100 Tons Mg Gantry Crane

 

The MG type 100-ton double girder gantry crane is a heavy-duty lifting solution designed for outdoor material handling operations in sectors such as steel yards, shipyards, construction sites, and logistics terminals. It is engineered for high capacity, durability, and efficiency, making it ideal for lifting and transporting extremely large and heavy loads.

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🔧 Technical Overview:

Rated Lifting Capacity: 100 tons

Span: Typically ranges from 18 to 35 meters (customizable)

Lifting Height: Depending on project needs (commonly 6–18 meters)

Work Duty: A5–A7 (medium to heavy-duty)

Power Supply: 3-phase AC, 380V/50Hz (customizable)

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🧱 Main Components:

Double Main Girders:

Welded box-type structure for strength and stability

Designed with FEM or DIN standards

Trolley with Winch Hoisting Mechanism:

Heavy-duty hoisting trolley runs along the girders

Equipped with a large drum and high-strength wire rope for 100T lifting

Legs (A-frame or L-type):

Rigid and robust to support heavy loads

Allows clear space for material transfer

End Carriages:

House the travel wheels and drive mechanisms

Ensures smooth, stable crane movement on rails

Ground Beam (Bottom Beam):

Connects both sides of the crane

Equipped with wheels that travel along ground rails

Electrical System:

Equipped with PLC control, soft start, overload protection, and limit switches

Optional remote control or driver's cabin

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✅ Key Features & Advantages:

High Load Capacity: Can lift up to 100 tons of material with stability and precision

Heavy-Duty Construction: Ideal for frequent or continuous lifting operations

Customizable Span and Height: Tailored to your specific site conditions

Reliable Components: Often equipped with motors and gearboxes from Siemens, SEW, or similar global brands

Advanced Safety Devices: Anti-wind protection, rail clamps, overload limiters, emergency stop, etc.

Efficient Operation: Smooth trolley and crane movement, often with variable frequency drives (VFDs) for energy efficiency and soft control

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🔄 Applications:

Steel mills & metal processing plants

Shipyards and boat manufacturing

Construction material yards

Bridge building and precast concrete handling

Heavy equipment loading/unloading

 

Core Components：Engine, Bearing, Gearbox, Motor, Gear

Place of Origin：Henan, China

Warranty：2 years

Weight (KG)：50000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Application：Outdoor

Keywords：Gantry Crane

Rated Loading Capacity：50Ton

Cross travelling speed：44.6m/min

Long travelling speed：47.1m/min

Control way：cabin

Power supply：Cable reel

Steel track：QU80

Power：3-phase AC 50HZ 380V

 

 

1.Main Girders (Double Girder Structure)

Function: Carry the load and support the trolley/hoist.

Structure: Welded box-type design for maximum strength and stiffness.

Material: High-quality structural steel (Q235B or Q345B).

Features: Camber design to reduce deflection under heavy load

 

Crane Legs (Support Frames)

Function: Support the main girder and connect to the ground beams.

Types:

A-frame: Symmetrical and widely used

L-type: Asymmetrical, offers better clearance and load handling on one side

Design: Strong box-welded or truss structure

 

Trolley (Hoisting Mechanism)

Function: Carries the hoisting winch and moves along the main girders.

Components:

Lifting motor, gearbox, and drum

Wire rope system

Hook block (with 100-ton rated capacity)

Control: Often includes dual-speed or VFD (variable frequency drive) for precise hoisting.

 

 

3.End Carriages

Function: Connect the legs and support travel wheels and motors.

Includes:

Crane traveling wheels (with rail clamps)

Travel drive motor and gearboxes

Buffer system to absorb impact at travel limits

4.Crane travelling mechanism

1) Working principle

The wheels are attached to axles or wheel blocks that help in distributing the load evenly across the crane.The drive motor activates the wheels through a system of gears and reducers, converting the motor's rotational force into torque.The wheels, mounted on the frame of the crane, roll along the rails on which the gantry structure is placed.The power to the wheels is transmitted via a combination of chains, belts, or direct coupling depending on the design of the crane.The crane traveling mechanism of a Double Main Girder Gantry Crane involves synchronized wheel and motor systems that enable the crane to move along its designated rails, with additional features ensuring safe, balanced, and efficient operation.

2) Functions of the crane operating mechanism

Horizontal movement: The primary function of the crane travelling mechanism is to move the entire crane structure along the rails or tracks that are placed on the ground or the sides of the installation area.

Support and Stability:The travelling mechanism ensures the crane is securely supported on the rails or tracks. It helps distribute the weight of the crane evenly and provides stability during movement.

Power Transmission:The crane travelling mechanism is powered by electric motors that drive wheels or gear systems. These motors convert electrical energy into mechanical energy, propelling the crane forward or backward.

Load Distribution:The travelling mechanism helps distribute the load evenly across the crane's wheels and tracks, preventing damage and ensuring the durability of the crane and its components.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The frame is typically made of high-strength steel to support the load and withstand the stresses during operation.

Wheel set: The trolley is equipped with wheels that run on the rails of the main girder. These wheels are often made of hardened steel or cast steel to ensure durability and wear resistance.

Drive device: Electric motors are commonly used to provide the necessary power for the trolley's movement A gearbox is used to control the speed and torque of the trolley's movement.Couplings connect the motor to the gearbox and ensure smooth transmission of power to the wheels.

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2) Function of the trolley operating mechanism

Horizontal Movement: The primary function of the trolley traveling mechanism is to move the trolley horizontally across the length of the main girders. This movement allows the crane to position the hoist over a desired load location.

Load Handling: By moving along the main girders, the trolley helps in positioning the hoist system accurately above the load, which is necessary for lifting and transferring goods efficiently.

Power Transmission: The traveling mechanism typically uses electric motors and gear systems to provide the necessary torque and speed for the trolley's movement. The motors can be either AC or DC, depending on the design and requirements of the crane.

Rails and Wheels: The trolley runs on rails that are mounted on the main girders. The wheels on the trolley are designed to travel along these rails, ensuring smooth and stable movement. The wheels may be fitted with flanges to prevent lateral movement and maintain alignment.

Safety Mechanisms: The traveling mechanism is equipped with safety features such as limit switches, braking systems, and overload sensors to prevent accidents and ensure the safe operation of the crane.

6.Crane wheel

1) Function of wheels

Load Bearing: In a double main girder gantry crane, each wheel supports a significant portion of the crane's load. The wheels must be engineered to handle both the static and dynamic loads imposed during lifting operations.

Material Handling and Safety: The design of crane wheels must ensure safe operation, especially when handling heavy or oversized loads. The wheels should be engineered to minimize noise and vibrations during operation.

Rail Compatibility: Crane wheels are designed to run on specific rail types (e.g., flat or curved tracks). The size and shape of the wheel flange must match the rail profile to ensure proper fit and smooth operation.

2) Design requirements

Material and Design: Crane wheels are typically made of high-strength steel or cast iron to withstand the heavy loads and stresses associated with lifting and transporting materials. The design often includes a flange to ensure proper alignment and prevent the wheels from derailing off the tracks.

7.Crane Hook

The crane hook of a double main girder gantry crane is an essential component used for lifting and transporting heavy loads.

Design and Structure

Material: Typically made of high-strength steel to withstand heavy loads and provide durability.

Shape: The hook often has a C-shape or a pointed end for securely holding lifting slings or chains.

Size and Capacity: It is designed to match the lifting capacity of the crane, which can range from a few tons to several hundred tons for large industrial cranes.

Types of Hooks

Single Hook: Common in standard applications, used for lifting a load from a single point.

Double Hook: Utilized when a more balanced load is needed, often in double main girder designs for higher lifting capacities.

Crab Hook: In gantry cranes, the hook may be mounted on a trolley or crab that runs along the girders.

Motor

The motor of a double main girder gantry crane is an essential component that provides the power necessary for lifting, traveling, and sometimes rotating the crane's hoist or trolley system.The motor's power rating must match the crane's capacity and the load it needs to lift. Typically, these motors range from a few kilowatts up to hundreds of kilowatts, depending on the lifting and traveling requirements.

Motors can be equipped with variable frequency drives (VFDs) for smooth speed adjustments and energy savings.Safety and control systems like overload protection, braking systems, and emergency stops are incorporated for safe operation.

The motor should be compatible with the electrical supply available at the operating site, which can vary (e.g., 380V/50Hz, 480V/60Hz).The motor in a double main girder gantry crane is used for operations such as lifting heavy loads, moving the crane along the tracks (longitudinal travel), and sometimes lateral movement (cross travel) of the hoist or trolley.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

A double main girder gantry crane, commonly used in heavy-duty operations, often incorporates safety mechanisms like sound and light alarm systems to ensure safe operations.

Sound Alarm (Horns/Buzzers): These are typically loud, audible devices that emit a distinctive sound to alert people in and around the working area. The sound level is designed to be high enough to be heard over operational noise.

Light Alarm (Flashing Lights/Beacons): Visual signals, such as flashing lights or rotating beacons, help alert personnel visually, especially in noisy environments where sound alarms may be insufficient.

2) Limit switch

A limit switch on a Double Main Girder Gantry Crane is a safety device used to prevent the crane from moving beyond a designated range. This ensures the protection of both the crane and its surroundings, as well as any loads being lifted.

Key Functions of Limit Switches:

Position Control: The limit switch helps monitor and control the position of the crane's trolley, hoist, and gantry to prevent over-travel and collisions.

Safety Shutdown: If the crane moves past its allowed limits, the limit switch signals the control system to stop the motor and prevent damage or hazardous situations.

Emergency Stop: It can act as an emergency cutoff to shut down the crane when it approaches the limits of its track or rail, preventing it from derailing or causing accidents.

Types of Limit Switches Used:

Mechanical Limit Switches: Activated by physical contact, often using a lever or cam that triggers the switch when moved by the crane's motion.

Electronic Limit Switches: Use sensors (e.g., inductive, capacitive, or optical sensors) for non-contact detection, providing higher durability and reducing wear and tear.

Rotary Limit Switches: Typically used in applications where rotational motion needs to be monitored, such as in hoists.

Linear Limit Switches: Used for applications where linear travel is monitored, commonly found in the movement of the trolley.

10.Safety Devices

1) 1. Overload Protection Device

Function: Prevents the crane from lifting loads that exceed its rated capacity.

2. Limit Switches

Function: Prevents the crane from moving beyond a set range during operations.

3. Emergency Stop Button

Function: Allows operators to quickly shut down the crane in case of an emergency.

4. Anti-Collision Device

Function: Prevents collisions between the crane and other structures or equipment.

5. Load Sway Control

Function: Reduces load sway during operations, which can be dangerous if uncontrolled.

6. Brake Systems

Function: Ensures that the crane remains in a stationary position when not in motion.

7. Safety Interlocks

Function: Prevents the operation of the crane if certain safety conditions are not met.

8. Warning Alarms and Signal Lights

Function: Alerts personnel in the vicinity of the crane's movement.

9. Anti-Tipping Device

Function: Protects against crane tipping due to uneven load distribution or excessive loading.

10. Cooling System for Motors

Function: Prevents motors from overheating during extended use.

11. Remote Control Systems

Function: Allows operators to control the crane from a safe distance.

12. Crane Monitoring Systems

Function: Provides real-time monitoring of operational parameters such as load weight, speed, and position.

13. Lighting and Visibility Aids

Function: Ensures that the operator has clear visibility, especially in low-light conditions.

11.Control Mode

1)1. Pendant Control

Description: The crane operator uses a wired control pendant to manage the movement of the crane and hoist.

Advantages: Simple to use, cost-effective, and provides direct control from a safe distance.

Usage: Commonly used in stationary or semi-stationary operations where the operator can be close to the crane.

2. Radio Remote Control

Description: Operators use a wireless control unit, which communicates with the crane via radio signals.

Advantages: Offers more flexibility as the operator can control the crane from a greater distance and access hard-to-reach areas.

Usage: Ideal for more complex operations and environments where operator mobility is essential.

3. Cabin Control

Description: The operator sits in a cabin on the crane itself and controls it using a combination of joysticks, buttons, or other controls.

Advantages: Provides a better view of the working area and greater precision in controlling the crane.

Usage: Suitable for heavy-duty operations or when a higher level of control is needed for positioning and maneuvering.

4. Automated Control (Semi-Automatic and Fully Automated)

Description: The crane can be controlled by programmed commands or integrated with automated systems for autonomous operation.

Advantages: Reduces human intervention, improves precision, and enhances safety for repetitive tasks.

Usage: Often used in large-scale operations where high efficiency and continuous operation are necessary.

5. Hybrid Control

Description: Combines manual operation (using pendant, remote, or cabin control) with automated features that can be engaged as needed.

Advantages: Offers versatility for operators who need to switch between manual and automated modes for specific tasks.

Usage: Common in systems designed to be adaptable to various operational requirements.

12.Sketch

 

Main technical

 

 

 

Here are the key advantages of a 100-ton MG-type double girder gantry crane, highlighting why it's a preferred solution for heavy-duty lifting applications:

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✅ Advantages of 100-Ton MG Double Girder Gantry Crane

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1. High Lifting Capacity

Capable of handling extremely heavy loads (up to 100 tons) with stability and safety.

Suitable for demanding applications like steel mills, shipyards, and bridge construction.

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2. Robust & Durable Structure

Heavy-duty box-type double girder design for excellent load distribution.

Made from high-strength steel, ensuring long service life and resistance to deformation.

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3. Versatile Design for Outdoor Use

Ideal for outdoor operations where overhead crane infrastructure isn't feasible.

Can be equipped with wind-proof rail clamps, storm anchors, and lightning protection for enhanced outdoor performance.

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4. Wide Span & High Clearance

Customizable span (often up to 35 meters or more) provides broad working coverage.

L-type or A-frame legs allow better clearance and handling space for oversized loads.

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5. Advanced Hoisting System

Equipped with a powerful winch-type trolley hoist for stable and precise lifting.

Dual-speed or frequency-controlled motors offer smooth hoisting with minimal sway.

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6. Reliable Travel Mechanism

Independent drives on each side ensure synchronized and stable crane travel.

Ground-level track design allows for easier installation and maintenance compared to overhead systems.

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7. Enhanced Safety Features

Standard safety devices include overload protection, limit switches, emergency stop, anti-collision systems, and derailment prevention.

Can withstand harsh weather and working environments with proper outdoor safety add-ons.

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8. Operator Comfort & Control Options

Optional air-conditioned operator cabin with wide visibility and ergonomic controls.

Also supports wireless remote or pendant control for flexible operations.

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9. Cost-Effective for Heavy Outdoor Work

Eliminates the need for building expensive support structures (like those required for overhead cranes).

Lower maintenance frequency due to rugged components and easy access.

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10. Customization & Scalability

Custom-built to match specific project needs: span, height, lifting speed, rail length, and more.

Easily upgradable with automation, smart diagnostics, or integration into logistics systems.

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📈 Ideal for:

Heavy fabrication yards

Precast concrete handling

Wind turbine manufacturing

Heavy machinery assembly

Shipbuilding and port logistics

 

 

 

1. Port Operations

Container Handling: Double main girder gantry cranes are commonly used at ports for lifting and transferring containers between ships and storage yards. Their high capacity and reach allow them to handle heavy and large cargo efficiently.

Bulk Material Loading/Unloading: These cranes can also manage bulk goods such as coal, iron ore, or grains.

2. Shipyards

Ship Construction and Repair: They are used to move heavy sections of ships during assembly or repair. The cranes' ability to cover wide spans and support significant weight makes them suitable for handling steel components and other large ship parts.

Launching and Docking: Double main girder gantry cranes assist in moving ships in and out of dry docks or onto slipways.

3. Construction Sites

Building Materials: In large-scale construction projects, these cranes facilitate the transport of building materials such as steel beams, concrete panels, and other heavy components across vast construction zones.

Bridge and Infrastructure Projects: The high capacity and long reach make them ideal for lifting heavy prefabricated segments and assembling infrastructure like bridges.

4. Steel Industry

Steel Handling: They are used to lift and transport heavy steel plates, coils, and beams within steel plants for processing, storage, or shipment.

Overhead Lifting: Double main girder gantry cranes are also used for overhead handling within facilities where wide spans are necessary.

5. Heavy Machinery Manufacturing

Assembly Line Support: These cranes can move large machinery components across the assembly line during the manufacturing process.

 

 

1. Design and Engineering

Blueprint and Structural Design: Engineering teams design the crane based on specifications, considering the weight, span, lifting capacity, and working environment.

Component Specifications: Detailed specifications for components such as the main girders, end beams, hoist system, trolley, and electrical components are prepared.

2. Material Selection and Procurement

Steel Material Selection: High-strength steel materials are chosen for the main girders, columns, and other critical parts.

Procurement: Materials, such as steel plates, sections, bolts, and electrical components, are sourced and inspected for quality.

3. Cutting and Pre-Fabrication

Cutting and Shaping: Steel components are cut, shaped, and welded into preliminary forms according to the design specifications.

Pre-Fabrication Assembly: Components such as beams and girders are pre-assembled to verify that they fit together properly.

4. Welding and Structural Assembly

Welding: Main girders, columns, and other structural components are welded to create a sturdy framework. Specialized welding techniques are used to ensure strength and durability.

Structural Assembly: The main girders and end beams are assembled, ensuring precise alignment for balanced load distribution.

Quality Control: Welding seams and joints are inspected using non-destructive testing (e.g., ultrasonic or X-ray testing) for any structural defects.

5. Machining and Finishing

Machining of Parts: Critical parts such as the wheels, trolley components, and hoists undergo machining for proper fitting and smooth operation.

Surface Treatment: Steel parts are cleaned and subjected to surface treatments like sandblasting and coating to prevent rust and enhance durability.

Painting and Coating: Protective coatings are applied for weather resistance, with a primer followed by top coats.

6. Assembly of Crane Components

Main Girder Assembly: The two main girders are mounted and aligned.

End Beam Installation: End beams are fixed to the main girders, forming the frame of the crane.

Hoist and Trolley Installation: The hoist mechanism and trolley are mounted on the main girder rails and tested for alignment and operational smoothness.

7. Electrical and Control Systems Installation

Wiring and Cabling: Electrical wiring is installed for power supply, control circuits, and safety systems.

Control Panel and Safety Features: The control panel is mounted, with safety features such as limit switches, emergency stops, and overload protection integrated and tested.

Control System Programming: The crane's control system is programmed and tested for correct operation.

8. Testing and Quality Assurance

Load Testing: The crane is subjected to load tests to ensure it can handle its rated capacity without issues.

Operational Testing: Functional tests are performed to check movements, responsiveness, braking systems, and electrical operations.

Inspection and Certification: The crane undergoes final inspections to verify compliance with safety regulations and standards. Certification may be issued by relevant authorities.

9. Final Adjustments and Delivery Preparation

Final Adjustments: Any minor adjustments are made to ensure smooth operation.

Documentation: Operation manuals, maintenance guidelines, and certification documents are prepared for delivery.

Packaging and Shipping: The crane is packaged securely for shipment, ensuring all parts are protected during transit.

10. Installation and Commissioning (at Site)

On-site Assembly: The crane is assembled at the customer's location if required.

Workshop view:

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%.