Core Features

1. Robust Truss Structure
The machine features a triangular truss twin-girder design constructed from high-strength S355 steel, providing excellent strength-to-weight ratio and stability during girder erection . The modular design allows for convenient transportation and on-site assembly.

2. Precision Control System
Equipped with an advanced electrical control system including PLC monitoring, the operator can achieve precise positioning and smooth load handling. Dual-trolley synchronous control ensures lifting errors of less than 20 mm, preventing beam deflection .

3. Self-Launching Capability
The self-walking through-hole mechanism enables the machine to advance to the next span without auxiliary cranes, significantly improving construction efficiency on multi-span bridge projects .

4. Safety Protection
Multiple safety systems are integrated, including overload limiter, lifting height limiters, emergency stop, voltage-loss protection, and wind speed alarm. The machine automatically stops operation when wind speeds exceed safe thresholds .

5. Flexible Adaptability
The machine is suitable for both straight and curved bridge erection, with adjustable span and height parameters to accommodate varying project requirements. It can handle standard span erection, first and last span operations, and variable-span construction .

 

 

 

Parameter	Specification
Rated Lifting Capacity	100 tons
Adaptable Bridge Span	30–50 m (customizable)
Working Duty	A5–A7
Power Supply	3-phase AC 380V, 50Hz
Lifting Speed	0.8–1.5 m/min (frequency control)
Longitudinal Travel Speed	0–6 m/min
Lateral Travel Speed	0–3 m/min
Adaptable Longitudinal Slope	≤ 2–5%
Minimum Curve Radius	R ≥ 150–350 m
Skew Bridge Angle	0–15°

 

1. Main Girder Structure (Truss System)

Main Truss Girders - Triangular or trapezoidal truss twin-girder design fabricated from high-strength S355 steel; forms the primary load-bearing structure

Cross Beams - Connect the twin main girders; provide lateral rigidity and load distribution

Diagonal Bracing - Ensures structural stability and prevents deformation under eccentric loads

Pin Connections - Modular joints allowing on-site assembly and disassembly for transportation

2. Lifting Trolley System

Lifting Trolleys - Two independent trolleys travel along the main girders; each equipped with hoisting winch and pulley blocks

Hoisting Winches - Frequency-controlled winches for smooth lifting and precise positioning of girders

Wire Rope & Pulley Blocks - Heavy-duty steel wire ropes with multi-fall pulley systems for 100T rated capacity

Lifting Hooks / Spreaders - Customized lifting beams and hooks designed to safely grip precast girders

Trolley Travel Drive - Motor-driven wheel assemblies enabling longitudinal movement along the main girder

3. Leg Assemblies (Support System)

Front Legs (Leading Legs) - Support the front end of the machine; often equipped with articulation for curve negotiation

Rear Legs (Trailing Legs) - Support the rear end; may include hydraulic adjustment for height variation

Leg Cross Frames - Horizontal bracing between leg columns for lateral stability

Telescopic / Adjustable Legs - Optional hydraulic or mechanical adjustment to accommodate varying pier heights

Leg Travel Bogies - Wheel or rail-mounted bogies at the base of each leg for longitudinal movement

4. Traveling & Steering Mechanism

Longitudinal Travel Bogies - Rail-mounted or trackless bogies that move the entire machine forward/backward

Lateral Travel Bogies - Enable side-to-side movement for precise girder alignment

Steering Cylinders - Hydraulic cylinders for adjusting machine direction on curves

Rail Clamps / Anchors - Secure the machine to the track or ground during lifting operations

Travel Drive Motors - Electric motors with gearboxes driving the bogie wheels

5. Hydraulic System

Hydraulic Power Unit - Central pump station supplying pressurized oil to all hydraulic actuators

Hydraulic Cylinders - Used for leg height adjustment, steering, and leveling

Control Valves - Directional, pressure, and flow control valves for precise operation

Oil Tank & Cooler - Reservoir and cooling system maintaining optimal hydraulic fluid temperature

Hydraulic Hoses & Fittings - High-pressure lines connecting the power unit to actuators

6. Electrical & Control System

Main Control Cabinet - Houses PLC, contactors, relays, and power distribution components

PLC Control System - Programmable logic controller for automated sequence control and monitoring

Operator Cabin / Remote Control - Ergonomic cabin or wireless remote for machine operation

Variable Frequency Drives (VFDs) - Frequency converters for smooth speed control of winches and travel motors

Sensors & Encoders - Position, load, height, and wind speed sensors for real-time feedback

Limit Switches - Prevent over-travel of trolleys, hooks, and legs

Cabling & Cable Reels - Power and signal cables with reeling systems for continuous movement

7. Safety Devices

Overload Limiter - Automatically stops lifting when load exceeds 100T rated capacity

Lifting Height Limiter - Prevents hook over-hoisting

Emergency Stop Buttons - Immediately halts all operations in case of emergency

Wind Speed Anemometer - Alarms and stops operation when wind exceeds safe limits

Anti-Collision System - Prevents collision between trolleys or with end stops

Voltage-Loss Protection - Safely holds load in position during power failure

Rail End Stops - Mechanical stops preventing machine derailment

8. Auxiliary Components

Counterweights - Ballast blocks for maintaining stability during lifting

Access Platforms & Walkways - Safe access for maintenance and inspection

Handrails & Safety Gates - Fall protection for personnel

Lighting System - Work lights for night operations

Diesel Generator (Optional) - Standalone power source for remote sites

Tool Kits & Spare Parts - On-site maintenance and repair equipment

 

 

 

 

Advantages of the Heavy-Duty 100T Bridge Erecting Machine

1. High Lifting Capacity

100-ton rated capacity enables erection of large precast concrete girders, steel box beams, and heavy segmented bridge sections in a single lift

Reduces the number of lifting operations and minimizes the risk associated with multiple-piece assembly

Suitable for both highway and railway bridge projects requiring heavy-duty lifting performance

2. Excellent Structural Strength & Stability

High-strength S355 steel truss twin-girder design provides an optimal strength-to-weight ratio

Triangular or trapezoidal truss configuration ensures excellent torsional rigidity and resistance to deformation

Modular pin-connected structure maintains structural integrity under eccentric and dynamic loads

3. Self-Launching & Through-Hole Capability

Self-walking through-hole mechanism allows the machine to advance to the next span without auxiliary cranes

Significantly improves construction efficiency on multi-span bridge projects

Eliminates the need for repeated disassembly and reassembly between spans

Reduces dependence on ground-level crane equipment and site logistics

4. Precision Control & Synchronization

Advanced PLC control system with real-time monitoring ensures accurate positioning

Dual-trolley synchronous control achieves lifting errors of less than 20 mm, preventing beam deflection and structural stress

Variable Frequency Drives (VFDs) provide smooth acceleration, deceleration, and precise speed regulation

Reduces impact loads on both the machine and the precast girders during lifting

5. Comprehensive Safety Protection

Overload limiter automatically stops lifting when load exceeds rated capacity

Wind speed anemometer alarms and halts operation when wind exceeds safe thresholds

Emergency stop, voltage-loss protection, and limit switches safeguard against operational hazards

Anti-collision system prevents trolley collision and derailment

Complies with rigorous international safety standards for lifting equipment

6. Flexible Adaptability to Project Conditions

Adjustable span and height parameters accommodate varying bridge designs

Suitable for straight, curved, and skew bridge erection with skew angles up to 15°

Handles standard span, first and last span, and variable-span construction

Adaptable to longitudinal slopes up to 2–5% and minimum curve radius of R ≥ 150–350 m

7. Cost & Time Efficiency

Rapid assembly and disassembly due to modular design reduces mobilization time

Self-launching capability minimizes auxiliary equipment costs

High lifting speed (0.8–1.5 m/min) and travel speeds accelerate project schedules

Reduces labor requirements and overall construction costs per span

8. Ease of Operation & Maintenance

Ergonomic operator cabin or wireless remote control for convenient and safe operation

Real-time sensor feedback enables operators to monitor load, position, and machine status

Access platforms, walkways, and handrails facilitate safe inspection and maintenance

Readily available spare parts and tool kits minimize downtime

9. Environmental & Site Adaptability

Optional diesel generator set enables operation at remote sites without grid power

Corrosion-resistant coating available for harsh environments (coastal, humid, or chemical exposure)

Trackless or rail-mounted options adapt to different site conditions

Low noise and emission configurations available for urban viaduct projects

10. Wide Application Range

Highway bridge construction - precast box girders, T-beams, and segmental sections

Railway infrastructure - heavy girder erection for rail overpasses and viaducts

Urban viaduct projects - space-constrained urban environments

Industrial and port infrastructure - heavy structural component installation

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Applications of the Heavy-Duty 100T Bridge Erecting Machine

1. Highway Bridge Construction

Precast Concrete Girder Erection - Lifting and positioning of precast box girders, T-beams, I-beams, and U-beams for highway overpasses and elevated expressways

Multi-Span Bridge Projects - Self-launching capability enables efficient erection across long multi-span highway bridges

Segmental Bridge Construction - Suitable for erecting segmented precast concrete sections in balanced cantilever or span-by-span methods

Highway Interchange & Viaducts - Ideal for complex interchange structures requiring precise girder placement over existing roads

2. Railway Infrastructure

Railway Bridge Erection - Lifting heavy precast girders for railway overpasses, underpasses, and bridge crossings

High-Speed Rail Viaducts - Suitable for erecting precast box girders in high-speed rail elevated sections

Metro & Light Rail Projects - Used in urban rail transit elevated viaduct construction

Railway Station & Yard Bridges - Erection of girders over railway lines with minimal disruption to rail traffic

3. Urban Viaduct & Elevated Road Projects

Urban Expressway Viaducts - Space-constrained urban environments where ground-level cranes are impractical

City Ring Roads & Elevated Corridors - Efficient erection of precast girders over busy city streets

Pedestrian & Cycle Bridges - Suitable for erecting medium-span pedestrian overpasses and cycle bridges

Urban Rail Transit - Metro elevated lines and light rail viaduct construction

4. Industrial & Port Infrastructure

Port & Harbor Bridges - Erection of heavy girders for port access bridges and cargo terminal viaducts

Industrial Plant Bridges - Pipe rack bridges, conveyor bridges, and heavy equipment access platforms

Mining & Energy Infrastructure - Bridge erection for mining haul roads, power plant access, and energy facility connections

Logistics & Freight Corridors - Heavy-duty bridge construction for freight rail and truck routes

5. Special Bridge Structures

Curved Bridges - Adaptable to minimum curve radius of R ≥ 150–350 m for curved viaduct erection

Skew Bridges - Handles skew angles up to 15° for non-perpendicular bridge crossings

Sloped Bridges - Operates on longitudinal slopes up to 2–5% for mountainous or hilly terrain

Variable-Span Bridges - Adjustable span parameters accommodate non-uniform bridge designs

First & Last Span Erection - Specialized capability for end-span girder placement

6. Construction Scenarios

Over Existing Roads - Erect girders over active traffic with minimal disruption using span-by-span launching

Over Water Bodies - Bridge erection over rivers, canals, and coastal waters without ground support

In Mountainous Terrain - Adaptable to slopes and curves for bridges in hilly or mountainous regions

In Dense Urban Areas - Compact design and remote control enable operation in space-limited city sites

At Remote Sites - Optional diesel generator enables operation without grid power access

Night Construction - Lighting system supports around-the-clock erection for tight project schedules

7. Project Scale & Scope

Small-Scale Projects - Single-span bridge erection for local roads and rural crossings

Medium-Scale Projects - Multi-span highway and railway bridges requiring efficient span-by-span launching

Large-Scale Projects - Long viaducts, elevated expressways, and high-speed rail infrastructure

Complex Projects - Curved, skewed, and sloped bridges requiring precise control and adaptability

8. Typical Project Examples

Highway Expressway Viaducts - 30–50 m span precast box girder erection

High-Speed Railway Elevated Sections - 32 m / 40 m precast box girder erection

Urban Metro Elevated Lines - 25–35 m U-beam and box girder erection

River Crossing Bridges - Multi-span girder erection over water bodies

Interchange Bridges - Curved and skewed girder erection over existing highways

 

Production Procedure of Heavy-Duty Bridge Erecting Machine

1. Design & Engineering

Requirements Analysis - Define bridge type, span length, rated capacity (e.g., 100T), and site conditions

Structural Design - Develop truss configuration, main girder dimensions, and load-bearing calculations

Finite Element Analysis (FEA) - Perform stress analysis and structural verification for safety compliance

Detailed Drawings - Produce fabrication drawings with precise dimensions and welding specifications

2. Material Preparation

Steel Selection - Procure high-strength structural steel (e.g., Q345B, S355) for main load-bearing components

Incoming Inspection - Verify material certificates and conduct mechanical property tests

Cutting - Use cutting machines or flame cutting to shape steel plates and sections according to drawings

Edge Preparation - Perform edge trimming, drilling, and beveling for weld joints

3. Fabrication & Welding

Surface Treatment - Remove rust, oil, and contaminants via sandblasting or grinding before welding

Welding Operations - Apply arc welding or gas welding for structural joints; ensure uniform, sound welds

Main Girder Fabrication - Weld truss modules including chords, diagonals, and cross beams

Quality Control - Inspect weld quality through visual examination and non-destructive testing (NDT)

4. Machining & Component Manufacturing

Precision Machining - Machine pin holes, bolt holes, and connection interfaces for accurate fit

Leg Assembly Fabrication - Manufacture front, middle, and rear leg structures with mounting flanges

Trolley & Winch Assembly - Build lifting trolleys, hoisting winches, and pulley blocks

Bogie Manufacturing - Produce travel bogies with wheels, axles, and drive mechanisms

5. Surface Treatment & Painting

Shot Blasting - Clean steel surfaces to Sa2.5 standard for coating adhesion

Primer Application - Apply anti-corrosion primer to all structural components

Topcoat Painting - Apply finish coats with specified color and thickness

Corrosion Protection - Optional hot-dip galvanizing or specialized coatings for harsh environments

6. Factory Pre-Assembly & Testing

Trial Assembly - Partially assemble main components to verify fit and dimensional accuracy

Mechanical Testing - Test winch operation, trolley travel, and bogie rotation

Electrical System Check - Verify PLC, VFDs, sensors, and control cabinet wiring

Load Test (Factory) - Conduct rated load and overload tests to validate lifting capacity

7. Disassembly & Shipping

Modular Disassembly - Break down into transportable modules with match-marking

Packaging - Protect components with wrapping, crating, and rust-preventive treatment

Shipping - Coordinate logistics for delivery to project site

Documentation - Prepare shipping list, assembly drawings, and operation manuals

8. On-Site Assembly

Site Preparation - Level and compact assembly area; ensure adequate space and access

Component Inspection - Verify all parts received and inspect for shipping damage

Foundation & Support - Install temporary supports or assemble on pre-built track

Leg Assembly - Position front, middle, and rear legs with temporary bracing

Main Girder Erection - Lift and connect main truss girders using cranes; verify alignment and parallelism

Cross Beam Installation - Install cross beams and bracing to integrate main girders

Trolley & Winch Installation - Mount lifting trolleys on main girder rails

Electrical & Hydraulic Connection - Connect control systems, sensors, and hydraulic lines

9. Commissioning & Load Testing

No-Load Trial Run - Test all motions: lifting, trolley travel, longitudinal/lateral movement

Safety Device Verification - Check overload limiter, limit switches, emergency stop, and anemometer

Rated Load Test - Lift 100T test load to verify structural integrity and performance

Overload Test - Conduct 110-125% overload test as per safety standards

Acceptance Inspection - Complete formal acceptance with client and regulatory authorities

10. Operation & Maintenance

Operator Training - Train operators on controls, safety procedures, and emergency protocols

Documentation Handover - Provide operation manuals, maintenance schedules, and spare parts lists

Scheduled Maintenance - Regular inspection of wire ropes, brakes, hydraulic fluids, and electrical systems

Ongoing Support - Provide technical support and spare parts availability throughout project duration

 

 

The company has installed an intelligent equipment management platform, and has installed 310 sets (sets) of handling and welding robots. After the completion of the plan, there will be more than 500 sets (sets), and the equipment networking rate will reach 95%. 32 welding lines have been put into use, 50 are planned to be installed, and the automation rate of the entire product line has reached 85%.

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