• Jun 17, 2025
• Case Studies

22/5T Overhead Crane to Philippine Steel Fabrication Plant

Check out the 22/5T QDX double girder overhead crane we supplied to a steel fabrication plant in the Philippines! Discover how it boosts efficiency and safety.

A steel fabrication company in Philippines, produces large-scale structural steel sections, girders, and pre-engineered building frames. The plant manufactures steel beams up to 18 meters in length as well as prefabricated trusses for bridges, warehouses, and industrial structures. To achieve delivery deadlines and quality standards, the company needed an overhead lifting system that could handle both massive workpieces (up to 22 tonnes) and smaller items (such as gussets and brackets) weighing up to 5 tonnes. Manual handling and forklifts were ineffective for high-volume operations due to their slowness and risk. The customer's crane requirement was for a strong, adaptable overhead crane that could handle a wide range of load sizes without requiring regular reconfiguration.

Customer Profile and 22/5T QDX Double Girder Crane Need

The steel fabrication customer has a workshop with hundreds of square meters and two parallel assembly lines. Their manufacturing method entails cutting, welding, drilling, and painting steel components. Materials arrive as raw plate and portions weighing between 1 and 22 tons each. Finished assemblies, like building frames, are moved as single components for quality inspection and loading. The customer required a crane system with twin hooks: a 22-ton primary hook for major assemblies and a 5-ton secondary hook for minor parts and tools. To safely lift large beams, they needed a spreader-type hook setup. The new crane needed to fit within the existing workshop runway beams, sustain high cycle rates (up to 50 lifts per day), and provide precise load positioning within ±20mm.

Challenges Faced Before Crane Installation

Before installing the double girder overhead crane, the plant relied on forklifts and a single 15t overhead crane, which created multiple operational roadblocks.

• Limited Capacity: Standard forklifts could not safely handle loads above 15t. Heavier steel beams had to be cut into smaller sections for lifting. This added 30–45 minutes per unit to fabrication cycles, reducing throughput and increasing labor costs.
• Poor Versatility: Switching from light to heavy modules necessitated replacing chain hoists or manually repositioning trolley blocks. These transitions took up to two hours per day. The approach disrupted processes and reduced overall equipment use.
• Inadequate Precision: Forklift operators struggled to align massive components within ±50mm tolerances required by assembly fixtures. Manual shimming and adjustments increased scrap rates by 8% and caused rework that disrupted production schedules.
• Workflow Bottlenecks: Heavy modules were unable to transfer between assembly bays due to the 15-ton crane's limited coverage of one production line. Teams had to stage parts in temporary storage rooms, which caused congestion on the work floor and forced inefficient material handling patterns.

22/5T QDX Double Girder Crane Design Provided to Meet Customer Needs

QDX Double Girder Crane Structural Components

The 22/5T QDX double girder crane features two parallel box girders fabricated from Q345B steel plates, welded into torsion‐resistant sections. Span: 30m between end trucks; lifting height under hook: 12m to clear assembled trusses. The crane's duty classification is FEM 2m, suitable for medium‑shock, high‑cycle operations (up to 60 lifts per day). End trucks employ forged steel wheels (HRC 58 hardness) with welded axles, distributing load across 8 wheels per side to minimize rail pressure.

Spreader Type Hook Arrangement on QDX Crane

To lift wide steel sections and beams safely, the crane uses a spreader type hook on the main trolley. The spreader block mounts two hook blocks at a fixed 4m spread. Each hook block features a latching safety hook and 360° swivel. The spreader ensures even load distribution and prevents beam bending or surface damage. For lighter parts, a secondary 5ton hook block is mounted directly on the trolley frame. Operators can select the main 22ton hook or the 5ton hook via control interlocks, eliminating manual hook changeover.

European Wire Rope Hoist and Single Trolley Implementation

Yuantai's solution involves a high-capacity European wire-rope hoist connected to a precision single-trolley assembly. This system offers dual-hook lifting with separate control, allowing for versatility with both big and light loads.

1. Hoist Capacity and Reeving

The hoist has two separate reeving drums, a 22t main hook and a 5t auxiliary hook. Each drum is sized and geared for its individual load, enabling for simultaneous lifts or rapid changeovers between heavy and lighter operations without re-reeving the ropes.

2. Wire Rope Specification

We installed a 28-mm wire rope with a tensile strength of 1960 N/mm² on the main drum to support 22-tonne weights. The secondary drum employs a 16mm rope made of the same high-tensile alloy, ensuring smooth and dependable lifts of up to 5t. Both ropes fulfill DIN safety margins and are pre-stretched to reduce strain under load.

3. Dual-Speed Hoist Operation

Dual-speed motors provide accurate load management, with the main hook lifting at either 4m/min for heavy-load stability or 0.4m/min for placement. The secondary hook operates at 8m/min or 0.8m/min to balance speed and precision for smaller things. Switching speeds on the fly allows operators to match lift rates to the task.

4. Braking System

A spring-applied disc brake secures the load when power is released. Under maximum load, brake creep remains below 0.5mm to prevent load drift during pauses. The design meets EN14492‑2 dependability standards and securely holds loads in power-loss scenarios.

5. Limit Switches and Safety Stops

Each hook path includes both mechanical and electrical higher and lower limit switches. These redundant systems shut power when the hook reaches the bridge or the drum's bare flanges, preventing overtravel. The electronic switches include software interlocks, which register any unusual stop occurrences for maintenance inspection.

6. Overload Protection

Each drum's output shaft has embedded load sensors that measure rope tension in real-time. If a lift exceeds 105% of the hook's rated capacity, an LED display will flash an alarm and prevent further hoisting. This feature ensures safe working loads and warns operators before mechanical strain begins.

7. Trolley and Bridge Travel

The single trolley uses sealed roller bearings between the twin girders. A lug-type gearbox powered by a variable frequency drive (VFD) allows for smooth acceleration and deceleration at speeds ranging from 0 to 12 meters per minute. The bridge moves at up to 20m/min under inverter control, allowing for quick repositioning over the runway.

8. Operator Control Interface

The crane is equipped with a wireless remote control for improved safety and excellent sightlines. Operators can remain out of the load path while keeping complete control over hoist, trolley, and bridge motions. The ergonomic handset duplicates pendant functionality such as speed selections, emergency stop, and status indications.

Rail and End Truck Configuration for QDX Double Girder Crane

The runway features HEA 200 beams bolted to the existing building columns. End trucks are bolted to rails with rail clamp adapters. Rail alignment was laser‐adjusted to ±2mm over 30m. Clamp adapters allow future conversion of elevation for building expansions. Catch stops with hydraulic buffers absorb impact at run‐out points.

Performance of 22/5T QDX Double Girder Crane in Diverse Tasks

Handling Large Steel Girders and Beams

The crane lifts 20tonne I‑beams across the assembly bay using the main 22ton hook and spreader. Operators use fast hoist speed for elevation, then switch to 0.4m/min for precise placement into bolting fixtures. The crane's minimal deflection under full load (calculated at 20mm midspan) keeps beam ends aligned within ±10mm tolerance, reducing fitting time by 30%.

Managing Lightweight Fabrication Components

For smaller gussets, brackets, and attachments (500kg–5t), operators engage the secondary hook. Clear hook travel and dual‐speed control allow accurate placement onto welding tables. This dual‐hook flexibility eliminated the need for separate chain hoists, saving 15 minutes per changeover.

Supporting Multi‑Bay Workflow

The crane's 30m span covers three adjacent bays. Finished frames are lifted from Bay1, traversed through Bay2 for painting, and positioned in Bay3 for quality inspection and load‐out. Single‑crane workflow reduced handling steps from three separate hoists to one integrated system, improving throughput by 25%.

Operating in Constrained Height Conditions

The customer's workshop ceiling rests at 15m. With a 12m hook height, the crane lifts tall truss assemblies without requiring roof modifications. The low‐headroom trolley design preserves 3m of clearance above hooks, enabling safe overhead travel of bulky loads.

Advantages of Yuantai 22/5T QDX Double Girder Crane

Yuantai's 22/5t QDX double-girder crane offers versatile lifting options, precision control, and durable construction to suit fabrication and handling demands. The following are the primary advantages incorporated into its design.

1. Versatile Dual‐Hook Operation

With a 22t main hook and a 5t secondary hook on the same trolley, operators can transition between heavy and light lifts without needing to re-rig hooks or add tackle blocks. The control pendant features a simple choice for alternating power and rope pay-out between drums. This improves capacity, reduces change-over time by up to 80%, and removes the safety risks associated with manual hook swaps.

2. Spreader Hook for Uniform Load Distribution

The crane can be equipped with a spreader-type hook assembly to span large steel sections. Using two lifting points balances the load and prevents twisting or torsional stress in I-beams and channels. This design also allows operators to see the load's center of gravity more clearly, making fixture or jig setup faster and safer.

3. High Precision and Smooth Motion

Variable-frequency drives on bridge and trolley motors, along with dual-speed hoisting, enable precise speed control for each lift. Soft-start and soft-stop ramp designs prevent unexpected jolts, reducing load swing and material damage. The device provides ±20mm positioning accuracy, assuring tight tolerances and reducing scrap rates by 15%.

4. Robust Structural Design

Twin-girder bridges have higher bending stiffness and load-bearing capability than single-girder cranes. FEM stress analysis was used to estimate web and flange thicknesses, allowing them to sustain extensive daily cycles without fatigue.

5. Safety and Compliance

All crane components satisfy EN15011 and ISO4301-1 requirements. The safety features include an electronic overload limiter, an anti-two-block device to prevent hook-block accidents, and redundant mechanical and electrical limit switches on the travel and hoist axes. TÜV-certified parts and a rigorous factory acceptance test (FAT) program ensure the crane performs safely and reliably from day one.

Other Applications for 22/5T QDX Double Girder Crane

The 22/5t QDX double-girder crane's dual-hook capacity and strong lifting power make it a versatile tool for businesses requiring both large and delicate lifts. The spreader-hook option enhances its versatility for managing large or uneven loads. Here are a few areas where this crane excels.

1. Shipbuilding and Marine Fabrication

In shipyards, the primary 22-ton hook lifts major hull parts and engine blocks, while the 5-ton secondary hook lifts smaller deck equipment and accessory modules. The spreader-hook attachment uniformly grips large plate panels and bulkheads to prevent warping or edge damage during transit from manufacturing to assembly docks.

2. Power Generation Equipment Assembly

During turbine and generator construction, the primary hook precisely aligns rotor components weighing up to 20 tonnes. The auxiliary 5t hook simultaneously lifts control cabinets, valve manifolds, and instrumentation racks. The crane's precision dual-speed control is crucial for aligning stators and rotor shafts to tight tolerances.

3. Steel Plate and Coil Processing

Coil bundles weighing up to 20 tons are moved between cutters and storage stations on slitting and recoiling lines. The secondary hook collects coil tool frames, cutter dies, and changeover carts. A spreader hook adheres to the curvature of the coil, effectively spreading the load and reducing edge or core damage during handling.

4. Port Container Handling

In indoor or cold-climate container yards, the 22-ton hook lifts complete containers with lock bars, while the 5-ton hook puts hatch covers, twistlocks, and lashing bars. Adjustable spread beams can accommodate conventional ISO container widths or half-height boxes, reducing turnaround time and eliminating the need for additional lifting equipment.

5. Prefabricated Building Production

The QDX crane is used by manufacturers of modular wall panels, roof trusses, and concrete floors to hoist big pieces weighing up to 22t into assembly jigs. The smaller hook is for lighter window and door frames. The spreader-hook system keeps panels flat and minimizes stress cracks during transportation between bonding, finishing, and staging facilities.

Yuantai Single Trolley with Two Hooks Bridge Crane

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The Single Trolley with Two Hooks Bridge Crane is designed for lifting and handling tasks that require dual-point support or simultaneous lifting of separate loads. Equipped with a single trolley carrying two independently controlled hooks, this crane allows operators to adjust spacing between lifting points to suit different load shapes and sizes. It is widely used in workshops, assembly plants, and warehouses where balanced lifting of long, bulky, or uneven loads is necessary. Key features include precise hook synchronization, flexible control options, and reliable safety systems, making it suitable for various industrial applications where efficiency and load stability are important.

Conclusion

Yuantai's 22/5T QDX double girder crane with single trolley dual hooks provided a versatile and high-capacity lifting solution for the Philippine steel production plant. The crane's spreader hook, dual-speed European wire rope hoist, and precise VFD controls allow for effective handling of both massive beams (22t) and lightweight components (5t). Custom structural design and safety features increased throughput, minimized downtime, and improved operator safety. This adaptable crane design is suitable for shipbuilding, power generation assembly, coil processing, port operations, and prefab building production with varied load profiles, in addition to steel fabrication. Yuantai continues to provide clients with bespoke overhead crane solutions that improve operational efficiency and workplace safety.