80 Ton Outdoor Double Gantry Crane

 

An 80-ton Outdoor Double Gantry Crane is a heavy-duty lifting system designed for outdoor applications, such as construction sites, shipyards, steel yards, and large industrial facilities. It consists of two parallel gantry beams supported by legs that run on rails or wheels, enabling movement along a fixed path.

 

Comparison: Rail-Mounted vs. Rubber-Tired Outdoor Gantry Cranes

Feature	Rail-Mounted Gantry	Rubber-Tired Gantry (RTG)
Mobility	Fixed path (rails)	Moves freely on ground
Stability	Very stable	Requires outriggers
Installation Cost	Higher (needs rails)	Lower (no rails needed)
Maintenance	Less tire wear	Tires need replacement
Best For	Permanent outdoor yards	Ports, temporary sites

 

Key Features:
Capacity: 80 metric tons (can be customized for higher loads).

Double Girder Design: Provides better stability and higher lifting capacity compared to single-girder cranes.

Outdoor Use: Built with weather-resistant materials (corrosion protection, high-quality paint, or galvanization).

Span & Height: Adjustable based on application (typically 10m–35m span, height as required).

Hoisting Mechanism:

Electric wire rope hoist (standard) or hydraulic lifting system.

Optional auxiliary hoist for lighter loads.

Traveling System:

Rail-mounted (common for heavy-duty use).

Rubber-tired (for flexible movement without rails).

Control System:

Cabin-operated (with AC/DC drive systems).

Radio remote control (for safer and flexible operation).

Pendant control (for smaller operations).

Safety Features:

Overload protection.

Limit switches (for hoisting and travel).

Anti-collision system (for multiple cranes).

Wind-resistant brakes (for outdoor stability).

An 80-ton Outdoor Double Gantry Crane is a heavy-duty lifting system designed for outdoor applications such as construction sites, shipyards, ports, and industrial yards. It consists of two parallel gantries that move along rails, providing high lifting capacity and stability. Below are the key components of such a crane:

1. Main Structural Components
Gantry Beams (Girders) – The horizontal beams that span the working area, supporting the hoist and trolley.

Legs (Upright Columns) – Vertical supports on both sides that bear the load and transfer it to the ground or foundation.

End Carriages – Wheeled structures at the base of the legs that allow the crane to move along the runway rails.

Cross Beams – Reinforce the connection between the two gantries for added stability.

 

 

2. Lifting Mechanism
Hoist Unit – The primary lifting device (electric or hydraulic) with an 80-ton capacity.

Trolley – Moves along the gantry beams, carrying the hoist for lateral positioning.

Wire Rope & Hook Block – Used to lift and lower loads safely.

Drum & Sheaves – Guide and store the wire rope during operation.

 

3. Drive & Motion System
Travel Motors – Electric or hydraulic motors that power the crane's movement along the rails.

Wheels & Rail System – Heavy-duty wheels and tracks ensure smooth movement.

Braking System – Ensures controlled stopping and safety during operation.
 

4. Electrical & Control System
Control Panel – Houses electrical components for crane operation.

Operator Cabin or Remote Control – Allows the operator to control the crane safely.

Limit Switches & Sensors – Prevent over-travel and overload conditions.

Power Supply System – Includes festoon cables, cable reels, or busbar systems for power distribution.

5. Safety & Auxiliary Components
Anti-Collision System – Prevents collisions between the two gantries or other equipment.

Windproof Devices – Rail clamps or anemometers to secure the crane in high winds.

Outdoor Lighting & Warning Signals – Ensures visibility and safety during night operations.

Ladders & Maintenance Platforms – Provide access for inspection and repairs.

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6. Foundation & Support System
Runway Rails – Heavy-duty tracks installed on a concrete foundation for smooth movement.

Anchor Bolts & Fixings – Secure the crane to the ground to prevent tipping.

 

SKETCH

Main technical

 

An 80-ton Outdoor Double Girder Gantry Crane is a heavy-duty lifting solution designed for rugged outdoor applications, such as ports, shipyards, steel yards, and construction sites. Here are its key advantages:

1. High Lifting Capacity (80 Tons)
Capable of handling extremely heavy loads, making it ideal for industries like shipbuilding, steel fabrication, and heavy machinery handling.

2. Robust & Durable Construction
Built with double girder design for superior strength and stability.

Made from high-quality steel to withstand harsh outdoor conditions (wind, rain, dust, and temperature variations).

3. Enhanced Stability & Safety
Wider span and double girders provide better load distribution, reducing swaying.

Equipped with anti-collision systems, overload protection, and emergency brakes for safe operations.

4. Weather-Resistant Features
Corrosion-resistant coating (galvanized or epoxy paint) to prevent rust.

Wind-resistant design (some models include rail clamps for high-wind areas).

Sealed electrical components (IP55 or higher) for protection against moisture and dust.

5. Customizable Span & Height
Adjustable span (typically 10m to 35m+) to fit different worksites.

Can be designed with fixed or adjustable lifting heights based on requirements.

6. Smooth & Precise Operation
Uses high-performance hoists (wire rope or chain) for reliable lifting.

Variable frequency drives (VFD) ensure smooth acceleration/deceleration, reducing load swing.

Optional radio remote control for safer and more flexible operation.

7. Low Maintenance & Long Service Life
High-quality components reduce wear and tear.

Easy-access maintenance points for inspections and servicing.

8. Versatile Applications
Ideal for:

Ports & Shipyards (loading/unloading containers, ship parts).

Steel Plants (handling coils, beams, and heavy plates).

Construction Sites (lifting prefabricated structures).

Power Plants (installing turbines and generators).

9. Cost-Effective for Heavy Lifting
More efficient than using multiple smaller cranes.

Reduces labor costs and speeds up operations.

Conclusion:
An 80-ton Outdoor Double Girder Gantry Crane is a powerful, durable, and reliable solution for heavy-duty outdoor lifting needs. Its high capacity, weather resistance, safety features, and customization options make it a preferred choice for industries requiring robust material handling.

 

Common Applications:
Shipbuilding & Repair – Handling ship sections, engines, and heavy components.

Steel & Metal Fabrication – Moving large steel beams, plates, and coils.

Construction Projects – Lifting precast concrete segments, bridge girders, and heavy machinery.

Ports & Logistics – Loading/unloading heavy cargo, containers, and bulk materials.

Power Plants & Heavy Industries – Installing turbines, generators, and large equipment.

Wind Energy Sector – Assembling and maintaining wind turbine components.

 

 

The production procedure for an 80-ton Outdoor Double Gantry Crane involves several key stages, from design and material procurement to fabrication, assembly, testing, and installation. Below is a structured outline of the production process:

1. Design & Engineering
Requirements Analysis: Determine load capacity (80 tons), span, lifting height, outdoor conditions (wind, corrosion resistance), and operational frequency.

Structural Design:

CAD modeling for the double girder gantry crane.

Finite Element Analysis (FEA) to ensure structural integrity under load.

Selection of materials (e.g., high-grade steel for outdoor durability).

Mechanical & Electrical Design:

Hoist mechanism (wire rope/chain), trolley system, end carriages, and rail design.

Motor power, gearbox, brakes, and control system (pendant/remote control).

Regulatory Compliance: Ensure adherence to standards (ISO, FEM, DIN, or ASME).

2. Material Procurement
Main Components:

Steel beams (for girders, legs, and cross-beams).

Wheels, rails, and runway beams.

Electric hoist/trolley system (80-ton capacity).

Motors, gearboxes, brakes, and cables.

Corrosion Protection: Weather-resistant paint, galvanization, or stainless steel components.

3. Fabrication
A. Structural Fabrication
Cutting & Welding:

Plasma/oxy-fuel cutting of steel plates/beams.

Welding of girders, legs, and end carriages (using submerged arc welding for high strength).

Machining:

Precision machining of rail contact surfaces and wheel bearings.

Shot Blasting & Painting:

Surface treatment for rust prevention.

Primer + epoxy paint for outdoor protection.

B. Mechanical Assembly
Trolley & Hoist:

Assembly of the 80-ton hoist (gear system, drum, wire rope, hooks).

Mounting the trolley on the girders.

Gantry Frame:

Bolt/weld the legs to the girders.

Install wheels and rail alignment system.

C. Electrical Installation
Wiring: Power supply, limit switches, sensors, and control panel.

Motor & Drive Setup: Variable Frequency Drives (VFDs) for smooth operation.

Safety Systems: Overload protection, emergency stop, anti-collision (if dual cranes).

4. Quality Control & Testing
Dimensional Inspection: Verify tolerances per design.

Non-Destructive Testing (NDT): Ultrasonic/X-ray welding inspection.

Load Testing:

Static Test: 125% of rated load (100 tons) for structural integrity.

Dynamic Test: 110% load (88 tons) to check functionality.

Electrical Safety Checks: Insulation, grounding, and emergency stop response.

5. Disassembly & Packaging
Labeling: Mark components for easy reassembly.

Weatherproofing: Protect electrical parts during transit.

Packaging: Use crates/straps for heavy parts (girders, hoists).

6. Installation & Commissioning
Site Preparation:

Level and reinforce the ground for rails/runway.

Install anchor bolts/rails as per layout.

Reassembly:

Erect gantry legs and girders using mobile cranes.

Install mechanical/electrical components.

Final Testing:

Trial run under operational conditions.

Client demonstration and training.

7. Documentation & Handover
Manuals: Operation, maintenance, and safety guidelines.

Certificates: Load test reports, material certifications, and compliance documents.

Warranty & Support: Provide after-sales service terms.

 

 

 

 

 

 

 

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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