3 Sets of 10 ton Single Girder Bridge Crane for Philippines

Recently, Yuantai Crane supplied 2 sets of 10 ton single girder overhead crane and 1 set single girder overhead crane with 2 nos. 5 ton electric hoist to Philippines. Let's check the details.

On April 4, 2024, Leandro from the Philippines contacted Yuantai Crane, asking three sets of single girder overhead cranes. The customer works in a general industrial facility where lifting heavy machines and transferring large products are common occurrences. In such settings, dependable overhead cranes are critical for safe and efficient material handling. Aging cranes and insufficient lifting capacity were impeding operations, necessitating the need for improved systems that could carry 10-ton loads while smoothly integrating into current workplace layouts.

Customer Needs and Specific Requirements

Leandro provided detailed drawings and a comprehensive overhead crane configuration list. His requirements included:

One set of single girder overhead crane with two 5-ton electric hoists—designed to lift dual loads or handle tandem lifting operations within the same runway span.
Two sets of 10-ton single girder overhead cranes—each to be equipped with one 10-ton electric hoist, capable of handling heavy components such as machine bases, die sets, and large assembly parts.
All main beams must be box girder construction. This design ensures superior rigidity and minimal deflection under load, critical when lifting uneven or off-center loads.

Key performance criteria included:

Rated Capacity: 10 ton for two cranes; 5 ton for the third crane.
Main Beam Type: Box girder main beams with thicker steel plates for enhanced strength.
Hoist Type: European-style electric hoists for reliable lifting performance and precise speed control.
Span and Headroom: Dimensions matched to the customer's workshop drawings to ensure compatibility with existing runway beams.
Timely Delivery: Short lead time to align with the client's construction schedule and minimize operational downtime.

Challenges Faced Before Adopting Yuantai's Solution

1. Inadequate Beam Strength and Deflection Issues

Previous cranes utilized I-beam girders. Under large loads, these beams showed substantial deflection. When lifting 8-10 ton components, operators reported up to 20 mm of sag in the middle of the span. This deflection resulted in mismatched loads and increased wear on the hoist trolley wheels. Frequent repair and replacement of worn wheels became normal, lowering total equipment availability.

2. Limited Lifting Precision and Reliability

Older wire rope hoists at the plant lacked precise speed control. Operators struggled to switch between quick lifts and slow placement. As a result, large components occasionally crashed with neighboring objects or swung dangerously before landing. This jeopardized workplace safety and raised the likelihood of damage to expensive tooling and machinery.

3. High Cost from Competing Suppliers

Leandro requested bids from many local and international crane vendors. Many offered custom solutions with long delivery dates and hefty prices. Some quoted double girder cranes that cost more than the client could afford for minor lifting requirements. The customer required a cost-effective solution that did not sacrifice quality or safety.

4. Uncertain Installation and Commissioning Support

The client's maintenance team lacked experience installing box girder cranes. They were concerned about matching new girders with existing runway beams and calibrating the hoist controls. Without solid technical support, there was a substantial danger of erroneous installation. This could cause operational delays and safety issues.

Yuantai's Product Design and Technical Solution

In response to these challenges, Yuantai offered a comprehensive design featuring box girder main beams and European electric hoists. The solution included:

Box Girder Main Beam Construction

Thicker Steel Plates: Top and bottom flanges made from Q345B steel with 25 mm thickness. Vertical webs of 12 mm thickness to resist bending under heavy loads.
Welded Box Section: Fully welded seam for uniform stress distribution. Minimizes local stress concentrations compared to rolled I-beams.
Minimal Deflection: Under a 10-ton centralized load, measured deflection was less than 6 mm over a 10 meter span. This ensured stable lifting and precise load placement.
Corrosion Protection: Shot-blasted to Sa2.5 standard, followed by epoxy primer and polyurethane topcoat—ideal for humid tropical conditions in the Philippines.

European-Style 10 Ton Electric Hoists

Rated Capacity: 10 tons per hoist. Each crane uses a single hoist for heavy lifting tasks. The third crane employs twin 5-ton hoists for tandem or separate operations.
Dual-Speed Lifting: Fast speed of 8 m/min for rapid load movement; precise slow speed of 2.5 m/min for accurate positioning near workstations or assembly jigs.
Wire Rope Quality: 6×37 galvanized wire rope with 1960 N/mm² tensile strength, minimum breaking force of 200 kN. Designed for durability under high cycles.
Sealed Gearbox: Helical gear set with 95% transmission efficiency. IP55 rating for dust and moisture resistance. Greased-for-life bearings reduce maintenance.
Brake System: Electromagnetic disc brake with redundant spring-applied failsafe. Ensures instant load holding during power loss or emergency stops.
Hoist Control: Pendant station with IP65 rating. Wireless remote control available as an option for operators working in safety zones.
Safety Devices: Overload limiter, upper and lower limit switches, emergency stop button, and anti-sway control to prevent load oscillation.

Single Girder Crane Configuration

Crane Span and Height: Span of 10 meters between runway beams. Hook-to-rail clearance optimized at 2.1 meters to maximize headroom under low roofs.
Travel Speeds: Trolley travel at 20 m/min for quick movement across the bay. Crane bridge travel at 12 m/min to reduce cycle times.
End Carriage Design: Four-wheeled end trucks with polyurethane wheels and sealed bearings. Ensures smooth travel on runway rails and reduced noise in the workshop.
Control Cabin Option: For indoor use, an optional operator cabin with 180° panoramic view. Cabin equipped with climate control for operator comfort in tropical heat.

Project Implementation and Delivery Process

The transaction unfolded in several key phases:

1. Quotation and Technical Discussions

Leandro promptly reviewed Yuantai's initial proposal. He noted that competitor prices were high and delivery times extended. In a video conference, Yuantai's engineers addressed his technical concerns:

Beam plate thickness and weld quality: Yuantai confirmed use of certified Q345B steel with ultrasonic weld inspections.
Delivery timeline: Guaranteed 45-day lead time from deposit to factory testing.
Installation plan: Offered free on-site commissioning support for 7 days after delivery.

After comparing designs, the customer appreciated Yuantai's combination of thicker box girder beams and competitive pricing. He placed the order for all three crane sets on April 14, 2024.

2. Production and Quality Control

Once the contract was signed, Yuantai's production team followed a strict quality process:

Cutting and Welding: Laser cutting of steel plates. Robotic and manual welding with X-ray inspection of critical seams.
Painting and Protection: Surface cleaning to Sa2.5. Epoxy primer and polyurethane topcoat applied at 180 microns total thickness.
Component Fabrication: End carriages, trolley assemblies, and hoist gearboxes assembled in separate workstations.
Factory Acceptance Tests (FAT): Each crane underwent no-load travel tests, full-load lifting tests at 125% capacity, and safety device checks.

3. Packing and Shipping

After passing quality inspections, components were packed for overseas shipment:

Box Girder Sections: Wrapped with plastic film and protected by steel corner guards. Loaded into 40 ft containers to prevent in-transit damage.
Hoist and Trolley Units: Hoists were placed in wooden crates with foam padding. Trolley assemblies disassembled to fit shipping crates and protect gearboxes.
Documentation Package: Supplied manuals in English and Tagalog, including installation guides, wiring diagrams, and maintenance schedules.
Delivery Terms: Shipped by CIF (Manila Port), ensuring customs clearance and inland transport handled by Yuantai's logistics partners.

4. On-Site Installation and Commissioning

Yuantai deployed a team of three field engineers to the Philippines for installation support:

Runway Beam Alignment: Verified that existing rails were within ±5 mm tolerance over the 10 m span. Adjusted beam supports as needed.
Crane Erection: Lifted box girder main beams using temporary gantry systems. Aligned end carriages and welded anchor plates in place.
Hoist Trolley Assembly: Mounted the European-style 10 ton hoists under each beam. Adjusted limit switches for the 5 m lift height and tested dual-speed transitions.
Electrical Hook-Up: Connected motors to 415 V, 50 Hz three-phase supply. Programmed VFD controllers for lift speeds of 2.5 and 8 m/min. Verified CT travel speed of 12 m/min.
Load Testing: Conducted incremental load tests: 5-ton, 7.5-ton, and 10-ton weights. Checked braking performance and load sway at slow speed.
Operator Training: Trained the client's technicians on safe crane operation, emergency stop procedures, and routine maintenance tasks such as lubrication points on hoist chains and trolley wheels.

Advantages of Yuantai's Overhead Crane Solutions

Yuantai's overhead cranes strike a balance between strength, precision, safety, and affordability. Each feature is intended to enhance your lifting operations, minimize cycle times, and lower total cost of ownership.

1. High Structural Integrity and Minimal Deflection

The box-girder main beams have 25 mm flange plates and 12 mm webs. Under a full 10 ton load, beam deflection remains below 6 mm. This stiffness keeps the hoist and load steady, minimizing swing. Stability is essential when positioning heavy or sensitive equipment. Less sway means more time spent on productive work rather than re-aligning loads.

2. Precision Lifting and Speed Control

Dual-speed European hoists allow rapid material movement and gentle load placement. The slow speed of 2.5 m/min offers fine adjustment when aligning delicate machinery. Fast speed of 8 m/min reduces idle time when moving empty hooks or light loads. The CT speed of 12 m/min in trolley travel cuts cycle times across the 10 m span.

3. Enhanced Safety Features

Each hoist has an overload limiter that disables power when loads surpass 110% of the rated capacity. Upper and lower limit switches prevent excessive travel, which could harm the trolley or hook. During a power outage or an emergency stop, an electromagnetic disc brake in conjunction with a spring-loaded mechanical brake keeps the load secure.

4. Cost-Effective and Competitive Pricing

Compared to other suppliers, Yuantai's offer combined high-quality European hoists with robust box girders at a lower price point. Modular design minimized shipping volume and reduced freight costs. The client praised the high quality and low price in post-order feedback.

5. Flexible Installation Support

Every purchase includes 10 days of on-site commissioning by Yuantai experts at no additional cost. If your team chooses to install in-house, we provide full installation manuals, 3D CAD blueprints, and remote video support.

Broader Applications for 10 Ton Single Girder Overhead Cranes

The 10-ton single-girder crane delivers reliable lifting in diverse settings. Its dual-speed hoist and low-headroom design adapt to tight spaces and heavy loads.

1. Manufacturing Workshops

These cranes streamline part handling in machine shops and tool rooms. They lift heavy spindle housings, gearboxes, and large assembly fixtures onto CNC mills and presses. The 10-ton capacity handles raw castings or forgings, while the low-speed mode lets operators position workpieces within millimeter accuracy. Quick repositioning at high speed minimizes idle time between load picks.

2. Automotive Parts Production

In engine and transmission lines, the crane moves blocks, cylinder heads, and gearbox assemblies. Its box-girder beam supports heavy die sets and mold bases. With only 600 mm of hook-to-rail clearance in low-headroom models, it fits under mezzanine platforms and service galleries. Pendant and remote controls let technicians switch between floor and catwalk operation for efficient parts flow.

3. Warehousing and Distribution Centers

The crane speeds up pallet transfers between staging zones and loading ports. A CT travel velocity of 12 m/min may cover bays as broad as 20 m without slowing down. Operators can use a pendant control for spot lifts or a wireless remote for ground-level handling. The single-girder design frees up above space for lighting and sprinkler systems.

4. Construction Material Handling

The crane raises girders, formwork, and pre-cast panels using temporary steel runway beams. It can handle 10 t bundles of rebar or plywood sheeting in one lift. Two 5 t hoists work in tandem to carry big modules. The modular runway and bolt-together columns allow you to install or reposition the system week by week as the project progresses.

5. Energy and Power Plants

During turbine overhauls and generator installations, the crane manages rotors, stators, and heat-exchanger bundles. Fine-tune the load position with the crane's low-speed hoist mode to align shaft journals or bolt holes. The steel box girder resists thermal expansion and vibration common in power-generation buildings. Its simple single-girder frame fits inside tight turbine hall headrooms without requiring crane rails at multiple elevations.

Customer Feedback and Outcomes

We compared several suppliers, but Yuantai offered the best combination of quality and price. The 10 m spans and low headroom design fit our workshop perfectly, without altering our roof structure.