Stationary Gantry Cranes

 

 

Stationary gantry cranes are fixed-position lifting systems designed for heavy-duty material handling in workshops, warehouses, and outdoor yards. Unlike mobile variants, they are permanently installed on foundations, offering superior stability and high load capacity for repetitive tasks

 

Key Features:
Fixed Structure: Bolted or welded to the ground, ensuring stability.
High Load Capacity: Typically ranges from 1 ton to over 500 tons, depending on design.
Span Flexibility: Can cover wide work areas (up to 30+ meters).
Manual or Electric Operation: Some use chain hoists, while heavy-duty models use electric wire rope hoists.
Durability: Made from structural steel (carbon or stainless) for long-term use.
Common Types:
Single Girder Stationary Gantry Crane – Cost-effective for light to medium loads (1-20 tons).
Double Girder Stationary Gantry Crane – Used for heavy-duty lifting (20+ tons) with higher hook height.
Semi-Gantry Crane – One leg runs on a rail while the other is supported by a building structure.
Portable (Adjustable) Gantry Crane – Not fully stationary but can be anchored temporarily.

 

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)：50000 kg

Core Components：PLC, Engine, Bearing, Gearbox, Motor, Pressure vessel, Gear, Pump

Control way：Cab, wireless remote control or customized

 

 

1. Main Structural Components
A. Gantry Legs (Columns)
Function: Provide vertical support and transfer loads to the foundation.
Design: Can be fixed (welded/bolted) or adjustable (for height variation).
Materials: Heavy-duty steel (carbon or stainless) for durability.

 

 

 

B. Girder (Bridge Beam)
Single Girder: Used for lighter loads (up to 20 tons).
Double Girder: For heavy-duty applications (20+ tons), offering greater hook height.
Box Girder vs. I-Beam: Box girders provide higher strength for heavy loads.
C. End Trucks (End Carriages)
Function: Support the girder and house the wheels/tracks (if rail-mounted).
Stationary vs. Rail-Mounted: Stationary cranes are fixed, while rail-mounted allow limited movement.

2. Lifting Mechanism
A. Hoist Unit
Electric Chain Hoist: For light to medium loads (1–10 tons).
Wire Rope Hoist: For heavy-duty lifting (10–600+ tons).
Manual Hoist: Used in low-budget or low-frequency applications.
B. Trolley
Function: Moves the hoist along the girder (manually or motorized).
Motorized Trolley: Used in high-efficiency operations.
C. Hook Block
Function: Holds the load via slings, chains, or lifting attachments.
Safety Features: Swivel hooks, safety latches.

 

3. Support & Stability Components
A. Base Plate & Foundation
Function: Anchors the crane to the ground for stability.
Material: Reinforced concrete with anchor bolts.
B. Cross Braces (Diagonal Supports)
Function: Reinforce the structure against lateral forces.
Common in: Large-span gantry cranes (e.g., shipyard cranes).
C. Bumpers & Buffers
Function: Absorb shock if the crane reaches movement limits.

 

4. Control & Power Systems
A. Control Panel / Pendant Station
Functions:
Manual pendant (wired or wireless).
Radio remote control (for hazardous environments).
B. Power Supply
Options:
Cable Reel System (for electric cranes).
Festoon System (sliding power supply along the girder).
C. Limit Switches & Overload Protection
Safety Features:
Upper/Lower Limit Switches – Prevent over-hoisting.
Load Cell – Monitors weight to avoid overloading.

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5. Optional Accessories
Crane Lights & Alarms – For safety in busy workspaces.
Anti-Sway System – For precise load positioning.
Crane Scales – Integrated weighing systems.
Weatherproof Covers – For outdoor use (e.g., ports).

 

Summary Table of Key Components

Component	Function	Common Types
Girder	Supports trolley & load	Single/Double Girder
Gantry Legs	Vertical support	Fixed/Adjustable
Hoist	Lifts the load	Electric/Wire Rope/Manual
Trolley	Moves hoist along girder	Manual/Motorized
End Trucks	Supports girder	Stationary/Rail-Mounted
Control System	Operator interface	Pendant/Remote
Foundation	Anchors crane	Concrete base

 

 

SKETCH

 

 

 

1. High Stability & Safety
Fixed foundation prevents movement, ensuring safer lifting than mobile cranes.
Minimal sway due to rigid structure, ideal for precision tasks.
2. Heavy Load Capacity
Supports 1 ton to 600+ tons, with double-girder models handling extreme weights.
More robust than jib cranes or mobile gantries.
3. Cost-Effective & Low Maintenance
No complex tracks (unlike overhead cranes), reducing installation costs.
Fewer moving parts → lower maintenance than mobile or rail-mounted cranes.
4. Customizable Design
Adjustable span (3m–40m+) and lifting height to fit workspace needs.
Options for indoor/outdoor use (weatherproof coatings available).
5. Space-Efficient
No runway beams required (unlike bridge cranes), freeing up ceiling space.
Can be installed in tight spaces (e.g., workshops with height restrictions).
6. Versatile Power Options
Electric hoists for heavy-duty automation.
Manual operation (chain hoists) for low-budget or infrequent use.

 

Common Applications of Stationary Gantry Cranes
1. Manufacturing & Assembly
Moving heavy machinery, molds, and industrial equipment.
Positioning large components in automotive/aerospace production.
2. Construction & Steel Fabrication
Lifting steel beams, concrete panels, and precast structures.
Assembling prefabricated building sections.
3. Warehousing & Logistics
Loading/unloading heavy pallets, containers, and large shipments.
Used in distribution centers for oversized cargo.
4. Shipbuilding & Ports
Handling ship engines, propellers, and hull sections.
Maintenance of dockside equipment (fixed gantries withstand marine conditions).
5. Power Plants & Energy Sector
Installing/maintaining turbines, generators, and transformers.
Lifting heavy reactor components in nuclear facilities.
6. Mining & Heavy Industry
Transporting large mining equipment, crushers, and ore bins.
Used in foundries for moving molten metal containers.
7. Railway & Infrastructure
Assembling railway tracks and train components.
Lifting bridge segments during construction.

 

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.

 

 

 

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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