable for steel plate?

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

How should roll changes be handled?

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

Can a large crane fleet be delivered in phases?

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

What should a commercial quotation include?

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

PUBLISHED CAPACITY PLATFORM

20–150 t or Custom

PUBLISHED SPAN RANGE

7.5–35 m

PROCESS MOTION

Controlled Rapid Immersion

CONTROL OPTIONS

Manual, PLC or Automatic

Vertical Shaft and Roll Quenching

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

Batch and Basket Quenching

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

Die and Mold Heat Treatment

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

Gear, Ring and Bearing Production

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

Forging Heat-Treatment Bay

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

Automatic Heat-Treatment Line

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

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

Load and Orientation

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

Transfer and Immersion Time

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

Temperature and Exposure

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

Bath and Medium

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

Duty and Availability

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

Power Loss and Recovery

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

Building and Runway

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

Controls and Acceptance

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

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

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

Oil Quenching Requires a Site-Specific Fire Review

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

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

Baskets and Racks

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

Lifting Beams and Spreaders

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

Tongs and Clamps

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

Vertical Lifting Fixtures

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

Dual-Point Suspension

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

Attachment Changeover

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

Interface Matrix

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

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

Design Review

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

Factory Testing

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

Site Acceptance

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

Workpiece and Fixture

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

Treatment Cycle

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

Tank and Environment

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

Workshop and Runway

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

Controls and Emergency Strategy

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

Commercial and Compliance Scope

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

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

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

How is heat treatment crane capacity calculated?

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

Can a standard overhead crane perform quenching?

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

Which quenching media can the crane serve?

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

How much does a heat treatment crane cost?

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

What happens if power fails during quenching?

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

Can the crane integrate with furnaces and tank controls?

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

What should be tested before handover?

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

Quenching Crane
Heat-Treatment Process System

PROCESS AREAS

Pretreatment, Zinc Kettle, Cooling & Finishing

HANDLING DUTIES

Transfer, Immersion, Tilting, Drainage & Maintenance

DESIGN CONDITIONS

Corrosive Fumes, Heat, Moisture & Cyclic Duty

PRICE BASIS

Engineered Project Quotation

01 · Single-Girder Process Crane

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

02 · Double-Girder Process Crane

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

03 · Twin-Hoist or Twin-Trolley Crane

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

04 · Automated Galvanizing Transport System

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

05 · Cantilever Zinc-Pot Crane

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

06 · Loading, Finishing and Maintenance Crane

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

Match the Crane to the Galvanizing Process Area

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

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

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

Controlled Immersion and Drainage

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

Chemical and Corrosion Protection

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

Heat and Fume Exposure

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

Electrical and Control Protection

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

Load, Motion and Collision Safety

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

Access, Isolation and Acceptance

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

Galvanizing Line Crane Automation and Process Integration

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

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

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

Design Basis

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

Control Documentation

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

Manufacturing Records

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

Factory Acceptance

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

Site Readiness

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

Installation

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

Commissioning

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

Lifecycle Support

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

Crane Equipment

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

Process Handling

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

Protection and Controls

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

Project Services

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

01 · Plant and process scope

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

02 · Building and runway

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

03 · Loads and attachments

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

04 · Tank line and handling route

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

05 · Process performance

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

06 · Environmental conditions

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

07 · Controls and interfaces

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

08 · Power, standards and acceptance

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

09 · Delivery and site scope

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

10 · Schedule and lifecycle

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

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

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

How is the required crane capacity calculated?

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

Why are two hoists used on some galvanizing cranes?

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

Is full automation necessary?

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

What corrosion protection is required?

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

Does a galvanizing line crane need explosion protection?

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

Can the crane communicate with the galvanizing line PLC?

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

What determines the number of cranes?

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

Why do galvanizing line crane quotations vary widely?

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

What should be demonstrated before final acceptance?

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

SUPPORT ARRANGEMENT

Independent Floor-Mounted Runway

WORKING COVERAGE

Rectangular Crane Bay

BRIDGE OPTIONS

Single or Double Girder

COMMERCIAL BASIS

Project-Configured Quotation

Production and Assembly Cells

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

Existing Industrial Buildings

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

Warehousing and Maintenance

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

Leased or Adaptable Facilities

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

Crane Bays Inside Larger Workshops

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

New Process Areas

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

01 / LOAD

Capacity and Load Geometry

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

02 / COVERAGE

Hook Envelope and Approaches

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

03 / STRUCTURE

Columns, Bracing and Foundations

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

04 / DUTY

Operating Cycle and Motion

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

05 / CLEARANCE

Headroom and Building Interfaces

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

06 / ENVIRONMENT

Site Conditions and Compliance

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

Runway Columns, Bracing and Foundations

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

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

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

Usable Hook Coverage

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

Available Headroom

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

Overhead and Floor Interfaces

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

Hoisting Mechanism

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

Bridge and Trolley Travel

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

Controls and Variable Speed

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

Crane Protection

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

Runway and Support Control

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

Operating Area

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

Crane Equipment

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

Independent Runway System

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

Site and Project Services

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

Manufacturing, Inspection and Documentation

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

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

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

01

Site Verification

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

02

Support Erection

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

03

Crane Installation

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

04

Commissioning

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

05

Lifecycle Maintenance

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

Load and Operation

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

Coverage and Structure

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

Site and Commercial Scope

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

Single-Girder Overhead Crane

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

Double-Girder Overhead Crane

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

LX Suspension Overhead Crane

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

Frequency-Conversion Overhead Crane

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

5 Ton Overhead Crane

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

All Overhead Crane Products

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

CONFIGURATIONS

Double or Four Girder

LISTED PRODUCT RANGE

5–500 t, Model-Dependent

WORKING CLASS

A6–A8, Model-Dependent

PRIMARY APPLICATION

Ladle Transfer and Pouring

Ladle Transfer

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

Controlled Pouring

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

Furnace and Charge Handling

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

Foundry Maintenance

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

01 / RATED LOAD

Complete Suspended Load

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

02 / LADLE INTERFACE

Trunnions and Attachment

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

03 / PROCESS ROUTE

Furnace-to-Pour Path

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

04 / DUTY

Load Spectrum and Cycle

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

05 / ENVIRONMENT

Heat, Dust and Splash

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

06 / SAFETY BASIS

Defined Failure Response

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

07 / RUNWAY

Building and Rail Interface

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

08 / CONTROL AND SCOPE

Operation and Project Boundary

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

1. Secure Ladle Engagement

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

2. Stable Vertical Lift

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

3. Controlled Cross and Long Travel

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

4. Pouring or Safe Placement

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

Operator Cabin

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

Remote or Automatic Control

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

Drive and Motion Control

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

Condition and Safety Monitoring

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

Engineering Package

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

Manufacturing Controls

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

Testing and Handover

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

Shipment and Site Readiness

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

Erection and Alignment

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

Commissioning and Acceptance

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

Lifecycle Maintenance

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

Double-Girder Casting Crane

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

Four-Girder Casting Crane

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

Metallurgical Bridge Crane

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

YX Metallurgical Bin Crane

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

Quenching Crane

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

Slab Handling Crane

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

SYSTEM FAMILY

Overhead, Underhung or Gantry

RATED CAPACITY

Defined by Maximum Lifted Load

LAYOUT BASIS

Bay, Runway and Process Route

PRICE BASIS

Project-Specific Quotation

Production Handling

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

Equipment Assembly

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

Plant Maintenance

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

Internal Logistics

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

01 / LOAD

Maximum Load and Attachment

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

02 / PROCESS

Travel Path and Coverage

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

03 / DUTY

Cycles and Load Spectrum

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

04 / GEOMETRY

Span, Lift and Headroom

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

05 / STRUCTURE

Building and Runway Capacity

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

06 / ENVIRONMENT

Indoor Operating Conditions

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

07 / MOTION

Speed, Control and Accuracy

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

08 / SCOPE

Standards and Project Boundary

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

Machining and Fabrication

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

Assembly and Positioning

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

Maintenance and Tool Change

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

Receiving and Dispatch

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

Wire-Rope Hoist or Open-Winch Trolley

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

Variable-Frequency Motion

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

Operator Interface

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

Monitoring and Automation

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

Lifting Protection

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

Travel Protection

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

Electrical Protection

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

Maintenance Access

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

ENGINEERING

Design Input Review

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

FABRICATION

Controlled Manufacturing

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

TESTING

Inspection and Functional Checks

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

DOCUMENTATION

Project Document Package

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

Pre-Installation Verification

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

Erection and Commissioning

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

Planned Maintenance

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

Lifecycle Support

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

Crane Equipment

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

Supporting Infrastructure

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

Delivery and Site Work

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

Which crane type is most suitable for a general workshop?

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

How is factory crane capacity selected?

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

Can an overhead crane be installed in an existing factory?

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

What information is needed to confirm crane span?

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

When is a double-girder workshop crane required?

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

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

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

Can one crane serve several production machines?

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

Does a crane quotation include the runway and installation?

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

Can workshop cranes use radio remote control?

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

How can comparable factory crane quotations be evaluated?

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

Single-Girder Bridge Crane

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

Electric Single-Girder Overhead Crane

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

Double-Girder Bridge Crane

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

Multi-Support Underhung Crane

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

Intelligent Electric Hoist Overhead Crane

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

Double-Trolley Electric Hoist Crane

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