- Sep 19, 2025
- Case Studies
3-ton Bridge Cranes and Steel Structures for Maldives
Discover durable 3-ton bridge cranes and custom steel structures designed for the Maldives. Perfect for enhancing your construction projects—let's build together!
A port logistics company in the Maldives expanded a warehouse for material transshipment and distribution. We supplied a 10m span, 5.2m lift bridge crane system. The crane uses two 3-ton wire rope hoists, each fitted with anti-collision devices. We also supplied the steel structure to support the crane and runways inside the extended warehouse.
Customer Crane Need
The customer needs a compact, reliable 3-ton bridge crane and a matched steel structure to move palletized goods, heavy crates and bundled cargo between vessels, trucks and storage racks. The supporting runway and columns must be sized for the dynamic loads, fatigue and deflection limits of frequent operation, with proper anchor/bolt design, grouted baseplates and safe access for inspection and maintenance.
Lifting Solution Offered: Bridge Crane and Steel Structure
After many communications, we have determined the following solution. In this program, a double girder overhead crane with double lifting trolleys and a steel structure were supplied.
1. Double Girder Bridge Crane
The core of the system is a double-girder bridge crane sized for dual-hoist operation, providing a lifting height of 5.2 meters and a span of 10 meters. Each girder and end truck was modeled to handle dynamic loads and tandem lifts. Two 3-ton wire rope hoists run independently on the bridge. The hoists can operate alone for routine tasks. They can also run simultaneously for tandem lifts and synchronized handling of long or heavy parts.
2. Steel Structure
The supporting steel structure was sized for the crane loads, dynamic effects, and runway geometry. We designed column spacing, beam section, and bracing to control deflection and vibration. Anchor bolt layouts follow foundation and grout best practice. We performed structural checks for load combinations, seismic effects (if applicable), and local code requirements.
Safety Devices
Modern overhead cranes are equipped with advanced safety devices to protect operators, equipment, and loads during operation. These systems are designed to minimize risks, prevent accidents, and extend the life of the crane. By combining mechanical protections with intelligent electronic controls, cranes achieve higher levels of reliability and efficiency in demanding environments.
1. Anti-collision
Anti-collision systems use laser, radar, or optical sensors mounted on each hoist to monitor the distance between cranes or other obstacles. When the system detects that two cranes are approaching a set distance, it automatically initiates a slow-down zone. If the separation limit is breached, the system stops the crane completely to avoid contact. This technology is critical in busy facilities where multiple cranes operate on the same runway, such as ports, shipyards, or large warehouses. It not only prevents accidents but also reduces downtime and costly repairs caused by collisions.
2. Motion Control
Variable Frequency Drives (VFDs) are used in both bridge and trolley travel to achieve smooth and precise motion control. The drives allow the crane to accelerate and decelerate gradually, which minimizes stress on structural components and reduces load swing. Smooth operation also makes it easier for operators to position loads with accuracy, especially in applications that require delicate placement. Additionally, VFDs improve energy efficiency by adjusting motor performance to the actual load demand.
3. Controls
For user convenience and safety, cranes are operated with a radio remote control, allowing operators to manage lifting and movement from a safe distance. A pendant control system is also included as a reliable backup option. The control system integrates Programmable Logic Controller (PLC) logic, which can coordinate tandem lifts involving two cranes or hoists. This ensures synchronization and load stability when handling oversized or heavy items. The dual control setup gives operators flexibility, improves efficiency, and adds redundancy for uninterrupted operations.
4. Why Wire Rope Hoists?
Wire rope hoists are chosen over other lifting mechanisms because they deliver superior performance in heavy-duty applications. They offer faster lifting speeds and can handle continuous or repeated lifts without compromising reliability. The wire rope's longer lifespan, especially when used with drum hoists, reduces maintenance needs and increases operational uptime. These hoists also provide smoother and more precise load handling, which is vital for industries like ports, steel plants, and logistics hubs.
5. Durability
To ensure long-term durability and structural integrity of crane, we applied a multi-layer protection system designed for harsh coastal conditions. The process begins with surface preparation, then a zinc-rich epoxy primer is then applied to provide cathodic protection, forming the first barrier against corrosion. This is followed by a high-build epoxy intermediate coat and a polyurethane top coat, both of which meet ISO 12944 standards for very high corrosivity categories. These coatings deliver strong chemical, abrasion, and UV resistance. For sites with the exposure, such as open-air waterfront structures, hot-dip galvanizing can be added to further strengthen protection and extend service life. This system not only safeguards the steel but also reduces long-term maintenance costs.
Yuantai Double Girder Gantry Crane
Other Applications for 3-Ton Bridge Crane and Steel Structure
A 3-ton bridge crane is not limited to port logistics. Its compact design, reliable lifting performance, and adaptability make it a valuable tool in many industries. Businesses that need efficient material handling, precise movement of parts, or safe lifting of light to medium loads can all benefit.
1. Warehouse overhead crane for pallet transshipment
In warehouses, a 3-ton bridge crane offers a practical solution for handling pallets quickly and safely. Its compact span allows it to operate efficiently in tight storage areas, while the low headroom design ensures full use of vertical space. This makes it ideal for transferring goods between racks, preparing shipments, or unloading delivery trucks. Compared with forklifts, a bridge crane reduces congestion and improves workflow in high-volume operations.
2. Manufacturing overhead crane for assembly jigs
A 3-ton crane can move heavy components like engines, presses, or molds with ease. It improves safety by reducing the need for manual lifting and helps workers align parts accurately during assembly. This type of setup is common in automotive, machinery, and electronics manufacturing, where production efficiency and consistent quality are critical.
3. Maintenance workshop bridge crane
Maintenance workshops rely on bridge cranes to lift and move heavy equipment during repair or servicing. A 3-ton crane can handle engines, HVAC units, or industrial machines without difficulty. It improves safety by reducing reliance on manual lifting and unstable hoists. The ability to move equipment between workstations gives workshops flexibility, which boosts productivity and facilitates a more seamless repair procedure.
4. Prefabrication and modular building plant crane
In prefabrication and modular construction plants, bridge cranes are essential for lifting panels, frames, and building modules. A 3-ton unit is strong enough to move stacked panels or completed sections while maintaining precision. Its stable performance ensures that components are not damaged during handling. By improving workflow and reducing manual labor, the crane supports faster production cycles and helps companies meet strict project deadlines.
