100-ton Gantry Hoist Crane

 

 

Introduction to 100-Ton Gantry Hoist Crane

A 100-ton gantry hoist crane is a heavy-duty lifting system designed to handle extremely large and heavy loads with precision and safety. Built for industrial-scale operations, it features a robust gantry structure supported by legs and is equipped with an electrically powered hoist capable of lifting loads up to 100 tons.

These cranes are commonly used in sectors like shipbuilding, heavy manufacturing, construction, power generation, and steel fabrication-where oversized equipment, components, or materials need to be lifted, moved, or positioned. The crane runs on rails or wheels and offers both vertical and horizontal load movement, enhancing operational flexibility.

Key features often include:

Double-girder design for maximum load support

High-capacity electric hoist with advanced safety controls

Customizable span, height, and lifting speed

Weather-resistant systems for outdoor applications

Remote or cabin operation for ease and safety

With their high capacity and durability, 100-ton gantry hoist cranes are essential for projects requiring the safe and efficient handling of massive loads.

 

Warranty：2 years

Weight (KG)：5000 kg

Feature：Gantry Crane

Application：warehouse, ports, yard, etc

Rated Lifting Moment：100kn

Color：Customized

Capacity：10-600t

Power supply：110V/220V/230V/380V/440V

Lifting mechanism：Electric Winch Trolley

Work Duty：A3-A6

 

 

 

1.

Double Girder Bridge

Two parallel horizontal beams span the width of the crane. This design provides enhanced strength and load distribution for heavy lifting applications.

Legs (Gantry Frame)

Massive vertical steel structures that support the bridge and transfer the load to the ground. They may be fixed or mobile depending on the crane's design.

100-Ton Electric Hoist

The hoisting mechanism that lifts and lowers the load. It includes:

Motor & Gearbox – Provides the necessary torque.

Drum & Wire Rope – Used to raise/lower the load.

Hook Block – Heavy-duty hook assembly that holds the load.

 

3.End Carriages (End Trucks)

Located at the ends of the gantry legs, these support the entire crane and contain the wheels or bogies for crane movement.

 

4.End Carriages (End Trucks)

Located at the ends of the gantry legs, these support the entire crane and contain the wheels or bogies for crane movement.

 

5.Travel Mechanism

Includes motors and wheels that allow the crane to move longitudinally along rails or tracks laid on the ground.

 

6.Crane wheel

1. Wheel type:

Driving wheel: driven by the driving device, responsible for driving the trolley to move along the track of the main beam. The driving wheel is generally connected to the motor, and the trolley is driven by the power of the motor.

Driven wheel: paired with the driving wheel, not directly connected to the motor, plays a role of auxiliary support and guidance. The driven wheel also rolls on the track, but does not participate in the drive.

Main wheel and guide wheel: some gantry cranes are equipped with guide wheels or side wheels on the wheels to ensure that the trolley moves in a straight line when moving and prevent lateral deviation.

2. Wheel material:

Steel wheel: Common crane wheels are made of high-strength steel, with strong wear resistance and load-bearing capacity, suitable for working under heavy load and high frequency.

Forged wheel: manufactured by forging process, with higher strength and longer service life, suitable for large-tonnage cranes.

7.Crane Hook

1) Hook type:

Single hook: Single hook is the most common form, with a simple structure and widely used in most lifting operations. Single hook is suitable for lifting most ordinary goods.

Double hook: Double hook is suitable for materials that are symmetrical or require two-point support, such as long objects. Double hooks can provide better balance and safety.

2) Use and maintenance of hooks:

During use, the hook needs to be checked regularly for deformation, cracks or wear, especially when lifting heavy objects, the hook will be under great pressure. If the hook has defects, it may cause major safety accidents.The rotating part of the hook should be lubricated regularly to maintain flexibility and prevent rust or jamming.Before each use, make sure that the safety lock is in good working condition to avoid accidental unhooking.

Motor

Drive and control of motors:

1) Electronic control system: The motors of cranes are driven and controlled by electronic control systems, which usually include control components such as contactors, relays, frequency converters and PLCs. The electronic control system can realize the functions of starting, stopping, accelerating, decelerating and braking the motors.

2) Variable frequency speed regulation: The frequency converter controls the speed by adjusting the frequency of the motor to achieve precise speed regulation. Using variable frequency speed regulation can not only reduce energy consumption, but also extend the service life of the motor and related machinery.

3) Overload protection: The motor is usually equipped with an overload protection device. When the motor load exceeds its rated value, the system will automatically cut off the power to protect the motor from damage.

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Sound and light alarm system & limit switch

1)Function of the sound and light alarm system

Start reminder: When the crane starts to run, the sound and light alarm system will automatically emit a loud warning sound, usually accompanied by flashing lights, to remind the staff and surrounding personnel that the crane is running.

Fault alarm: When the crane fails (such as overload, limiter failure, motor overheating, etc.), the sound and light alarm system will immediately sound an alarm to prompt the operator to check.

Emergency alarm: During the operation of the crane, if an emergency (such as power failure or mechanical failure) is detected, the system will send a continuous alarm signal through sound and light, requiring immediate measures.

2)Function of limit switch

Position control: The limit switch can accurately control the operating position of the crane to prevent the trolley, trolley or hook from exceeding the preset range.

Safety stop: When the crane runs to the set maximum limit, the limit switch will automatically cut off the power supply and stop the crane from continuing to run to prevent collision or derailment.

Prevent overwinding: The limit switch in the lifting mechanism can prevent the hook from overwinding, that is, after the hook rises to the top, the system will automatically stop the operation of the motor to prevent the wire rope from being over-tightened or broken.

10.Safety Devices

1) Overload limiter: used to detect the weight of the load lifted by the crane to prevent overloading. If the weight exceeds the set value, the system will automatically cut off the power supply or sound an alarm to remind the operator.

2) Electromagnetic brake: provides reliable braking function, automatically brakes when the motor is powered off or fails, and prevents the heavy object from sliding down or losing control.

3) Safety hook and lock: ensure that the sling and hook are firmly connected to prevent the risk of material sliding during the lifting process.

4) Safety clamp: installed on the lifting mechanism to prevent the hook from losing control during the descent process and provide additional safety protection.

5) Safety net and guardrail: set up safety nets and guardrails in the working area of ​​the crane to prevent people from entering the dangerous area by mistake.

6) Electrical protection device: including overcurrent protection, overheating protection and short circuit protection to prevent electrical faults from causing fire or equipment damage.

7) Emergency stop button of the control system: in an emergency, the operator can quickly cut off all power and stop the operation of the crane immediately.

8) Regular maintenance and overhaul: Develop regular maintenance and overhaul plans to ensure that all safety devices are functioning properly and eliminate potential faults in a timely manner.

 

11.Control Mode

1) Manual control: The operator controls the various functions of the crane (such as lifting, running, trolley movement, etc.) through manual joysticks or buttons. This method is simple and intuitive, and is suitable for small or medium-tonnage cranes. Or the operator uses a wireless remote control to control the movement of the crane, which provides a larger range of activities and flexibility, and is suitable for some complex or dangerous working environments.

2) Automatic control: The use of a programmable logic controller (PLC) for control can realize automatic operation and improve work efficiency and safety. The PLC system can be programmed to implement complex control logic, such as automatic upper and lower limits, overload protection, etc.

3) Frequency conversion control: Using a frequency converter to adjust the speed of the motor can achieve smooth acceleration and deceleration, reduce the impact on the mechanical system, and extend the service life of the equipment. This control method is usually used for cranes with high speed requirements.

4) Integrated control system: The various control functions of the crane are integrated into a central control platform, and the operator can manage and monitor the entire crane through an interface, including lifting, moving, positioning and other functions.

5) Remote control: Through wireless network connection, the operator can control the crane from a safe distance, which is suitable for operations in dangerous environments and reduces the safety risks of the operator.

 

12.Sketch

 

Main technical

 

 

Here are the main advantages of a 100-ton gantry hoist crane:

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Advantages of a 100-Ton Gantry Hoist Crane

Heavy Load Capacity

Specifically designed to lift extremely heavy objects-up to 100 tons-making it ideal for large-scale industrial tasks.

Versatility in Application

Can be used in various environments, including shipyards, steel plants, construction sites, and power stations.

Flexible Installation

Unlike overhead cranes, gantry cranes do not require a building structure for support, which reduces infrastructure costs and allows for outdoor use.

Mobility

Many 100-ton gantry cranes can be mounted on rails or wheels, allowing them to travel across large sites and access different work zones.

Customizable Design

Span width, lifting height, hoisting speed, and control systems can all be tailored to meet specific operational needs.

Electric-Powered Operation

Efficient and cost-effective with reduced manual effort. Allows for smoother and more precise load handling.

Enhanced Safety Features

Typically equipped with overload protection, emergency stop systems, limit switches, and real-time load monitoring to ensure safe operation.

Low Long-Term Maintenance

Built with durable materials and modern control systems, reducing the frequency and cost of maintenance over time.

Improved Productivity

Enables faster material handling and positioning, which increases workflow efficiency and reduces project timelines.

Outdoor Performance

Well-suited for harsh environments; weatherproof designs allow operation in various climate conditions without loss of performance.

 

 

 

Here's a comprehensive list of applications for a 100-ton gantry hoist crane:

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Applications of a 100-Ton Gantry Hoist Crane

Shipbuilding & Marine Industry

Lifting large ship components like hull sections, engines, and propellers during construction or maintenance.

Steel & Metal Fabrication

Handling heavy steel plates, coils, and structural assemblies in fabrication shops or steel mills.

Power Generation Facilities

Installing and maintaining large turbines, generators, transformers, and other heavy equipment.

Construction Sites

Moving precast concrete segments, large steel beams, and heavy construction equipment on-site.

Railway & Train Manufacturing

Transporting train car bodies, bogies, and other components during assembly or repair.

Aerospace Industry

Positioning aircraft fuselage sections, wings, and other oversized aerospace components.

Mining & Heavy Equipment Maintenance

Lifting large mining machines or components like crushers, excavators, or haul truck frames for assembly or servicing.

Wind Energy Sector

Installing and assembling heavy wind turbine components such as nacelles and tower segments.

Logistics & Container Yards

Handling massive cargo containers or oversized freight that requires high-capacity lifting.

Oil & Gas Industry

Moving heavy equipment like drilling rigs, pipeline sections, or refinery modules.

 

 

 

1) Demand analysis and design: According to the specific needs of customers (such as lifting capacity, span, work site, etc.), carry out detailed technical analysis to determine the specifications and functional requirements of the crane. Design the main components of the Global Industrial Gantry Crane, such as the main beam, trolley, and outriggers, to ensure that they meet national standards and customer requirements. Use CAD software for detailed 3D modeling to ensure the rationality and safety of the structure. Design the electronic control system, including motors, control boxes, inverters, limit devices, and safety alarm systems, to ensure the automation and ease of operation of the crane.

2) Material procurement: According to the design plan, purchase the required steel, motors, electrical components, wire ropes, pulleys and other raw materials to ensure that all materials meet the relevant quality standards and requirements.

3) Manufacture of steel structure: According to the design drawings, cut and weld the steel plates to form the basic structure of the main beam and outriggers. High-strength steel is usually used to ensure the strength and durability of the crane. Manufacture the lifting trolley, including the motor, brake, wheels and its frame structure. The welding of the main beam and the outrigger needs to be strictly controlled, and the welds need to be non-destructively tested (such as ultrasonic or X-ray flaw detection) to ensure that the welding quality is defect-free.

4) Machining: The wheel is one of the core components of the Global Industrial Gantry Crane. It needs to be precisely processed by lathes and other machining equipment to ensure that its diameter, roundness and surface finish meet the requirements. The gears and couplings used in the transmission system need to be processed with high precision to ensure their good coordination with the motor and transmission system. Drilling and milling grooves are required on the main beam, trolley and other components to ensure the accurate installation of motors, pulleys and other components.

5) Surface treatment: Sandblasting is performed on steel structural parts to remove the oxide layer and rust on the surface to ensure the adhesion of subsequent painting. Anti-corrosion treatment is performed on the main beam, outrigger, trolley and other components, usually spraying anti-corrosion paint, anti-rust paint and topcoat to ensure the durability of the crane in harsh environments.

6) Installation of electrical system: Install the crane's motor, inverter, control cabinet, limit switch and other electrical equipment to ensure that it can achieve accurate lifting, movement and positioning. According to the electrical design plan, carry out cable wiring and electrical component connection to ensure that the electrical system can run smoothly.

7) Assembly: Assemble the processed main beam, outriggers, trolleys and other parts, and fix them by bolts or welding. Install pulleys, drums and other parts, and correctly thread the wire rope to ensure that the hook can be lifted and lowered normally. Install the trolley on the main beam to ensure that it can run smoothly. Install the wheels on the trolley and install the track in the working area of ​​the crane to ensure that the trolley can run stably on the track.

8) Debugging and testing: Test the various functions of the crane, including lifting, moving, braking and limit devices, without load to ensure that all functions are normal. Load the weight within the safe range, test the crane's load capacity, running stability, braking effect and various safety devices to ensure that they meet the design requirements.

9) Quality inspection: Check the appearance quality of welds, spraying, etc. to ensure that the crane has no obvious defects. According to national or industry standards, test the various performance indicators of the crane to ensure that they meet the design requirements. After all tests are passed, the factory inspection is carried out to ensure that the quality of the crane is fully qualified.

10) Transportation and installation: The assembled crane is disassembled into parts and transported to the installation site specified by the customer. The crane is reassembled according to the on-site conditions and the final adjustment and positioning are carried out. Secondary commissioning is carried out at the customer's site to ensure that the crane can operate normally in the actual working environment.

 

 

 

 

 

 

Material Inspection

Quality Inspection: Strict quality inspection is carried out on the purchased raw materials to ensure that they meet the design requirements and national standards.

Material Storage: Qualified materials are stored according to classification to prevent corrosion or damage.

Cutting and Forming

Steel Cutting: Use plasma cutting, laser cutting or flame cutting and other technologies to cut the steel according to the size of the design drawing.

Forming Processing: Form the steel plate through bending, rolling, welding and other processes to manufacture the main beam, end beam and other structural parts.

Welding

Component Welding: The cut and formed steel parts are welded into the main structures such as the main beam, end beam and trolley. The welding process needs to be strictly controlled to ensure the structural strength and welding quality.

Weld Inspection: Use non-destructive testing technology (such as ultrasonic testing, radiographic testing) to inspect the welds to ensure that there are no cracks or other defects.

Machining

Precision Machining: Precision machining is performed on the key components of the crane, such as wheel sets, bearing seats, pulleys, etc., to ensure their dimensional accuracy and surface quality.

Assembly of the whole machine

General assembly: On the basis of pre-assembly, the overall assembly of the crane is carried out, including the final installation of the main beam, end beam, lifting mechanism, walking mechanism, etc.

Commissioning and testing

Under dynamic conditions, the operating performance of the crane is tested, including the testing of lifting, walking, steering and other functions. The overall size of the assembled bridge crane is checked to ensure that all dimensions meet the design requirements.

Spraying and anti-corrosion treatment

Surface treatment Rust removal: Rust removal on the surface of the crane, common methods include sandblasting, pickling, etc. Primer spraying: Spray anti-corrosion primer on the treated surface to prevent metal oxidation and corrosion. Topcoat spraying Color spraying: Spray topcoat according to customer requirements or industry standards to give the crane a protective and decorative effect. Marking: After spraying, mark the crane's identification information in accordance with the specifications, such as model, rated load, etc.

Factory and installation

Packaging and transportation

Packaging protection: Protectively package the key components of the crane to prevent damage during transportation. Transportation arrangement: According to the equipment size and transportation conditions, select a suitable transportation method to transport the crane to the customer's site.

Acceptance and delivery

Customer acceptance

On-site acceptance: The customer conducts on-site acceptance of the crane according to the contract requirements and technical specifications to check the performance and quality of the equipment.

Problem rectification: If any problems are found, the manufacturer needs to rectify them in time to ensure that the equipment fully meets the customer's requirements. Delivery and use Operation training: The manufacturer usually trains the customer's operators to ensure that they can operate the crane correctly and safely.

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