- Jul 23, 2025
- Case Studies
6 MHO single girder gantry cranes to Philippines
Precision handling of heavy molds and frequent transfers between workstations are critical for efficient production in the precast concrete industry. Yuantai pr
Precision handling of heavy molds and frequent transfers between workstations are critical for efficient production in the precast concrete industry. Yuantai provided six MHO single girder gantry cranes, two rated at 5 tons and four at 10 tons, to a top manufacturer of concrete underground pipes in the Philippines. This case study investigates the Philippine precast concrete industry setting, the customer's operating requirements, hurdles prior to crane adoption, the comprehensive MHO crane design, performance outcomes after installation, and other applications of MHO gantry crane.
Customers Overview
According to the client, they are engaged in the production of concrete pipe chips. In recent years, their orders have grown due to the increased demand for precast concrete for tunnel tubes, wall panels, and beams in the Philippines. So they built a new workshop, which required a lifting system to help them with a range of production transportation tasks.
Role of MHO Single Girder Gantry Crane in Tunnel Pipe Production
Heavy steel molds, also known as concrete tube sheet steel molds, are used in the construction of tunnel pipes to shape the concrete into exact pipes. Each production cycle follows a closely controlled sequence: the molds are filled with concrete mix, cured under particular circumstances, then transferred for demolding, cleaning, and reinforcing mesh installation before being relocated for the next pour. Molds packed with wet concrete can weigh between 2 ton and 8 ton, depending on pipe diameter and wall thickness. Accurate handling equipment is required. MHO single girder gantry cranes are critical in streamlining this repetitive and heavy-duty process. These cranes, which run on rails alongside permanent mold benches, transfer loaded molds between workstations such as the pouring area, vibration platform, and cleaning or mesh installation stations, decreasing human handling injuries and production delays dramatically. Their rail-mounted design, high positional accuracy, and compatibility with 8-15m spans enable seamless integration into tunnel pipe production lines. Furthermore, the MHO gantry crane's flexible lifting attachments and simple-to-maintain components provide efficient operation, high-volume throughput, and minimal downtime in challenging industrial settings.
Operational Needs in Concrete Tunnel Pipe Workshop
The customer's workshop comprises a row of eight steel‐reinforced concrete molds anchored directly to the factory floor. Each mold measures up to 3 m in diameter and 2 m in length, weighing 4 ton when empty. During concrete pouring, the fully loaded mold reaches approximately 8 ton. Throughout a 12‑hour production shift, each mold cycles through five process stations. Before adopting the MHO cranes, the facility relied on floor‐mounted chain hoists and forklifts to move molds between nearby benches. This method of handling is less efficient and takes a long time for each cycle. The customer therefore wanted a lifting solution for the new workshop that met the following requirements:
- Rapid mold transfers at fixed locations
- Precise positioning within ±30 mm to align molds under the pour head
- Safe lifting of loads from 2 ton empty molds up to 8 ton wet molds
- Continuous operation over two shifts with minimal maintenance
- Integration with custom lifting fixtures to cradle each mold securely
The requirement for high throughput meant that each crane had to perform at least 150 lifts per day without degradation in performance. In addition, the workshop floor did not have overhead support beams, so the gantry cranes needed to travel on rails mounted directly to the floor adjacent to the bench rows.
Challenges Faced Before Using MHO Single Girder Gantry Cranes
1. Inefficient Material Handling with Forklifts and Chain Hoists
Prior to Yuantai's engagement, the customer's workshop used forklifts to carry demolded molds from one station to another, as well as chain hoists built on temporary beam constructions to lift heavy-loaded molds. These methods posed several challenges. Forklifts were unable to perfectly line molds with the pouring machine's inlet tube or cleaning stations, necessitating several hand modifications. The chain hoists required workers to manually attach slings over each mold, extending handling cycles by 10-15 minutes. During peak production, molds formed queues in front of benches, producing bottlenecks and delaying following pours.
2. Safety Incidents and Mold Damage
The usage of forklifts and improvised beam hoists endangered workers. Molds shifted rapidly when forks were not correctly positioned, causing surface damage to the steel molds and minor injuries to workers. The workshop had three near-misses in which molds tipped slightly during forklift transfer. These incidents prompted internal safety investigations and three-hour work stoppages, which reduced overall facility utilization.
Maintenance and Downtime Issues
The homemade beam hoists and transportable lifting equipment need regular inspections and repairs. Chain hoists lacked overload protection and no built-in maintenance reminders. The repetitive 8-ton loads quickly wore down components like load chains and brake assemblies, resulting in an average of four hours of unexpected downtime per failure. The workshop's maintenance budget allotted approximately 20% of yearly operating expenses to ad-hoc crane repairs and parts replacement, which is unsustainable over time.
MHO Single Girder Gantry Crane Design Provided
1. Custom Single Girder Configuration
Yuantai designed six MHO single girder gantry cranes with rail-mounted operation to meet client needs and constraints. The two 5-ton cranes moved empty and demolded molds weighing 2-4 tons, while four 10-ton cranes handled loaded molds at the concrete pouring station. The single girder design utilizes a U-shaped welded box section made of Q345B structural steel, providing an ideal balance of strength and weight. Using a single girder reduced headroom needs to fit within the workshop's eight-meter ceiling clearance. Rail supports were anchored to concrete footings spaced at 5m intervals to ensure a sturdy basis for crane travel rails.
2. Hoist and Travel Mechanism
Each MHO crane features an electric wire rope hoist with dual‑speed motors, permitting fast lifts for 2 ton loads and controlled slow lifts for precise placement of heavier 8 ton molds. The hoist drum uses a high‑friction, multi‑groove design to prevent rope slippage, extending wire rope life by 30%. Trolley travel across the girder employs four flanged steel wheels on hardened axle shafts, guided along the box section's lower flange. Bridge travel along rails uses motorized bogies with polyurethane‐lined wheels that reduce noise and protect the rail running surface. Variable frequency drives manage acceleration and deceleration of both trolley and bridge motions, achieving positioning accuracy within ±20 mm.
3. Integrated Safety and Control Systems
Safety measures are critical in the precast sector. Each MHO crane has an overload protection system that detects hoist motor current draw and prevents operation if loads exceed the rated limit. Anti-collision sensors at each end of the girder identify stationary objects or cranes on adjacent lanes, resulting in automatic slowdown and controlled stops. Operators can use the emergency stop buttons on the crane and pendant control station to immediately stop all motion. The pendant includes a key-locked master switch to prevent unauthorized use. An optional wireless remote control module allows floor personnel to accompany the load, increasing visibility during transfer and reducing manual alignment efforts.
4. Crane Spreader Integration for Mold Handling
To correctly cradle the cylindrical molds, specialized lifting accessories such as a crane spreader are necessary. Yuantai created quick-change spreader beams with adjustable hook points and custom nose pads that fit the mold curvature. To transfer empty molds, use a four-leg chain sling with a central lifting point for stability. When molds are filled with concrete, operators transfer to a two‑leg sling with reinforced chain and shackles designed for 10 ton weights. The attachment modification process takes less than 15 minutes and doesn't require specialized gear, allowing for maximum uptime between production jobs.
Installation and Commissioning of MHO Single Girder Gantry Cranes
1. Site Preparation and Rail Installation
In March 2025, Yuantai's field engineers conducted a detailed site survey of the workshop floor. Concrete footings for the rail supports were cast in April, with M30 anchors set to carry vertical and lateral rail loads. Laser alignment tools ensured rail straightness within ±2 mm over the entire 60 m length of the crane lanes. Rails were then bolted to the support brackets and surface‑ground to remove burrs and ensure continuous wheel contact. End stops with hydraulic buffers were installed to absorb energy at the travel limits, preventing abrupt impacts that could damage the crane or the molds.
2. Crane Assembly and Functional Testing
Once rail works were complete, the single girder crane components arrived in five pre‑assembled sections. Yuantai technicians used hydraulic gantries and mobile cranes to lift girder sections into position on the bogies. Wheels were shimmed to correct wheel loads and maintain levelness within ±1 mm. Hoist units were bolted to the girder flange, reeved with wire rope, and aligned using dial indicators. Electrical wiring, including VFD units and control wiring, was routed in cable trays and tested for continuity. The commissioning phase included no‐load and full‐load tests. Each crane underwent 125% capacity static load testing in accordance with local lifting regulations, followed by dynamic performance trials simulating typical mold transfers. Position accuracy, travel speeds, and safety device responses were validated. By May 2025, all six cranes passed certification and were turned over for production use.
Performance Outcomes and Task Handling
1. Production Throughput Improvements
After the MHO single girder gantry cranes entered service, the workshop saw immediate production gains. Mold transfer times dropped from an average of 20 minutes using forklifts and chain hoists to under 5 minutes per move with the gantry cranes. With six cranes operating simultaneously across eight bench stations, the plant increased mold cycle throughput by 45%. Daily production of concrete tunnel tubes rose from 120 m of pipe per shift to 175 m—a 46% increase—without adding labor hours. This improvement translates into a monthly output gain of approximately 1 350 m of pipe, enhancing the customer's ability to meet accelerated project schedules for underground drainage and subway tunnel segments.
2. Safety Record and Incident Reduction
Safety metrics improved significantly after the crane installation. In the six months prior, the workshop reported three near‑miss incidents related to mold handling. Since commissioning the MHO cranes, no mold‑handling incidents have occurred. The overload protection devices prevented attempted over‑hoisting of 9 ton wet molds. Anti‑collision sensors eliminated collisions between cranes and fixed workshop infrastructure. A formal safety audit by the customer's insurance underwriter noted a 100% compliance rate with Philippine lifting equipment regulations and ISO 10855 standards for gantry cranes, reducing insurance premiums by 8% in the following renewal period.
3. Maintenance and Reliability Gains
The modular design and use of high‐quality components—such as German‐made hoist gearboxes and sealed crane wheels—have minimized maintenance requirements. Scheduled inspections every 1 000 operating hours require only visual checks of wire rope wear, lubrication of gearbox input shafts, and electronic diagnostics of the VFD controllers. Unplanned downtime for crane repairs has been under one hour per crane in six months, compared to an average of four hours per failure with the previous chain hoist system. The customer's maintenance team estimates a 30% reduction in crane‐related maintenance costs for the year.
Yuantai MHO Single Girder Gantry Crane
Advantages of Yuantai's MHO Single Girder Gantry Crane
1. Operational Efficiency and Cost Savings
The customer has realized significant cost savings by installing six MHO gantry cranes, including increased throughput, reduced labor for mold transfers, and lower maintenance costs. Eliminating the requirement for external crane rentals and forklift rework has saved an estimated PHP 2 million in monthly operational expenditures. The faster handling method also allows operators to focus on mold preparation and quality inspections rather than transportation activities, increasing plant efficiency.
2. Enhanced Flexibility and Scalability
The MHO series single girder cranes can be reconfigured easily to different spans or relocated within the workshop as production needs change. Should the customer expand their mold benches or add additional process stations, new rail supports and crane modules can be installed without major structural modifications. This adaptability supports long‑term scalability in a market where construction volumes may fluctuate.
3. Durability in Harsh Workshop Environments
Steel molds and wet concrete generate abrasive dust and moisture. The MHO cranes employ sealed IP54 motors and dust‑resistant wire rope hoists to withstand these conditions. The galvanized steel rails resist corrosion in humid tropical climates. The polyurethane rail wheels reduce noise and cushion impacts, extending rail life by up to 25% compared to steel wheels. Such durability ensures consistent performance and minimizes workshop disruptions due to environmental wear.
Other Applications of MHO Gantry Crane
While this case focused on tunnel pipe production, the six MHO single girder gantry cranes are well suited to other fixed‐location repetitive manufacturing processes. In precast wall panel factories, the cranes can move heavy molds through casting, vibrating, curing, and storage areas. In concrete pile and prestressed beam plants, they handle tensioning bed equipment and finished elements with similar lifting requirements. The modular crane design also supports use in ceramic tile presses, textile machinery assembly lines, and steel plate processing where loads up to 10 ton require precise, repeatable handling. Rubber‐tyred configurations of the same MHO series further expand applications into open yards for precast slab stacking or steel coil warehouses where floor rails are impractical.
