• Mar 06, 2026
• Case Studies

10 Ton MH Single-Girder Gantry Crane for UAE Concrete Plant

Upgrade your UAE concrete plant with a 10 ton MH single-girder gantry crane—boost efficiency and handle heavy loads with ease. Learn more now!

A precast concrete manufacturing plant in the UAE needed a robust lifting system to cope with its heavy-duty operations. According to the customer, their plant handles large steel forms and finished concrete components. Their plant is semi-open-air, with high temperatures, sometimes even in the presence of frequent sandstorms, which can cause damage to machinery and equipment. They needed a crane that could be used for both indoor and outdoor lifting.

Project Challenges

Precast concrete production requires reliable lifting equipment. In this project, the client operates a precast concrete plant in Abu Dhabi Industrial City. The plant produces precast walls, slabs, pipe culverts, and other large concrete components used in construction projects across the region. These products are heavy and often require careful handling during demolding, storage, and truck loading. The customer needed a crane that could move large concrete elements smoothly between production areas and the outdoor storage yard. At the same time, the equipment had to work reliably in a demanding environment and fit within the existing plant layout. Several technical challenges shaped the final crane design.

• One of the main requirements was high lifting capacity under strict height limits. The plant needed to lift concrete molds, steel formwork, and finished components weighing up to about 10 tons. However, the lifting area was located under an existing roof structure that limited the available lifting height to around 5 meters. This meant the crane design had to maximize the effective hook height while still fitting under the building structure. Our engineering team carefully optimized the gantry frame and hoist configuration to use the available vertical space efficiently. This allowed the crane to safely handle heavy precast components without interfering with the roof or nearby structures.
• Another major challenge was the outdoor working environment. The crane operates in an open yard exposed to extreme sunlight, high temperatures, and blowing sand. In summer, daytime temperatures can exceed 40 °C. Dust and sandstorms are also common in this region. These conditions can affect motors, electrical systems, and moving parts if the equipment is not designed properly. To ensure long-term reliability, the crane uses motors with higher insulation grades such as Class F or Class H. Electrical cabinets are protected with sunshades to reduce heat buildup. Sealed components and durable materials help protect key parts from dust and sand infiltration.
• The site layout also created space constraints. The storage yard is long and narrow, with truck lanes running alongside the lifting area. The client needed a solution that could lift and move heavy loads without interfering with trucks entering or leaving the yard. Gantry cranes operating on fixed tracks provided an ideal solution. By installing rails parallel to the truck lane, the crane can travel along the length of the yard while keeping pathways clear. This layout improves safety and keeps logistics running smoothly.

Lifting Solution We Provided

After understanding the customer’s working environment and lifting requirements, our engineering team proposed a 10-ton MH type single girder gantry crane equipped with a CD electric wire rope hoist. The crane operates on rails installed directly on the yard ground, which allows stable and efficient movement across the production area. The overall span of the crane is 12 meters and the lifting height is 5 meters, which was carefully selected to match the customer’s working area and the size of the materials they handle. This configuration allows the crane to cover the full working zone while maintaining strong structural stability. Our goal was to provide a lifting system that is simple to operate, reliable for daily production, and capable of handling heavy materials safely in an outdoor industrial environment.

1. MH Single Girder Structure Design

The crane adopts a classic MH single girder gantry structure with a welded box-beam main girder supported by rigid steel legs. The box girder design offers an excellent balance between strength and weight. It keeps the structure relatively light while still providing high rigidity under heavy loads and strong wind conditions. This is especially important for outdoor cranes used in open yards. The closed box structure also improves resistance to torsion and bending compared with open beam designs. To improve operational coverage, we designed cantilevers on both sides of the girder. These overhangs allow the hook to reach slightly beyond the rail centerline, making it easier to position loads and align materials without needing additional support structures.

2. Hoisting and Trolley System

The lifting mechanism adopts the CD series electric wire rope hoist, which is durable, convenient and easy to maintain, and is suitable for the working conditions of the concrete plant. Concrete production sites are often dusty and humid, and require frequent handling of heavy materials, which requires lifting equipment with high reliability and overload resistance. As a classic product with mature technology, the wire rope winch system of the CD hoist is more wear-resistant and shock-resistant than the chain hoist when coping with heavy loads and frequent lifting, with smooth operation and high safety; at the same time, its structure design is relatively simple, which makes it easy for technicians to get started in the later maintenance in areas like the UAE, as well as easy to purchase common parts.

3. Traveling System and Rail Structure

The gantry crane moves along steel rails installed on reinforced concrete foundations. These rails are carefully leveled to distribute the wheel loads evenly and ensure smooth crane travel. Each end carriage uses wear-resistant 45# forged steel wheels, which provide high load-bearing capacity and long service life. The wheel assemblies are designed with sealed bearings and protective covers to prevent dust and sand from entering critical components. In addition, the rail system includes end stops and buffer devices to prevent over-travel. This rail-mounted design ensures stable movement even when the crane handles loads close to its rated capacity.

4. Electrical System and Control Method

The crane operates on a standard 380 V, 50 Hz three-phase power supply, which matches common industrial electrical systems in the UAE. We selected frequency-controlled motors for the main travel and trolley motions. Variable frequency drives allow smooth acceleration and deceleration, which reduces mechanical stress on the structure and minimizes load swing during operation. The crane is operated from ground level using a pendant controller or wireless remote control. This design improves operator safety because the user can maintain a safe distance from the load while still having a clear view of the lifting area.

5. Duty Classification and Safety Protection

This crane was designed according to FEM and ISO standards and classified as A5 duty level. This means it is suitable for frequent lifting operations and continuous industrial use. To protect both operators and equipment, several safety systems are integrated into the crane. These include an electronic overload protection device that stops the hoist if the load exceeds the rated 10-ton capacity. Upper and lower limit switches prevent the hook from over-traveling. Emergency stop buttons allow operators to immediately shut down the crane in unexpected situations. All rated capacities and operating instructions are clearly labeled to ensure safe use.

6. Structural Durability for the UAE Climate

Since the crane operates in an outdoor environment in the UAE, we paid special attention to durability in high temperatures and dusty conditions. The control cabinet is enclosed in an IP65-rated housing to protect electrical components from dust and sand. A sunshade cover and ventilation design help reduce heat buildup inside the cabinet. All crane motors use high-temperature Class F insulation, which allows stable operation even in hot climates. Gearboxes, bearings, and moving parts are sealed to prevent sand from entering mechanical systems. The steel structure is protected with corrosion-resistant coatings to extend service life in harsh desert environments.

On-Site Installation and Technical Support

After the crane arrived at the customer’s facility, our technical team worked closely with the client to organize the installation process. We carefully planned the lifting and assembly sequence so the installation could proceed without interrupting the plant’s normal operations. Using mobile cranes, the gantry legs were positioned and secured on the prepared runway rails. The main girder was then lifted and connected to the legs with high-strength bolts, forming the complete gantry structure. After the structural assembly, our technicians installed the hoist and trolley system under the beam and aligned the traveling wheels with the runway rails. Accurate rail alignment and wheel adjustment are very important for smooth crane travel, so we carried out detailed measurements and corrections during this stage. The installation team also checked electrical connections, cable routing, and grounding to ensure safe operation in the plant environment. By following a clear installation plan and strict safety procedures, the entire erection process was completed efficiently while maintaining a safe work area.

Commissioning and Operational Testing

Once installation was complete, our engineers began the commissioning phase to make sure the crane performed exactly as designed. The electrical control system was configured on site, including setting travel limits, adjusting braking response, and calibrating overload protection. We performed multiple functional tests of the hoisting, trolley travel, and crane travel motions to confirm smooth and precise operation. Trial lifting operations were carried out under the supervision of both our engineers and the customer’s technical staff. During these tests, we carefully monitored load stability, motor performance, and braking reliability. After confirming stable performance under working conditions, we completed a full-load test to demonstrate that the crane could safely handle its rated capacity.