- Oct 20, 2025
- Case Studies
10 Ton QD Overhead Crane for Bangladesh Steel Mill
Discover the powerful 10 tons QD double girder overhead crane, perfect for enhancing efficiency in Bangladesh's steel mills. Elevate your operations today!
This customer is from Bangladesh and they are engaged in manufacturing of steel such as steel coils, steel sheets, galvanized steel sheets etc. Due to the increased production of steel products in the customer's workshop in recent years, the lifting demand in the workshop has increased and they needed an efficient and durable crane.
- Lifting capacity suitable for heavy steel coils and stacks of galvanized sheets.
- Reliable performance across multiple shifts and long working hours.
- Stable load handling with smooth trolley travel to prevent material damage.
- A cab-controlled system to allow the operator a full view of loading and unloading.
- Compatibility with the existing runway structure and material flow inside the mill.
- A design that allows precise coil placement onto storage racks, cutting lines, or transport vehicles.
- Reduced waiting time for coil movement to match the increased production output.
These requirements pointed toward a double girder crane with a robust hoist system and long-span bridge, controlled directly from an overhead cab.
Customer's Production Challenges before Using New Equipment
Prior to the installation of the new 10-ton QD double girder overhead crane, the steel mill their current material handling equipment was primarily reliant on a overhead crane that had been in use for many years. While practical, the crane couldn't keep up with modern production standards. As coil and sheet output rose, the pressure on the equipment and manufacturing process became apparent. The following significant issues highlight the challenges encountered prior to the update.
1. Production growth outpaced crane capacity
The mill's operations quickly surpassed the capability of the single crane. As coil and sheet production rose, the crane created a bottleneck in everyday operations. Materials frequently had to wait in queues before being transferred to storage or the next processing line, causing delays that spread throughout the manufacturing schedule. Operators were often forced to wait several hours for crane availability, which impacted overall plant performance and hampered the fulfillment of client orders.
2. Limited throughput in material handling
Steel coils and sheet bundles are heavy and require careful, repetitive handling throughout the production process, from rolling and galvanizing to storage and transportation. With only one crane in operation, these processes were severely slowed. Each load transfer took longer since the crane was constantly backed up with repeated requests. Due to the limited throughput, the number of loads carried per shift was lower than required, resulting in longer cycle times and frequent delays in delivering finished items to consumers.
3. Overload on existing crane and maintenance concerns
Because of the strong demand for orders, the crane they already had in the shop was frequently running for extended periods of time, exceeding its intended duty cycle. This abuse generated severe wear on the hoisting mechanism, trolleys, and electrical equipment, resulting in repeated failures. The mill had to deal with high repair costs and unexpected downtime, which disrupted production schedules. The maintenance crew struggled to balance preventive maintenance with urgent breakdown repairs, making the situation unsustainable as production demands increased.
4. Safety risks due to congestion
In addition to reducing output, the reliance on a the existing cranes resulted in dangerous working conditions. With limited lifting capacity, operators stacked materials higher than recommended and depended largely on forklifts to adjust coils and sheets. This resulted in packed workstations and an increased risk of accidents, such as materials toppling, collisions in restricted aisles, and product and equipment damage. The inefficient transportation of loads not only reduced productivity but also raised severe safety concerns for shop floor workers.
Design of 10 tons QD Overhead Crane
After many communications with the customer, we determined the final crane program. In order to meet our customers' needs, we offer a 10-ton double girder overhead crane equipped with a cab. The crane is robust and many customers have commented that this type of crane remains reliable even after long periods of operation. The following designs are mainly used for this type of crane:
1. Double girder structure for higher stability
The crane uses a robust double girder bridge design that provides superior load distribution and rigidity. This structure allows higher lifting stability, greater span coverage, and improved hook travel compared to single girder cranes. The double girder arrangement also minimizes beam deflection under heavy load, which is essential when handling steel coils that can weigh several tons each. Additionally, the increased structural strength enables the crane to support auxiliary equipment such as maintenance walkways, lighting systems, and cable ducts without compromising performance.
2. High-duty hoist and trolley system
The hoist is rated for 10 tons capacity and designed with a duty cycle suitable for continuous steel mill operations. Its heavy-duty lifting motor ensures long service life under repetitive loading conditions. The trolley moves smoothly across the bridge girders on hardened wheels, ensuring consistent performance with minimal vibration. For enhanced safety, the hoist motor is equipped with overload protection, fail-safe braking systems, and thermal monitoring to prevent overheating during long shifts. Together, the hoist and trolley system allow precise and reliable coil lifting, reducing the risk of damage to valuable steel products.
3. Operator cab for safe and efficient control
The crane is equipped with a fully enclosed operator cab suspended below the bridge. From this vantage point, the operator has a clear line of sight to the loading area, coil racks, and conveyor systems. The cab is ergonomically designed with comfortable seating, climate control options, and a user-friendly control console to minimize operator fatigue during long working hours. Cab control is particularly advantageous in steel mills, where heavy and bulky coils require close observation and manual intervention to ensure safe and accurate placement.
4. Bridge travel and precise positioning
For smooth and controlled movements, the bridge is powered by motors with variable frequency drives (VFDs). These drives allow gradual acceleration and deceleration, preventing coil sway and enhancing operator confidence during lifting operations. The VFD system also improves energy efficiency and reduces mechanical wear on the drive components. With this feature, the crane can achieve precise positioning of coils onto storage racks, trucks, or processing lines, ensuring efficient workflow within the mill.
5. Safety systems and protections
Safety is a critical priority in steel mill operations. To protect both operators and ground staff, the crane is equipped with a comprehensive range of safety systems, including:
- Overload limiters to prevent the crane from exceeding its rated capacity.
- Emergency stop circuits accessible from both the cab and auxiliary locations.
- End-of-travel limit switches on the trolley and bridge to prevent overrun.
- Audible and visual alarms to alert floor staff when the crane is in motion.
- Anti-collision devices (optional) to avoid interference with adjacent cranes in multi-crane bays.
These integrated protections ensure compliance with industry safety standards while creating a safer and more productive working environment.
How the New Crane Handled Challenging Tasks
In a busy steel mill environment, the efficiency of material handling directly impacts production flow, safety, and product quality. The 10-ton QD double girder overhead crane plays a crucial role in meeting these demands by managing a wide variety of heavy and delicate lifting tasks with precision and reliability. Built for continuous operation, the crane not only handles the weight of massive steel coils and sheet bundles but also provides the speed and control required to keep up with the mill’s fast-paced operations. Its robust design, stable double-girder structure, and advanced control system make it an indispensable tool for maintaining productivity while minimizing risks of material damage and workplace accidents.
1. Steel coil lifting and placement
Galvanized coils weighing up to 10 tons are lifted directly from the rolling line. The crane moves them to storage racks or coil cars. Double girder stability ensures the hook remains centered during coil movement, reducing the risk of coil tilting. The crane’s wide span and steady travel motion also allow operators to transport coils over long distances within the workshop without sudden swings, ensuring smooth and safe handling of these valuable products.
2. Handling galvanized steel sheets
Large bundles of galvanized sheets must be lifted without bending or damage. The crane’s precise trolley movement allows the operator to lower the hook gently onto sheet bundles and move them safely across the workshop. To further protect sheet surfaces, the crane can be equipped with specialized lifting attachments, such as spreader beams or magnetic lifters, minimizing direct contact and reducing the chances of scratches or deformation.
3. Loading coils onto transport vehicles
The crane positions coils onto trucks or rail wagons for distribution. Cab control gives the operator visibility to place coils securely without excess adjustments. This reduces loading time and prevents damage during handling. With synchronized motion control, the crane ensures smooth lowering of coils onto loading beds, preventing sudden impacts. The efficiency gained at this stage improves logistics turnaround, helping the steel mill meet delivery deadlines more effectively.
4. Feeding production lines with raw material
Coils are moved into decoiling and cutting lines as raw material. The crane’s continuous duty cycle supports frequent feeding of these machines, keeping production uninterrupted. Its reliable lifting mechanism and anti-sway features ensure that coils are placed accurately into position, reducing downtime caused by misalignment. This continuous and precise feeding process directly contributes to higher throughput and consistent production quality across the entire mill.
Yuantai Overhead Cranes for Steel Mills
10 tons QD double girder overhead crane — Other applications
The 10-ton QD double girder overhead crane is not only indispensable in steel mills, but it is also widely used in a variety of industries that require dependable heavy lifting. This crane's large weight capacity, solid structure, and adaptability to varied working settings allow the safe and efficient handling of heavy, oversized, or high-density cargoes.
1. Metal fabrication plants
In metal fabrication shops, the crane assists in lifting heavy steel plates, long beams, fabricated frames, or large welded assemblies. It allows precise positioning of materials during cutting, bending, or welding processes. By minimizing manual handling, the crane reduces the risk of workplace injuries while also speeding up production cycles.
2. Mechanical engineering workshops
For mechanical and heavy machinery workshops, the crane is crucial for handling engines, machine tool beds, gearboxes, and other large components. During assembly and disassembly, it provides stability and precision, ensuring that parts are safely aligned without causing damage. This greatly enhances efficiency in repair and production operations.
3. Foundries and casting plants
In foundries, overhead cranes are used to transport molds, raw materials, finished castings, and molten metal ladles. Given the high-temperature and harsh environment, the crane’s durability and safety mechanisms are critical. It enables smooth, safe handling of hazardous materials while supporting continuous production in casting workshops.
4. Warehouse and logistics centers
Warehouses and distribution hubs use the crane to move heavy cargo, machinery pallets, or bundled steel products. It helps streamline material flow, especially in facilities dealing with oversized or unusually shaped goods that forklifts cannot easily handle. This makes storage and retrieval operations more efficient while reducing handling time.
5. Power plants and maintenance facilities
In power generation facilities, the crane is used for lifting and positioning turbines, generators, boilers, and other large-scale equipment during installation and maintenance. Its ability to handle heavy loads with precision ensures smooth repair operations, minimizes downtime, and supports safe handling of critical components in high-stakes environments.
