• Jun 13, 2025
• Case Studies

5-Ton, 10-Ton Overhead Crane for Warehouse in Netherlands

Explore our 5-ton and 10-ton overhead cranes designed for warehouses in the Netherlands. Boost efficiency and safety in your operations—check them out today!

A Dutch distribution company planned to build new warehouses in 2024, which were completed by the first part of 2025. Multiple overhead travelling cranes were required to accommodate a wide range of load profiles, from light pallet loads to big equipment modules. Yuantai delivered three crane systems, including a 5-ton single girder, two 10-ton double girder cranes and two 12.5-ton double girder overhead cranes. Each crane employs a European wire rope hoist and tandem trolley configuration. This case study discusses the client's industry context, lifting needs, issues with previous equipment, Yuantai's bespoke crane designs, product benefits, performance in a variety of activities, and other crane applications.

2. Customer's Operational Goals

After speaking with the client, we determined that they had the following needs:

• Flexibility: Cover light pallet loading (up to 5 t), mid-weight equipment handling (up to 10 t), and heavy machinery modules (up to 12.5 t).
• Precision: Load positioning within ±25 mm for racking, assembly, and packaging operations.
• Reliability: Continuous operation over two 8-hour shifts, five days per week.
• Safety and Compliance: Adhere to EN 15011 and Dutch health and safety regulations for lifting equipment.

Challenges with Prior Lifting Equipment

According to the customer, their previous warehouse facilities were relatively old. As the business volume expanded, their progress was a little slow due to the low lifting capacity of the previous lifting facilities. In addition, the warehouse facilities were a bit old, and even if they replaced the heavier cranes, the old warehouse facility structure could not support such a heavy weight.

1. Under-Capacitated Chain Hoists and Forklifts

Initially, the warehouse relied on manual chain hoists for light loads and forklifts for mid-weight moves. Chain hoists handled loads up to 1 ton but proved slow and labor-intensive for pallet racks. Forklifts managed 2–4 ton pallets but could not reach high racking or handle bulky machinery bases. Transitioning items between forklift and manual hoist cost valuable minutes and risked damage to goods.

2. Single Girder Cranes with Limited Duty Rating

An existing single girder crane, rated for 5 tonnes, was installed over the ambient zone. Its fixed-speed trolley and hoist limited precision control. Frequent stops and starts caused load sway.

3. Need for Heavy-Duty Options

In the climate-controlled zone, machinery modules up to 12 tonnes needed safe lifting for installation and maintenance. Packers and assembly crews also handled heavy drums of raw materials (10–12 t). The client lacked a high-capacity crane capable of accurate placement in narrow aisles. Renting mobile gantries added cost and disrupted workflows. They required a permanent heavy-duty crane solution to integrate with existing building structure.

Custom Crane Design by Yuantai

Yuantai proposed three overhead travelling crane systems:

1. A 5 ton single girder crane with European wire rope hoist and end-carriage trolley, covering the ambient storage zone.
2. Two 10 ton double girder crane for the packaging and assembly area, with two wire rope hoist arrangement for precise load control.
3. Two 12.5 ton double girder crane in the heavy-duty equipment bay, featuring a dual trolley configuration for split load handling.

1. Structural and Mechanical Design

Single Girder 5 Ton Crane

The 5 T bridge uses a fabricated box-girder of Q345B steel. Span: 13 m. The underslung trolley mounts to the bottom flange, maximizing hook height (8 m under beam). End trucks use forged steel wheels with monolithic flanges. The crane's deadweight is minimized for lower runway stresses.

10 Ton Double Girder Crane

For the mid-range capacity, Yuantai selected a double girder design. Twin box girders spaced to clear bulk storage racks. Span: 13 m. Main girders are 320 mm deep. This design reduces deflection under 10 t by 50% compared to single girder. Supports a tandem hoist arrangement—two 5 ton wire rope hoists operating in synchrony for heavy or wide loads.

12.5 Ton Double Girder Crane

The heavy zone crane features deeper girders (400 mm depth) and robust end trucks for the 12.5 t load. Span: 13 m. Equipped with dual trolley system, enabling two hoists to operate independently or in tandem. Ideal for lifting uneven or spread-beam loads up to 12.5 t. Air-conditioned cabin optional for operators during high-precision lifts.

2. European Wire Rope Hoist and Tandem Trolley

All three cranes use the NR-type European wire rope hoist:

• Lifting capacity: 5 t per hoist (10 t crane uses two hoists in tandem; 12.5 t crane uses one 5 t and one 7.5 t hoist in tandem).
• Hoisting speed: 8/0.8 m/min (fast/slow) with dual-speed motor.
• Wire rope: Ø16 mm, 1960 N/mm², six-strand rope for high fatigue life.
• Brake: DC spring-applied disc brake for reliable load holding with <0.5 mm creep.
• Trolley: Variable speed via VFD, 0–15 m/min with precision control mode.
• Safety: Overload limiter, anti two-block, upper/lower limit switches, emergency stop.

Tandem operation on the 10 t and 12.5 t cranes synchronizes hoist travel using a master-slave control module, ensuring equal load share and minimal differential.

3. Electrical and Control Systems

Every crane features a central control panel with PLC for safety interlocks and diagnostics. Bridge and trolley drives use Schneider Electric VFDs. Travel motors: low-noise, TEFC, IE3 efficiency. Pendant station: ergonomic dead-man switch, hoist/travel controls, speed change buttons. Wireless remote optional for ground operations.

Performance in Diverse Operational Tasks

1. Ambient Storage and Pallet Handling

The 5 ton single girder crane significantly improved throughput in the ambient zone. Operators lifted full pallets (up to 2 t) onto high racks (7.5 m) with no need for fork trucks. Average pallet put-away time dropped from 5 minutes to 1.5 minutes per pallet. This crane also moved 5 t roll cages between loading docks.

2. Packaging Line Load Transfer

The 10 ton double girder crane serves the assembly and packaging area. It lifts large crate bundles (up to 8 t) onto packing conveyors. Tandem hoist control allows precise tilt correction when handling asymmetrical loads. Operators use the slow hoist speed (0.8 m/min) for final placement, reducing product damage by 75%.

3. Heavy Machinery Module Installation

The 12.5 ton crane handles machinery modules and engine blocks (10–12 t). Dual trolleys let one hoist lift the load while the other adjusts balance or angle. This feature was critical when installing a 12 t compressor into a machine base with ±10 mm alignment accuracy. The crane's soft-start travel prevented load pendulum, protecting both product and structure.

4. Multi-Zone Flexibility

All three cranes run on a continuous runway system, allowing transfer of heavy items from ambient storage to packaging to heavy equipment bays without unloading. This saves up to 30 minutes per transfer cycle. The VFD travel control ensures smooth transitions between zones.

Advantages of Yuantai's Overhead Travelling Crane Solutions

1. Modular Design and Easy Installation

Girders and end trucks arrive in pre-assembled modules. On-site assembly took under five days per crane, minimizing warehouse downtime. Modular rails bolt to the building structure with minimal welding.

2. High Precision and Load Control

Dual-speed hoists and VFD travel with positional feedback allow placement within ±20 mm. Tandem hoist control further refines load balance and tilt.

3. Durability and Low Maintenance

Use of European wire rope hoist and IE3 motors reduces wear. Sealed bearings and lifetime lubrication cut maintenance hours by 60%. Initial six-month service log shows zero unplanned stops.

4. Energy Efficiency and Cost Savings

Regenerative braking on VFD drives recovers up to 5% of consumed energy during deceleration. IE3 motors yield 10% lower electrical draw than standard motors. Estimated annual electricity savings: 4 800 kWh per crane.

Broader Applications of Overhead Travelling Cranes

An overhead travelling crane offers unmatched versatility and efficiency across a wide array of industrial sectors. Its ability to lift heavy loads, span large work areas, and integrate precise motion controls makes it a core asset in facilities ranging from heavy‐duty fabrication shops to high‐throughput port terminals. Below are some of the key environments where these cranes deliver measurable productivity and safety gains.

1. Steel Fabrication Workshops

In steel plate and beam fabrication shops, double‐girder cranes routinely lift assemblies up to 20tonnes. Fabricators use the cranes to move raw plates between cutting, rolling, and welding stations. Their rigid bridge and twin‐hoist setups enable simultaneous handling of long beams, reducing handling steps and ensuring alignment accuracy during complex weld joint preparation.

2. Automotive and Heavy Equipment Assembly

Assembly lines for engines, gearboxes, and chassis sub‐assemblies require overhead cranes in the 5–15tonne range. Dual‐trolley crane configurations allow technicians to mount heavy powertrain modules directly into vehicle bodies. By synchronizing two hoists, operators achieve gentle, level positioning—critical for mating transmission bell housings or aligning engine mounts within millimeter tolerances.

3. Warehouse and Distribution Centers

Warehouses deploy single‐girder cranes rated between 5t and 10t to service pallet racking, container handling, and order‐picking zones. Rail‐mounted overhead cranes clear aisles of forklifts, maximizing floor space and improving safety. Their rapid trolley speeds and load‐moment indicators accelerate pick‐and‐place operations, increasing throughput in cross‐dock and high‐bay storage areas.

4. Port Terminals and Shipyards

In confined dock halls, a mix of gantry and overhead cranes moves shipping containers, prefabricated ship modules, and heavy machinery during repair work. Double‐girder cranes with high‐cycle hoists support frequent lifts in both dry docks and covered maintenance bays. Their robust frames withstand side thrusts from container stacks and offshore equipment, while anti‐collision systems maintain safe separation between adjacent cranes.

5. Power Plants and Substation Maintenance

Power generation facilities rely on overhead cranes to handle transformers (10–25t), turbine rotor assemblies, and generator stators. Extended‐headroom crane designs clear the large stator stacks and cooling piping. Tandem‐hoist configurations lift heavy rotors evenly, enabling technicians to drop them into place within tight alignment tolerances.

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Conclusion

Yuantai's supply of a 5 ton single girder, 10 ton double girder, and 12.5 ton double girder overhead travelling crane met their varied lifting needs in their new Netherlands warehouse. Each crane—equipped with European wire rope hoists and tandem trolley systems—handled diverse tasks from pallet storage to heavy equipment installation. These crane systems also apply to steel fabrication, automotive assembly, ports, and power plants seeking reliable overhead lifting solutions. For organizations requiring versatile, heavy-duty overhead cranes, Yuantai's expertise in design and installation delivers tailored results and long-term performance.