- Jan 06, 2026
- Case Studies
5 Sets EOT Cranes Applied in Pakistan Steel Plant
Yuantai Crane delivered five double girder EOT cranes to a new steel plant in Pakistan, consisting of one 25-ton magnet crane and four 15-ton hook cranes for efficient lifting.
Industry Background and Customer Profile
The customer is a major steel plant operator in Pakistan. They produce billets, slabs, and finished steel products for domestic and export markets. Steel plants require robust material handling solutions. They lift molten metal using ladle cranes. They move steel billets with billet handling cranes. They transfer scrap with magnet cranes. They handle bulk scrap with grab cranes. This client needed a complete set of EOT overhead cranes to support their new facility.
Customer's Material Handling Needs
This newly built steel mill needed cranes that would operate efficiently and consistently, and the customer needed to lift heavy loads safely. Due to the harsh environments in some locations, cranes need to withstand dust, high temperatures and intense lifting. According to customers, their main enhancement needs are as follows:
1. Ladle Handling
The customer's ladle handling required two double girder cranes for lifting the steel ladles. Ladle handlers require a reliable tilting system to provide smooth operation for pouring steel so that the operator can avoid splashing while pouring. In addition, the material at the ladle interface should be strongly heat resistant.
2. Billet Handling
They also need cranes with a maximum lifting capacity of 12 tons to move the billets. The 12-ton double-girder crane for billets must move very hot, heavy pieces fast and accurately. It needs a hoist and trolley with rapid traverse and exact stopping. Clamps should secure billets without surface damage. The structure and paint must tolerate high local temperatures and sparks. Rails and expansion joints should be specified to handle thermal expansion. Quick, repeatable transfers to the rolling mill keep the production line flowing and reduce billet cooling time.
3. Scrap Charging
During our discussions, the customer clearly defined two key lifting needs for scrap handling, and we developed the crane solution around these requirements. For scrap charging, the customer need a 12 ton double-girder magnet crane, with the 12-ton main hoist used for charging bulk ferrous scrap into the furnace and the 5-ton auxiliary hoist used for sorting and lighter handling tasks. The magnet system needed adjustable holding force to safely lift irregular scrap and ensure clean release. Demagnetizing functions, safety interlocks, and reliable electrical controls were also required. Easy maintenance was important, so the magnet coils, rectifiers, and suspension points had to be simple to inspect and replace. For bulk scrap feeding, the customer required a 12-ton grab crane capable of moving large scrap volumes with short cycle times. The grab had to deliver a high fill factor, use wear-resistant jaws, and operate smoothly in dusty, high-temperature conditions.
Challenges Before Using Yuantai's EOT Cranes
Before choosing new overhead cranes, the steel plant faced several operational pressures that directly affected safety, efficiency, and output. Existing lifting systems struggled to keep up with modern steelmaking demands. Daily work involved higher risks, slower handling, and frequent interruptions. These issues made it clear that the plant needed a more reliable and better-designed EOT crane solution to support stable production and long-term growth.
1. Outdated Lifting Equipment
Before Yuantai’s EOT cranes arrived, the plant depended on old lifting equipment that no longer matched its working needs. Operators found it hard to balance loads smoothly, especially during ladle transfer. Small adjustments took more time and attention. As a result, safety risks increased and each lifting cycle slowed down, which reduced overall production efficiency.
2. Insufficient Scrap Handling
Scrap handling was another major challenge for the plant. The previous scrap cranes had limited lifting height and could not feed scrap directly into the electric arc furnace. Workers had to move scrap manually from ground level before charging. This added extra steps to the process and exposed workers to unnecessary hazards. During peak production hours, these delays became more obvious. Scrap supply could not keep pace with furnace demand, which directly affected melting efficiency.
3. Frequent Downtime and Maintenance
The aging cranes also caused frequent downtime. Their control systems were outdated and difficult to maintain. Key components such as wire ropes and magnet assemblies wore out quickly under heavy-duty cycles. Breakdowns often happened without warning. Each unplanned shutdown disrupted production schedules and increased maintenance costs.
4. Limited Precision and Safety Features
Operators lacked precise speed control. Hoists had single-speed motors. Cranes did not have dual-speed lifting modes. This made ladle tilting jerky. Scrap drop zones were inaccurate. Safety features like overload protection were missing. This increased risk of accidents.
Yuantai's EOT Crane Solution
Yuantai designed and delivered five double-girder EOT cranes tailored to the customer’s specific lifting needs. Two 30/10-ton ladle cranes were supplied with A7 duty class for heavy, frequent ladle handling and precise positioning. One 12-ton billet handling crane was built to A6 duty class for reliable, medium-duty transfers of hot billets. One 12/5-ton scrap-charging magnet crane, rated A7, provides a 12-ton main magnet for furnace charging and a 5-ton auxiliary hoist for sorting and lighter tasks. Finally, one 12-ton double-girder grab crane (A6) was provided for fast, high-volume scrap feeding with durable jaws and responsive cycles. Each crane was specified for its task, with suitable capacity, duty rating, and features to ensure safe, efficient operation in a demanding industrial environment.
1. Design Features of Ladle Cranes (30/10T)
The 30/10T ladle cranes were built for the most demanding area of the plant. With an A7 duty class, they support continuous heavy lifting and safely handle molten ladles weighing up to 30 tons. The dual hook design gives you flexibility. The main hook manages ladle transport, while the auxiliary hook supports maintenance and setup tasks. An intelligent tilt mechanism allows both slow and fast tilting speeds, giving operators smooth and accurate control during pouring. Heat-resistant motors and special cooling fans protect the trolley and hoist from extreme temperatures. Multiple safety devices, including overload protection, limit switches, emergency stop functions, and an anti-sway system, help you reduce risk during every lift.
|
Lifting Capacity |
30/10T |
|
Hook |
Dual Hook |
|
Working Class |
A7 |
2. Design Features of Billet Handling Overhead Crane
The 12T billet handling crane focuses on speed and accuracy in a hot environment. Its A6 duty class supports frequent lifting cycles during billet transfer. A high-temperature resistant wire rope, rated for up to 1200°C, allows safe handling of hot billets straight from the rolling process. Dual-speed hoist and trolley movements let you position billets slowly and accurately onto roller tables. An encoder-based auto-positioning system further improves placement accuracy and reduces the need for manual correction. The compact trolley design ensures smooth travel even in narrow workshop aisles, which is critical when space is limited.
3. Design Features of Scrap Charging Magnet Overhead Crane
The 12/5T scrap charging magnet crane is designed for fast and reliable furnace charging. The primary 12T magnet uses high-energy Neodymium material to lift large volumes of ferrous scrap efficiently. The auxiliary 5T hook gives you added flexibility for scrap sorting and light lifting tasks. With an A7 duty class, this crane supports frequent magnet on and off cycles without performance loss. A closed-loop control system adjusts magnet current based on scrap density, which helps prevent magnet overheating and reduces energy use. Dust-proof housing protects the electromagnetic coils from steel dust, extending service life in harsh conditions.
4. Design Features of Grab Crane (12T)
The 12T grab crane handles bulk scrap movement with stable and controlled operation. Its A6 duty class suits moderate working cycles commonly found in scrap yards and charging zones. The hydraulic grab assembly uses oil-powered arms to open and close with strong gripping force, allowing efficient scooping of loose scrap. Sensors on the grab arms monitor pile height and control grab depth, helping you avoid overload and maintain consistent lifting performance. The grab bucket is made from high-strength, wear-resistant steel plates, so it withstands abrasive materials and delivers long-term durability with minimal maintenance.
Installation and Commissioning Process
Yuantai coordinated closely with the Pakistan steel plant's engineering team. Key steps included:
1. Site Survey and Layout Confirmation
Before any equipment arrived, our engineers inspected the facility to ensure that all important dimensions and utilities were correct. They measured the workshop's length, width, and clear height. The runway beam positions were designated in relation to the production lines and access lanes. Power supply sites, including three-phase outlets and control panel locations, were mapped. We verified that the runway columns would not interfere with existing pipes or ductwork. This step also involved a study of floor flatness and load-bearing capacity. The end result was a thorough plan drawing depicting crane placements, trip limitations, and cable routing. By sharing these drawings with the plant's civil, mechanical, and electrical teams, we secured scope alignment and avoided site problems during installation.
2. Factory Acceptance Testing (FAT)
Factory Acceptance Testing (FAT) took place at Yuantai's manufacturing plant under full-load conditions. Technicians assembled each crane bridge, hoist, trolley, and control panel. They then ran simulated workload cycles matching the steel plant's specified daily usage. The dual-speed hoist modes were tested at both low and high speeds. We activated anti-sway controls and measured residual swing angles. Meltdown protection—designed to cut power if motor temperatures rose above safe levels—was also verified.
3. Packing and Shipping
Protecting heavy equipment during transit is critical to avoiding damage. Following the Factory Acceptance Test (FAT), each hoist and trolley assembly was treated with corrosion inhibitor and encased in UV-resistant plastic. They were packed in special hardwood containers with internal bracing. Control panels were enclosed in plywood and secured with shock-absorbing foam. Every fastener, spare part, and accessory was packed and labeled. English-language operation manuals, wiring diagrams, and maintenance checklists were printed and stowed in weatherproof document pouches on the crates.
4. Installation Support
Upon arrival at the plant, Yuantai first used a laser level to calibrate the track beams. Column bases were grouted and bolted, followed by the crane-lifting of bridge girders and adjusting wheel spacings. Hoists were mounted, ensuring proper clearance and settings. All bolts were torqued according to structural drawings, and wiring was routed along supports. This process, typically taking two weeks, was completed in ten days due to efficient planning.
5. On-Site Testing
Following installation, we performed on-site testing by powering the control panels and conducting no-load checks on all functions. Full-load tests used certified weights at 100% and 125% of rated capacity, measuring acceleration and comparing results to Factory Acceptance Test (FAT) data. We assessed safety features, making immediate adjustments for any issues. A final report documented test results and corrective actions.
6. Final Hand-Over
At project close-out, Yuantai provided a handover package that included as-built drawings of runway beam layouts and cable routes, inspection reports from Factory Acceptance Testing (FAT) and on-site tests, calibration certificates for load cells and sensors, and electrical wiring diagrams. A spare parts list for critical items like brake linings and control relays was also included, along with a maintenance schedule detailing lubrication points, brake and gearbox checks, and non-destructive testing recommendations. A dedicated support line and online portal were established for technical assistance and service requests.
Advantages of Yuantai's EOT Crane Solutions
1. Adaptability to Harsh Steel Plant Environments
Yuantai's EOT overhead cranes are built with heavy-duty components. Motors, gearboxes, and hoists have sealed housings. This protects them from heat, dust, and oil mist. The cranes operate reliably in the extreme conditions of steel manufacturing.
2. High Lifting Precision and Safety
Dual-speed hoists allow fast lifting of empty hooks. They switch to slow speeds when lowering or positioning heavy loads. This precise control prevents steel splashes and reduces the risk of accidents. Overload limiters stop lifts above rated capacity. Emergency stops engage mechanical brakes instantly.
3. Cost-Effective Modular Design
Double girder runway beams provide high headroom. This allows large loads like ladles and billet bundles. The modular hoist and trolley assemblies simplify on-site installation. Yuantai provided design drawings for client-fabricated girders. This shared fabrication model saved transport costs and customs duties.
4. Versatility for Multiple Applications
Beyond steel plant use, these EOT overhead cranes suit other heavy industries:
- Power Generation Plants: For lifting turbines, generators, and stator coils during maintenance outages.
- Oil & Gas Refineries: For moving heavy pipes, reactors, and heat exchangers in processing units.
- Shipyards: For handling ship blocks, engines, and hull modules during assembly.
- Cement and Mining Operations: For loading bulk materials and moving heavy mine equipment.
- Automotive Manufacturing: For lifting press frames, stamping dies, and large engine blocks on assembly lines.
Yuantai EOT Cranes for Steel Mills
Conclusion
This case study demonstrates how Yuantai's EOT cranes for Pakistan steel plant delivered a complete material handling solution. By understanding the steel production industry and the client's lifting challenges, Yuantai designed robust double girder overhead cranes with specialized hoists. Dual-speed, dual-control, and advanced safety features improved efficiency and reduced downtime. The cranes adapted to harsh workshop conditions and continuous heavy-duty cycles. Beyond this steel plant, similar EOT crane systems serve power generation, oil & gas, shipbuilding, mining, and automotive sectors. Yuantai continues to provide tailored overhead crane and material handling solutions that meet diverse industrial needs.
Contact Yuantai for Customized Crane Solutions
For professional advice on EOT overhead cranes, gantry cranes, or electric hoists for heavy industries, visit our overhead crane page or contact us for a free consultation.
