150 Tons Double Girder Gantry Crane
Product Introduction
A 150-ton double girder gantry crane is a heavy-duty lifting solution designed for handling extremely large and heavy loads, often used in industries such as shipbuilding, steel fabrication, precast concrete, and large-scale manufacturing or construction projects.
Key Features:
Load Capacity: 150 tons (150,000 kg), making it suitable for lifting massive items like structural components, machinery, or containers.
Double Girder Design: Incorporates two parallel girders that provide enhanced strength and stability. This design allows for higher load capacity and better distribution of stress.
Gantry Structure: The crane moves on ground-level rails using supporting legs (gantry legs) on either side, allowing for large working spaces beneath it. It's ideal for outdoor or semi-outdoor use.
Span and Lifting Height: Customizable span (distance between the rails) and lifting height depending on site needs, typically ranging from 18m to 40m span and up to 25m lifting height.
Hoist System: Equipped with a heavy-duty electric or hydraulic hoist and trolley system that runs along the girders for horizontal movement of the load.
Applications:
Shipyards: For lifting and positioning large ship sections.
Steel Plants: Handling steel coils, slabs, and heavy components.
Construction Sites: Lifting precast segments and beams.
Power Plants: Maintenance and assembly of heavy turbine parts.
Safety and Control:
PLC-based or wireless remote control systems are common, along with features like overload protection, anti-collision sensors, emergency stop systems, and automatic diagnostics for enhanced safety and efficiency.
Rated Loading Capacity：5 ton, 10 TON, 100 ton, customized, 16/3.2 ton, 20/5 ton, 32/5 ton, 50/10 ton
Max. Lifting Height：40m, customized
Span：35m or clients' demands
Warranty：1 Year
Weight (KG)：20000 kg
Core Components：PLC, Engine, Bearing, Gearbox, Motor, Pressure vessel, Gear, Pump
Control way：Cab, wireless remote control or customized
Pictures & Components
1.Double Girders
Function: Serve as the primary horizontal load-bearing structure.
Material: High-strength structural steel (e.g., Q345 or equivalent).
Design: Welded box-type or truss-type girders for high strength and reduced weight.
Features: Accommodates the trolley and hoisting system for load movement along the span.
Gantry Legs
Function: Support the girders and transfer the crane's weight to the ground.
Type: A-frame or box-type design.
Material: Heavy-duty steel with bracing to resist torsion and buckling.
Mounting: Typically bolted or welded to the girders and wheels.
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Trolley with Hoist
Function: Moves along the girders and performs lifting/lowering operations.
Components:
Hoist: Usually a wire rope hoist or winch for heavy lifting.
Drum, Motor, Brake System: For vertical load handling.
Trolley Frame: Houses the hoisting mechanism and moves horizontally.
Drive: Motorized with VFD control for precise speed regulation.
3.End Beams / End Trucks
Function: Connect the gantry legs to the wheels and support horizontal travel.
Design: Rigid construction with mounting for drive systems and buffers.
4.Crane Travel Mechanism
Function: Moves the entire crane along the ground rails.
Drive: Motorized wheels powered by electric motors and gearboxes.
Wheels: Forged steel wheels, often equipped with flanges and rail clamps.
Control: Anti-sway, soft-start, and frequency-inverter-controlled systems.
5.Trolley travelling mechanism
1.The trolley traveling mechanism of an industrial gantry crane is responsible for moving the hoist or lifting mechanism horizontally along the crane's main beam or gantry. This allows the crane to position the load precisely in the transverse direction.
2.The trolley traveling mechanism consists of several key components:
Components of the Trolley Traveling Mechanism
Drive Unit: Typically an electric motor, the drive unit provides the power to move the trolley. The size and capacity of the motor depend on the crane's lifting capacity and the required speed of the trolley.
Gearbox: The gearbox reduces the high speed of the motor output to a lower speed suitable for the trolley's travel. It also increases the torque, which is necessary to move the hoist mechanism and any attached load.
Wheels or Rollers: The trolley rides on wheels or rollers that are mounted on axles. These wheels or rollers travel along the flanges or tracks on the main beam, allowing the trolley to move back and forth.
Brake System: A braking system is integrated into the trolley to control its movement and to hold it in position when needed. This can be a mechanical brake, an electromechanical brake, or a dynamic braking system.
3.The trolley traveling mechanism is crucial for precise positioning of the load in the transverse direction. It allows the crane to place loads accurately at different points along the length of the gantry. Proper maintenance and regular inspections are essential to ensure that the trolley mechanism operates smoothly and safely. Any issues with this mechanism can significantly impact the crane's operational efficiency and safety, making it vital to address any problems promptly.
6.Crane wheel
1.The crane wheel of an industrial gantry crane is a critical component that allows the crane to move along its runway beams or rails. These wheels are designed to support the weight of the crane, its load, and any additional dynamic forces generated during operation.
2.Here are the key features and functions of crane wheels:
Features of Crane Wheels
Material: Crane wheels are typically made from high-strength materials such as steel or cast iron to ensure they can withstand the heavy loads and stresses involved in lifting operations.
Size and Configuration: The size of the wheels varies depending on the capacity and design of the crane. They can be larger for heavier cranes to distribute the load more evenly. The number of wheels per axle and the number of axles per crane can also vary based on design requirements.
3.Crane wheels play a vital role in the mobility and stability of industrial gantry cranes. They are responsible for transferring the weight of the crane and its load to the runway beams or rails while allowing for smooth travel. The durability and efficiency of the crane's movement largely depend on the quality and condition of these wheels.
4.Proper maintenance of crane wheels, including regular inspections and timely replacement of worn components, is crucial for the safe and reliable operation of the crane. Neglecting wheel maintenance can lead to increased downtime, reduced efficiency, and potential safety hazards.
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7.Crane Hook
1.The crane hook of an industrial gantry crane is a critical component that allows the crane to lift and move various loads. The hook is the point of contact between the crane's hoisting mechanism and the load, making it a crucial interface for safe and efficient operations.
2.Here are the key features and functions of crane hooks:
Features of Crane Hooks
Material: Crane hooks are typically made from high-strength steel or alloy steel to ensure they can withstand the heavy loads involved in lifting operations. The material is chosen for its durability and resistance to wear and tear
Design: The design of the hook includes an opening at the top where it attaches to the hoist rope, chain, or other lifting device. The bottom part of the hook has a curved shape that allows it to securely engage with lifting points on the load.
Safety Latch: Many hooks are equipped with a safety latch or locking mechanism to prevent the load from accidentally slipping off. This latch must be manually opened to release the load at the desired location.
Load Ratings: Each hook is rated for specific maximum loads, and it is essential to use hooks that are rated for the intended loads to ensure safety and compliance with regulations.
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Motor
The motor of an industrial gantry crane is a critical component that provides the power necessary for lifting and moving loads. Motors in gantry cranes are typically electric and can be categorized into two main types based on their function: the hoisting motor and the travelling (or traversing) motor.
The hoisting motor is responsible for lifting and lowering the hook or grab that engages with the load. This motor's primary function is to control the vertical movement of the crane's loading mechanism.
Crane motors are the powerhouse of industrial gantry cranes, providing the energy required for both lifting and moving operations. The performance, reliability, and safety of the crane are heavily dependent on the motors' efficiency and durability. Proper selection, maintenance, and regular inspections of these motors are crucial for ensuring the crane operates smoothly and safely. Any issues with the motors can lead to operational inefficiencies, increased downtime, and potential safety risks, making prompt attention to motor problems essential.
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Sound and light alarm system & limit switch
1.Industrial gantry cranes are equipped with a sound and light alarm system and limit switches to enhance safety and operational efficiency. These components play crucial roles in preventing accidents and ensuring that the crane operates within its designated parameters.
2.Sound and Light Alarm System
The sound and light alarm system is designed to alert personnel in the vicinity of the crane about its operational status. This system is particularly important in environments where the crane operates in close proximity to workers or where visibility is limited.
3.Limit Switches
Limit switches are electronic devices that serve as critical safety features on industrial gantry cranes. They detect the position of the crane or its components and cut off power when the crane reaches its operational limits, preventing potential accidents and damage.
4.Both the sound and light alarm system and limit switches are integral to the safe operation of industrial gantry cranes. The alarm system ensures that personnel are aware of the crane's movements and operational status, reducing the risk of collisions or other hazards. Limit switches, on the other hand, automate safety by physically preventing the crane from operating beyond its design limits. Together, these systems contribute to a safer workplace and protect both the crane equipment and the personnel working around it. Proper maintenance and regular testing of these systems are essential to ensure they function reliably and effectively.
10.Safety Devices
Overload Protection Devices
Overload protection devices are designed to prevent the crane from operating beyond its safe working load limits. These devices monitor the load being lifted and will either send an alert or shut down the crane if the load exceeds the specified limit. This is crucial for preventing structural damage to the crane and avoiding accidents that can occur due to overloading.
Limit Switches
As mentioned earlier, limit switches automatically stop the crane when it approaches the end of its travel range or when any of its components reach their operational limits. These switches are essential for preventing the crane from exceeding its physical boundaries, which could result in damage to the structure or collision with obstacles.
Anti-Collison Devices
Anti-collison devices are particularly important in environments where multiple cranes operate in close proximity or where there is significant ground traffic. These devices use sensors, cameras, or other technologies to detect the presence of other objects in the crane's path and either alert the operator or automatically halt the crane's movement to prevent a collision.
Emergency Stop Buttons
Emergency stop buttons are manually operated controls that allow the crane operator or any authorized personnel to immediately stop all crane operations in case of an emergency. These buttons are strategically placed within easy reach of the operator and are often red and highly visible.
Brake Systems
Brake systems on industrial gantry cranes are designed to hold the load securely in place when not in motion and to provide controlled stopping during operations. These brakes can be mechanical, electrical, or a combination of both, and they are critical for preventing unexpected load movements that could lead to accidents.
Levelness Indicators
Levelness indicators are used to ensure that the crane is level during operation, especially when lifting precise or delicate loads. Uneven lifting can cause loads to shift, potentially leading to loss of control and accidents. These indicators help operators maintain the crane's balance and stability.
Safe Working Load Indicators
Safe working load indicators clearly mark the maximum safe load capacity for the crane. This information is vital for operators to ensure that the crane is not overloaded and operates within its design specifications.
11.Control Mode
1.Manual Control
Direct Intervention: The crane operator directly controls the hoisting and traveling movements of the crane using handwheels, levers, or push buttons. This mode requires skilled operators who can manually synchronize the movements to achieve the desired positioning of the load.
Simple Mechanisms: Manual control systems are generally simpler in design and may be less prone to complex failures.
Limited Precision: The precision of the crane's movements is limited to the operator's skill and experience.
2.Semi-Automatic Control
Assisted Operation: The crane operator uses control devices such as joysticks or paddle switches to command the crane, but the system includes automated features that assist in controlling speed and synchronization.
Enhanced Safety: Semi-automatic systems often include safety features like automatic stops at load limits or travel limits.
Improved Efficiency: These systems can improve operational efficiency by reducing the need for highly skilled operators.
3.Fully Automatic Control
Programmable Logic Controller (PLC): The crane's operations are governed by a PLC, which can be programmed to perform specific sequences of operations automatically.
Precise Control: Fully automatic systems offer precise control over the crane's movements, allowing for complex maneuvers to be executed consistently.
Reduced Human Error: Automated systems reduce the potential for human error, enhancing safety and reliability.
Remote Operation: In some cases, fully automatic cranes can be operated remotely, removing the operator from potentially hazardous environments.
4.Radio Control
Wireless Operation: The crane operator uses radio transmitters to control the crane from a distance, which can be particularly useful in environments where visual contact with the crane is limited.
Increased Flexibility: Radio control allows operators to move freely around the work area while maintaining control of the crane.
Safety Considerations: Proper frequency management and security measures must be in place to prevent interference or unauthorized operation of the crane.
5.Computer Control
Advanced Systems: Some gantry cranes may employ computer systems that integrate advanced features such as machine vision, artificial intelligence, and data analysis to optimize operations.
Data Collection: Computer-controlled cranes can collect operational data, which can be used for maintenance planning and operational optimization.
Interface Options: Operators may interact with the crane through touch screens or other advanced interfaces, providing detailed feedback and control options.
12.Sketch
Main technical
Advantages
Advantages of a 150-Ton Double Girder Gantry Crane
1. High Load Capacity
Designed to lift extremely heavy materials (up to 150 tons) safely and efficiently.
Ideal for industries like shipbuilding, steel manufacturing, and heavy construction.
2. Enhanced Structural Strength
Double girders offer better load distribution and increased structural rigidity.
Capable of supporting long spans and high lifting heights without deformation.
3. Wider Operational Range
Can cover large work areas, especially in outdoor environments.
Suitable for applications where overhead crane installation is impractical.
4. Customizable Design
Span, lifting height, speed, and control system can be tailored to specific project requirements.
Options available for special lifting tools or multi-point lifting.
5. High Stability and Safety
Dual girders and robust gantry legs provide excellent stability during operation.
Equipped with safety features like:
Overload protection
Limit switches
Anti-collision devices
Emergency stop systems
Wind alarms (for outdoor cranes)
6. Durability and Longevity
Built from high-grade structural steel, often with anti-corrosion treatment for outdoor use.
Designed for long-term service in tough environments (rain, wind, dust, etc.).
7. Efficient Material Handling
Increases productivity by enabling fast, reliable handling of large components.
Reduces labor needs and manual lifting operations.
8. Flexible Installation
Can be installed on ground-level rails or elevated tracks.
No need for a permanent overhead structure like a bridge crane.
9. Multiple Control Modes
Can be operated via:
Cabin control
Remote control (wireless)
Pendant (wired) control
Increases operator comfort and safety.
10. Cost-Effective for Heavy Loads
More economical than building a large overhead crane system with the same capacity.
Especially beneficial for temporary or project-based heavy lifting sites.
Application:
A 150-ton double girder gantry crane is specifically engineered for handling extremely heavy loads in demanding industrial environments. Its strength, stability, and customization options make it suitable for various large-scale applications:
🏗️ 1. Shipbuilding Industry
Use Cases:
Lifting and assembling ship blocks and hull sections
Installing engines, propellers, and other massive components
Why Ideal: Requires high-capacity lifting with precision across large outdoor assembly yards.
🏢 2. Steel and Metal Production
Use Cases:
Moving large steel coils, billets, ingots, or castings
Handling raw materials or finished steel structures
Why Ideal: High strength and thermal resistance for harsh, high-temperature environments.
🏞️ 3. Infrastructure and Construction
Use Cases:
Lifting concrete bridge segments, beams, or precast components
Assembling large machinery or turbines at the construction site
Why Ideal: Portable gantry setup allows flexibility on large job sites without needing a fixed building.
⚙️ 4. Power Plants and Energy Projects
Use Cases:
Handling turbines, generators, transformers, and other heavy equipment
Moving oversized components during maintenance or upgrades
Why Ideal: High precision and heavy-duty capacity required for complex power installations.
⚓ 5. Port and Shipyard Logistics
Use Cases:
Handling shipping containers, engines, or large cargo units
Transferring heavy equipment from dock to barge
Why Ideal: Excellent for outdoor operations with long spans and variable load handling.
🚂 6. Railway and Locomotive Manufacturing
Use Cases:
Lifting train carriages, bogies, frames, or entire rail vehicles
Assembling parts in production or maintenance facilities
Why Ideal: Long lifting height and heavy capacity needed for large rail equipment.
🏭 7. Heavy Equipment Manufacturing
Use Cases:
Handling machinery components like excavator frames, industrial presses, and large molds
Transporting completed machinery or tooling across production bays
Why Ideal: Efficient, high-capacity movement of oversized parts and machines.
🛠️ 8. Aerospace and Defense
Use Cases:
Lifting rocket parts, aircraft fuselage sections, or military vehicles
Why Ideal: Precision handling of massive, high-value, and often sensitive components.
Crane production procedure
1. Design and Engineering
Detailed Engineering: Develop detailed engineering drawings and specifications, including the main beam, hoist, trolley, end carriages, and other components.
Simulation and Modeling: Use computer-aided design (CAD) and simulation tools to model the crane's performance and optimize its design.
2. Material Selection
Material Specifications: Select high-quality materials that meet the requirements for strength, durability, and heat resistance. Common materials include high-strength steel, alloys, and specialized coatings.
Procurement: Source materials from approved suppliers, ensuring they meet the necessary quality and certification standards.
3. Component Fabrication
Cutting and Shaping: Cut and shape raw materials into the required components, such as beams, columns, and brackets. This may involve processes like plasma cutting, laser cutting, and machining.Welding and Assembly: Weld components together to form the crane's structural elements. This includes welding the main beam, end carriages, and other load-bearing parts.
4. Assembly
Sub-Assembly: Assemble individual components, such as the hoisting system, trolley, and end carriages, into sub-assemblies. This involves fitting parts together and ensuring proper alignment.Main Assembly: Combine sub-assemblies to construct the complete crane structure. This includes mounting the hoist and trolley on the main beam, attaching the end carriages, and installing the control systems.
5. Integration of Systems
Electrical Systems: Install electrical components, including motors, control panels, wiring, and sensors. Ensure that the crane's electrical systems are properly integrated and tested.
Control Systems: Implement and configure control systems, such as programmable logic controllers (PLCs), remote controls, and safety devices. Verify that the control systems function correctly and are calibrated.
6. Testing and Quality Assurance
Pre-Operational Testing: Conduct pre-operational tests to check the crane's functionality, including load testing, operational testing of the lifting and traveling mechanisms, and control system checks.
Safety Testing: Verify that safety features, such as limit switches, alarms, and emergency stops, are working correctly and meet safety standards.
Inspection: Perform a detailed inspection of the crane's structure and components to ensure compliance with design specifications and quality standards.
7. Final Adjustments and Calibration
Fine-Tuning: Make any necessary adjustments to optimize the crane's performance and ensure smooth operation. This may include calibrating sensors, adjusting controls, and fine-tuning the lifting system.
Documentation: Prepare and review documentation, including operation manuals, maintenance guides, and safety instructions.
8. Delivery and Installation
Transport: Arrange for the transport of the crane to the installation site, ensuring that it is handled and shipped safely to prevent damage.
Installation: Oversee the installation of the crane at the customer's facility, including assembly, alignment, and connection to power sources and control systems.
Training: Provide training for operators and maintenance personnel to ensure they are familiar with the crane's operation and safety procedures.
9. Commissioning and Handover
Commissioning: Conduct final commissioning tests to verify that the crane operates correctly under real-world conditions and meets performance specifications.
Handover: Officially hand over the crane to the customer, providing all necessary documentation, including certificates of compliance, warranty information, and maintenance schedules.
Workshop view
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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