10 Ton Overhead Cranes to Bangladesh

The customer operates a precast concrete plant near Dhaka, Bangladesh. The facility manufactures beams, wall panels, and modular segments for residential and in

The customer operates a precast concrete plant near Dhaka, Bangladesh. The facility manufactures beams, wall panels, and modular segments for residential and infrastructure projects. To meet tight schedules, the plant needed reliable material handling solutions capable of lifting and positioning heavy concrete elements repeatedly each day.

Previously, the plant used a mix of single girder hoists and mobile cranes. These methods slowed production and increased the risk of damage to finished elements. They also posed safety concerns: manual rigging and intermittent mobile crane movements led to near-miss incidents and extended cycle times.

Customer Needs And Pre-Implementation Challenges

1. Lifting Capacity And Multiple Workstations

The plant required a 10 ton safe working load (SWL) crane to handle the largest precast beams (up to 9 t each) and bundles of smaller panels. They needed coverage across three production bays: steel reinforcement, concrete casting, and final stacking. The previous single girder hoist could only cover one bay at a time, forcing crews to relocate hoists or wait for mobile cranes.

2. Throughput And Cycle Time Targets

Production targets called for 60 beam units per day. Manual repositioning and mobile crane setup added 15 minutes per lift cycle. The plant sought to reduce handling time to under 5 minutes per lift to meet throughput goals without adding shifts.

3. Safety And Ergonomic Concerns

Manual rigging and chain hoists exposed operators to pinch and crush hazards. Though local data in Bangladesh are not formally tracked, the plant recorded three rigging-related injuries in 2024. Management prioritized reducing these risks through automated lifting and precise load control.

Space Constraints And Installation Window

The factory roof trusses allowed a maximum hook height of 7 m under girder. Runway beams spanned 25 m in each bay. The plant could only afford a two-day production stoppage per bay for crane installation. They needed solutions that fit existing runway rails and required minimal modifications.

Equipment Design And Technical Specifications

Double Girder Overhead Crane Structure

We supplied three double girder overhead travelling cranes, each rated at 10 t SWL with ISO 4301-5 duty class M5 for frequent cycles up to 350 per day. The double girder design offers reduced deflection under load (below L/800, where L is span) and higher lateral stiffness compared to single girder models. Each crane spans 25 m and travels on 43 kg/m rails mounted to existing runway beams.

Main Beam And End Carriages

Main girders are welded I-sections of high-strength steel, with finite-element analysis to validate stress distribution under 10 t loads. End carriages use forged steel wheels and sealed roller bearings for low rolling resistance and dust resistance in the casting areas.

Hoist Trolley And Wire Rope Hoist

The hoist trolley carries an electric wire rope hoist per GB/T 14406. It delivers 8 m/min lift speed and 20 m/min trolley travel speed. The hoist uses a dual-speed motor (0.8 m/min and 8 m/min) for precise load positioning and rapid approach. The wire rope is 8×36 IWRC, galvanized, with a safety factor of 6×SWL and tested at 1.25×SWL proof load in factory tests.

Control And Safety Systems

Pendant Control: Ergonomic dead-man switch with cable reel, IP65 rated for wet environments.
Overload Limiter: Strain gauge sensor on hoist drum monitors tension, cutting power above 100 % SWL and triggering visual and audible alarms.
Limit Switches: Mechanical upper and lower hoist limits, trolley end-travel limits, and main beam end-stop buffers.
Soft-Start And Soft-Stop: Variable frequency drives on hoist and trolley motors reduce jerk, minimizing load swing.
Emergency Stop: E-stop on pendant and optional radio remote to halt all motions immediately.

Electrical And Environmental Protections

All motors have class F insulation and IP54 protection against dust and water spray. Control panels feature overload relays, phase-failure protection, and fused isolation switches. Cables run in steel conduit to protect against mechanical damage and chemical spray from curing compounds.

Foundation And Installation Adaptations

The existing runway rails were re-aligned and shimmed. We installed vibration-damping pads under support brackets to reduce noise in the finished panel storage area. Pre-welded rail sections were bolted to the runway beams, allowing installation and testing within 48 hours per bay.

Implementation Process And Commissioning

Site Survey And Planning

Our engineers conducted a laser survey of roof clearances, runway alignment, and cabling routes. They produced a detailed installation plan, including crane positioning, power supply points, and operator access platforms. The plan minimized production disruption by scheduling work over two consecutive long weekends.

Installation And Testing

Installation teams set up cranes in each bay over 48 hours. They positioned girders using mobile jibs and bolted end carriages to rails. The hoist trolley was mounted, wired, and connected to the building's 380 V three-phase supply. Initial no-load runs verified travel and hoist controls. Static proof tests at 125 % SWL (12.5 t) validated structural integrity. Dynamic load tests lifted 10 t loads through full travel, logging motor currents and rope tension to confirm compliance.

Operator Training And Handover

Following successful tests, we provided two days of on-site training. Operators learned safe lifting procedures, daily inspection checklists, and emergency protocols. Each received an operation manual, maintenance schedule, and load test certificate. A final sign-off form documented acceptance by the plant manager.

Advantages Of The 10 Ton Overhead Crane Design

1. High Load Capacity And Rigidity

This crane uses a double-girder bridge to carry 10-ton loads with minimal bending. The twin girders keep the hook steady, even at full capacity. This stability ensures you can position large precast elements or heavy machinery accurately. Reduced deflection lowers the risk of surface damage and cuts down on rework.

2. Frequent Cycle Capability

Built to ISO 4301-5 M5 standards, the crane can perform 100 000 lift cycles over its service life. In busy precast or production shops where teams make over 300 lifts each day, the crane handles the load without early wear. The heavy-duty motors, gearboxes, and brakes are rated for these high-frequency operations, which boosts uptime and lowers maintenance needs.

3. Modular Installation And Future Expansion

The crane's main parts—girders, end carriages, and rails—are fully modular. You can extend the runway by adding extra bays, end trucks, and girders. The control system runs on a common 380 V bus and can link up to five cranes in tandem. This lets you scale your lifting system as your facility grows.

4. Energy-Efficient Operation

Variable frequency drives on the hoist and trolley motors smooth out starts and stops, cutting peak current draw by up to 25 % versus direct-online starters. When the hoist lowers a load, regenerative braking returns power to the plant's electrical network. These features reduce energy bills and lower wear on mechanical parts.

Alternative Applications For The 10 Ton Overhead Crane

1. Steel Fabrication And Machining Shops

This crane fits steel plate and beam shops where raw sections weighing up to 10 t must move between stations. It handles transfers from the cutting table to press brakes and welding booths. The precise trolley travel lets operators align heavy parts for automated plasma cutters. High hook approaches clear raised fixtures and maintenance platforms.

2. Shipbuilding And Ship Repair Yards

In covered workshops and dry docks, the crane lifts ship blocks, engine units, and propeller shafts. It offers hook heights up to 10 m, fitting under portside sheds and gantries. Operators can position hull sections for welding or install heavy machinery during refits. Corrosion-resistant finishes and IP54-rated motors ensure reliable use in humid, marine environments.

3. Automotive Assembly Plants

On just-in-sequence production lines, the crane moves engine blocks, transmission assemblies, and body-in-white subframes. It integrates with roller conveyor infeed and robotic welding cells. Fast bridge and trolley speeds keep pace with line takt times. Pendant or radio controls let technicians position parts precisely for torquing and inspection tasks.

4. Warehouse And Logistics Centers

In high-bay storage or cross-docking facilities, the crane loads and unloads palletized goods and 10 t containers. It works alongside automated guided vehicles to streamline material flow. The dual-speed hoist adjusts between rapid handling and slow positioning. Regenerative drives reclaim energy during load descent, reducing operating costs in 24/7 distribution centers.

Conclusion

The 10 ton double girder overhead travelling cranes delivered to the precast concrete plant in Bangladesh addressed the customer's needs for higher load capacity, faster cycle times, improved safety, and reliable operation under dust and humidity. Their robust design—ISO 4301-5 M5 classification, dual-speed hoist trolley, and advanced safety systems—resulted in a 67 % cycle time reduction, zero lifting incidents, and a 30 % drop in maintenance costs. Beyond precast concrete, these cranes serve steel fabrication, shipbuilding, automotive assembly, and logistics centers, offering different solutions for heavy material handling in demanding industrial environments.

Yuantai 10t Overhead Crane

10 Ton Overhead Cranes Yuantai Supply

The 10 Ton Overhead Crane is a versatile lifting solution designed to handle loads up to 10 tons. This crane is available in various configurations, including:

1. 10 Ton Single Girder Overhead Crane

10 tons single girder overhead travelling crane: it consists of one main girder with simple design and easy operation. The following solutions are available according to the different application working conditions:

Celling-mounted Single Girder Suspension Overhead Crane

2. 10 Ton Double Girder Overhead Crane

The 10 ton double girder overhead crane consists of two parallel main girders, a design that allows it to carry heavier loads. Suitable for heavy duty work and spanning applications.