- Sep 15, 2025
- Case Studies
20 Ton Grab Bridge Crane for India
Check out our case study on a 20-ton grab bridge crane designed for India! Discover the challenges, solutions, and impressive results that transformed operations. Dive in!
We delivered a customized 20-ton grab bridge crane for a raw-material preparation plant or scrap yard. The crane increases single-lift throughput, cuts labor needs, reduces on-site dust problems, and runs reliably under heavy, continuous duty.
Customer Crane Need
The client needed a heavy duty grab bridge crane to transport large quantities of bulk materials such as coal, iron ore and steel scrap. Their current equipment had low single-lift capacity, so it required multiple picks and extra handling. In addition, due to the hot and dusty environment of the customer's application, the original cranes had been operating in this environment for a long time, which damaged the electronic equipment and increased the customer's maintenance needs. Therefore, they needed a specialized heavy-duty grab crane equipped with dust protection.
Our Lifting Solution
According to the customer's needs, we offer a 20-ton dedicated grab bridge crane for the following reasons:
- Single-lift capacity and throughput. A 20-ton rated grab lets the customer move more material per cycle. This improves yard throughput and reduces the number of crane moves required for the same tonnage. Grab bucket cranes are commonly used to speed up bulk loading/unloading and to increase turnaround times in cement, coal, and scrap applications.
- Heavy-duty, continuous service (A7 duty). The site needs a crane that can handle many cycles at high loads. We designed the machine to an A7 duty/service class so the structure, hoist, and controls are sized for long life under continuous heavy use.
- Stiff, durable structure: double girder design. For a 20-ton lift that will operate many times per day and over long spans, a double girder bridge gives higher rigidity, greater hook height, and easier integration of a cab and walkways. Double girders also simplify heavy-duty hoist integration and reduce long-term fatigue in the structure.
- Grabs (grapples or clamshells) let operators pick up loose, bulk, or irregular materials quickly and securely. They close around the load to cut spillage and material scatter. Grabs handle many bulk goods—coal, ore, powders, scrap—and speed up loading and unloading at pile faces, ship holds, and feeders. Compared with forklifts or bucket trucks, grabs make bulk handling faster and safer.
Crane Design We Provied
As the customer's grab bridge cranes had to perform continuous heavy-duty operations at the waste plant. We have designed our cranes to incorporate rugged structural designs, durable components to ensure that they provide reliable lifting performance and reduce crane maintenance and downtime.
1. Main Beam
This crane is built on a double girder bridge structure, which provides superior strength and stiffness compared to single-girder models. The rated capacity is 20 metric tons, which allows the crane to safely handle large volumes of bulk material in one cycle. The span is engineered according to the customer's yard layout and rail system, ensuring smooth integration with existing infrastructure. In terms of duty class, the crane meets A7 classification under ISO and FEM standards, which means it is suited for heavy, continuous duty cycles such as repeated lifting, lowering, and material transfer in fast-paced operations.
2. Specialized Spreader
The crane is equipped with a configurable grab designed to match the type of material being handled. For fine, free-flowing materials like coal, sand, or fertilizer, a clamshell grab is ideal, as it ensures high fill factors with minimal loss during transport. For mixed or bulky scrap, an orange-peel grab is used, with segmented tines that close tightly around irregular shapes. The grab is sized to match the 20-ton lift rating, which reduces the need for multiple smaller lifts and boosts productivity.
3. Work System and Components
At the heart of the crane is the hoist and gearbox assembly, designed for the rated 20-ton load with an appropriate safety margin. These components are built for frequent starts, stops, and long operation hours. Travel drives are equipped with variable frequency drives (VFD), which provide smooth acceleration, reduce wear on mechanical parts, and allow precise positioning of the trolley and bridge. This helps avoid shock loading and extends the crane's lifespan.
The main control interface is located in the operator's cab, with an ergonomic layout that minimizes fatigue during long shifts. Climate control and wide sight lines give operators confidence and comfort, while optional remote control systems allow flexibility for certain tasks. Safety systems include redundant holding brakes, overload protection, anti-collision sensors, and travel limit switches, ensuring that both equipment and personnel remain protected during operations.
How the Grab Bridge Crane Meets the Customer's Lifting Needs
The bridge cranes we offer are based on the basic usage needs of our clients, so we provide solutions and final designs that make our clients very happy.
1. Large Capacity and Faster Single-Handling Efficiency
The 20-ton rated grab lets operators pick significantly more material per cycle. A larger grab volume, matched to material density, increases fill per pick. That reduces the number of cycles needed to move a fixed tonnage. This directly lowers handling time and boosts yard throughput. Industry sources note that properly sized grab bucket cranes can reduce loading/unloading turnaround and logistics time.
2. High Strength for Harsh Steel/Yard Conditions
Double girder structure, heavy-duty hoist, and A7-class design deliver structural strength for continuous heavy cycles. Double girders improve fatigue life and allow for higher hook height and longer spans. This makes the crane robust in intense yard workflows and improves service life.
3. High Reliability and Minimal Downtime
We specified industrial-grade components, redundant safety systems, sealed electrical enclosures, and easy access for routine maintenance. Combined with a duty-class design, these measures reduce forced outages. In dusty, high-temperature environments, sealing and filtration extend the life of electrical and electronic parts. Studies show occupational dust exposure is common in steel operations and harms both health and equipment.
4. Reduce Dust Pproblems and Improve Environmental Safety
The grab lowers material drop height and confines the load during travel. Sealed electrical systems and dust-tolerant mechanical layouts cut dust ingress. This both protects equipment and reduces fugitive dust in the yard. Best practices in steel manufacturing emphasize capturing dust at source and using robust equipment to limit spread.
Yuantai Grab Overhead Crane
Other Applications for the 20-ton Grab Bridge Crane
The 20-ton grab bridge crane is a highly versatile piece of equipment designed for heavy-duty bulk material handling. Industries that rely on the efficient transfer of bulk or irregular materials often choose this crane because of its ability to adapt to different grab attachments, such as clamshell grabs for free-flowing materials and orange-peel grabs for irregular loads.
1. Coal Handling Plants and Stockyards
In coal handling plants and stockyards, the grab bridge crane plays a central role. Coal must be moved quickly and safely from stockpiles to conveyors or directly into power plant feed systems. Clamshell grabs make this process efficient by reducing spillage and ensuring a steady flow of fuel to boilers. The crane’s robust design ensures reliability, even in dusty and high-temperature environments that are typical of coal facilities.
2. Iron Ore and Mineral Yards
Iron ore and mineral yards also rely heavily on grab bridge cranes. These operations handle large quantities of dense, abrasive materials that require strong and durable lifting equipment. The crane is used to transport ore from storage areas to processing units or loading points. Because of its high lifting capacity and precision, it minimizes downtime and keeps material flow consistent, which is critical in large-scale mineral processing and export operations.
3. Scrap Metal Recycling Yards
Scrap metal recycling yards present a different challenge: irregularly shaped, tangled, and heavy scrap pieces. Here, the orange-peel grab attachment is invaluable. It grips uneven loads securely, whether dealing with sheet metal, beams, or mixed scrap. By using a grab bridge crane, recycling yards can speed up sorting and loading operations, reduce manual labor, and improve workplace safety.
4. Ports and Terminals
At ports and terminals, where efficiency directly impacts shipping schedules, grab bridge cranes are used for bulk cargo handling. These cranes streamline the loading and unloading of ships carrying coal, grain, ores, or other bulk commodities. With their ability to handle large volumes in a short time, they help reduce vessel turnaround times, which is vital in competitive maritime logistics.
5. Cement Plants and Raw Material Handling
Cement plants also benefit from these cranes, particularly for raw material handling. Materials such as lime, slag, and clinker must be moved from storage areas to hoppers and silos. A grab bridge crane ensures smooth feeding into production processes, reducing bottlenecks and maintaining consistent cement quality. The crane’s precision and control also help minimize spillage, which is important when dealing with fine or powdery materials.
Purchase checklist: What buyers should consider before buying a grab bridge crane
Buying a grab bridge crane usually costs a lot of money, and if you want to buy one, you must carefully consider a variety of factors. Here is a list of some of the things we offer for buying a grapple crane:
1. Duty classification
One of the most critical checks is the duty classification of the crane. Cranes used in demanding environments, such as steel mills or power plants, may operate for long hours with high lifting frequencies. For a 20-ton grab bridge crane, duty classes like A7 or equivalent are usually recommended.
2. Grab type and compatibility
The grab itself determines how efficiently the crane handles materials. Different applications call for different grab designs—clamshell grabs work well for fine bulk materials like sand or grain, while orange-peel grabs are better suited for irregular scrap or rock. Selecting the right grab reduces spillage, speeds up handling, and lowers long-term wear costs.
3. Double girder vs. single girder
The double girder design provides greater stability, allows higher lifting heights, and is more suitable for continuous duty cycles. However, some suppliers may still suggest a single girder option for cost savings. For heavy-duty and continuous use, a double girder system typically ensures longer service life and better reliability.
4. Dustproofing and enclosure ratings
Bulk handling often takes place in environments with high dust levels, such as coal yards, cement plants, or mineral processing sites. Ask for details on IP (Ingress Protection) ratings for electrical cabinets, motor housings, and control systems. In addition, confirm whether the crane has proper filtration and ventilation systems to prevent overheating in dusty environments. Poor dustproofing can quickly shorten the life of electrical and mechanical components.
5. Hoist and gearbox specifications
The hoist and gearbox are the heart of the crane’s lifting system. In regions with high ambient temperatures, it is important to ask if the hoist motor and gearbox suffer from thermal derating, which reduces performance when temperatures rise. High-quality hoists are designed with cooling systems or oversized motors to maintain consistent lifting speeds even in challenging climates.
