- May 29, 2025
- Case Studies
10 Ton HD Bridge Crane to Mali for Car Repair Shop
Check out our 10 Ton HD Bridge Crane, perfect for your car repair shop in Mali! Boost efficiency and safety while lifting heavy loads with ease. Get yours today!
Industry Profile and Customer Background
The customer operates a busy automotive repair and maintenance workshop in Bamako, Mali. The shop handles engine overhauls, transmission replacements, chassis repairs, and body-work on passenger vehicles and light trucks. Prior to this project, mechanics relied on portable engine hoists and forklifts, which limited capacity, coverage, and safety. As vehicle volumes rose, the shop needed a dedicated lifting solution to improve workflow and reduce manual effort.
Customer Needs and Pre-Implementation Challenges
Load Capacity and Coverage Requirements
The workshop needs to lift automotive parts up to nearly 10 tons. In addition, they required the cranes to have a span of 15 meters between the rail girders in order to serve both repair stations without blocking the maintenance access. Select a 10-ton Safe Working Load (SWL) for future use in light truck axle and suspension assemblies.
Height and Speed Specifications
Hook height needed to reach 5 m under beam to clear vehicle lifts and mezzanine platforms. Lifting speed of 5 m/min for rapid approach and a low-speed 0.8 m/min for precise positioning were specified. Trolley travel speed of 20 m/min would minimize non-productive moves between bays.
Safety and Duty Cycle
The shop runs two 8-hour shifts five days per week. They required an ISO 4301-1 duty class A5 crane rated for up to 125 000 cycles per year. Safety features like overload protection, anti-sway control, and emergency stops were essential to meet local workshop regulations and minimize risk of lifting accidents.
Limitations of Previous Equipment
Mechanics used engine hoists with 2 t capacity but only offered localized coverage. Forklifts needed clear space and could not position heavy loads precisely over service pits. Engine removal took up to 30 minutes per vehicle. Minor collisions and chain hoist failures caused repeated workshop delays and two finger-crush incidents in 2024.
Product Design and Technical Specifications
1. HD Series Single-Girder Bridge Crane Structure
We supplied a 10 ton HD series single-girder bridge crane with 15 m span and 5 m lift height. The main beam is a welded box girder made from Q345B steel. FEA validation showed deflection under full load stays below L/800 of span length, ensuring stable load control.
2. End Carriages and Runway Installation
End carriages run on 43 kg/m crane rails, mounted to the workshop’s steel roof trusses. Sealed roller bearings resist dust and oil mist. Rail alignment was achieved with laser leveling to ±3 mm accuracy.
3. Electric Wire Rope Hoist
The HD crane uses an HD-series open-winch hoist with dual-speed gearbox. Lift speeds are 0.8 m/min and 5 m/min. The 8×36 IWRC wire rope has a 6×SWL safety factor. A spring-applied, electro-released brake holds loads securely when power is off.
4. Trolley and Bridge Drives
Both trolley and bridge run on separate VFD-controlled motors. Trolley speed ranges 3–20 m/min, bridge 5–25 m/min. Soft-start and soft-stop functions minimize jerk and load swing during starts and stops.
5. Control and Safety Devices
- Pendant Control: Dead-man switch and emergency stop.
- Overload Limiter: Strain gauge sensor cuts power at 100% SWL.
- Limit Switches: Upper and lower hoist, trolley end-travel.
- Anti-Sway Control: VFD acceleration ramps.
- IP54 Enclosures: Dust and splash protection for motors and panels.
Advantages of Our 10 Ton HD Bridge Crane
1. Improved Efficiency and Throughput
The engine removal and installation cycle time per vehicle was reduced from about 330 minutes to a few minutes. 20 lifts per day, saving hours of labor and increasing maintenance capacity by 25%.
2. Enhanced Safety and Risk Reduction
Since installation, the shop recorded zero lifting-related injuries. Mechanical overload protection and smooth VFD control eliminated chain jolts and load sway that previously caused pinch incidents.
3. Reliability and Low Maintenance
They had a long process of repairing the cranes because the previous cranes were not able to handle the entire process successfully, and because the old equipment had been in use for a long time, they needed to spend a certain amount of downtime each year repairing the equipment. After installing the new crane, there were no usage problems for several months. They need very little time to maintain their cranes, which reduces their repair costs while minimizing crane downtime.
4. Versatile Load Handling
With a 10 ton SWL, the crane now handles heavy transmissions, complete chassis assemblies, and hydraulic presses. Its precise control also assists in lifting electric vehicle battery packs in the shop’s EV conversion line.
Implementation and Operational Results
Installation and Commissioning
Delivery to Bamako took five weeks from order. Installation took four days: rail mounting, beam placement, hoist and trolley rigging, and wiring. We conducted static proof load tests at 125% SWL and dynamic trials at full speed, documented according to EN 13001 guidelines.
Operator Training and Handover
We provided one day of on-site training. Technicians practiced load lifting, emergency stops, and daily inspection checklists. Each received an operation manual, wiring diagram, and maintenance schedule.
Applications for the 10 Ton HD Bridge Crane
The 10 ton heavy-duty (HD) bridge crane adapts to a wide range of lifting tasks across indoor and outdoor settings. Its robust design, optional low-headroom features, and environmental protections ensure reliable service in varied workflows and climates.
1. Indoor Workshop Bays
In service workshops, the crane spans two maintenance pits while servicing three lift points on a single runway. A low-headroom trolley lets the hoist sit close to the beam flange, maximizing clear hook height for deep under-vehicle access. Technicians can switch between lift points without relocating vehicles, cutting setup time and improving bay utilization.
2. Outdoor Parking and Inspection Area
Equipped with IP54-rated motors and sealed end-truck bearings, the crane operates through rainy seasons without corrosion or motor stalls. It lifts vehicles outdoors for underbody inspections, eliminating the need to transfer them indoors. This direct-lift capability speeds up fleet maintenance and reduces shop congestion.
3. Mobile Service Unit Integration
A covered bay adjacent to the crane runway accommodates a mobile truck lift that docks under the bridge. With the crane’s 10 ton capacity, heavy engine or transmission modules can be swapped on site. This integration combines the flexibility of mobile lifts with the power of a fixed crane, improving service turnaround for large equipment.
4. Automotive Manufacturing and Assembly
On small assembly lines, the crane installs engines, transmissions, and subframe assemblies into chassis jigs. Its precise trolley travel and hoist control align heavy components with minimal manual adjustment. The crane’s throughput supports light-manufacturing workflows where repeatable, reliable lifts keep production moving.
5. Agricultural Equipment Maintenance
Tractor and harvester service centers use the crane to handle bulky drivetrain parts—transmissions, hydraulic pumps, and loader arms. Its high capacity accommodates fully assembled units, reducing disassembly steps. The crane’s weatherproof finish makes it suitable for both indoor barns and open-shed workshops.
6. Small-Scale Fabrication Shops
Metalworking shops lift welded assemblies, steel plates, and machining fixtures with ease. The crane’s 10 ton safe working load (SWL) covers heavy steel frames and molds. Adjustable end-truck buffers prevent over-travel in tight shop layouts, ensuring both safety and efficient material flow.
7. Warehouse and Logistics Centers
In distribution hubs, the crane moves palletized heavy goods, stacks steel drums, and handles machinery components. Its long span covers multiple aisles, reducing forklift traffic. Regenerative drives capture energy during load descent, lowering operating costs in around-the-clock operations.
Yuantai 10 Ton Bridge Crane
Conclusion
The 10 ton HD series single-girder bridge crane delivered to the Mali vehicle repair shop met all of the requirements, including increased load capacity, expanded span coverage, precise lift control, and robust safety measures. It decreased engine swap cycle times from 30 minutes to 8 minutes, cut maintenance hours by 83%, and eliminated lifting accidents. Aside from workshop application, this crane design is suitable for light automotive assembly, agricultural equipment service, small fabrication shops, and warehouse activities.
