- Oct 09, 2025
- Case Studies
45 Ton Specail Designed Electric Hoist for Philippines
Yuantai Crane provided a custom 45-ton electric hoist solution for a Philippine client to lift a 50-ton boiler steam drum 30 meters high with minimal movement.
The customer is a leading boiler fabrication and installation contractor in the Philippines. Their work involves supplying and installing large industrial boilers for power plants, manufacturing facilities, and large-scale heating systems. In this sector, handling and positioning heavy, cylindrical components—such as steam drums—are critical steps in the boiler‐erection process. Ensuring precise, safe, and stable lifting is essential to maintain schedules, avoid costly rework, and protect worker safety.
Client Requirements
The customer was working on a large boiler project and needed a customized material handling solution to lift a pressure vessel ladle approximately 14 meters long and weighing approximately 45 tons. According to the customer, they needed to lift the boiler package from the ground to the ceiling beams, which were double truss beams with a distance of only 5 meters wide between the truss beams. The steam bag must be lifted from the ground to the double truss top beam 30 meters above the ground. So the handling system had to span a narrow gap while keeping the load steady and barely moving horizontally. Key requirements include:
1. High Lifting Capacity
Considering the safety margin, we asked the customer about the weight of the materials he usually lifts, and finally determined a lifting capacity of 45 tons. Also check rated duty cycles and expected wear for long lifts; heavy loads and long rope lengths increase heat and fatigue, so you want components sized for continuous safe service.
2. Vertical Lift Height
A 30-meter vertical travel is a long, high-head application and affects hoist selection, rope length, drum capacity, and headroom. Make sure the hoist drum and reeving arrangement can carry the required rope length without exceeding recommended drum layers. Confirm that controls and brakes are rated for long lifts and that limit switches and overspeed protection are set for 30 meters. You should also verify building access and headroom at top and bottom so the trolleys, motors and any motor brakes will fit.
3. Minimal Horizontal Movement
Because the steam drum needed only slight repositioning after lift-off, the system should minimize lateral travel from the moment it leaves the ground. This means specifying a fixed spreader or short, stiff slings that match the drum geometry and using synchronized hoists with an equalizing bar or spreader beam to prevent skewing. Also check trolley guidance and end-stops so the hoists don’t drift along the beam. When you talk with manufacturers, ask how they will control lateral motion during pick-up and how they will handle small repositioning tasks once the load is suspended.
4. Stable Load Control
Stability through the entire lift is essential to protect people, the structure, and the vessel. Controls should offer smooth start/stop and gentle acceleration, typically via VFDs and soft-start profiles. Anti-sway measures such as controlled acceleration, load-sensing feedback, and taglines during the final position can help.
5. Robust Structural Support
The H-beams that span the 5-meter gap have to carry half the load each and meet strict deflection and fatigue limits. With a specified bottom flange thickness of 40 mm and a top plate of 26 mm, make sure the beams are engineered, fabricated and certified for the applied bending and shear from a 45-tonne tandem lift.
Challenges Before Adopting Yuantai's Hoisting Solution
Before Yuantai's solution was introduced, the customer faced multiple obstacles that made the lifting process complex and unsafe. The task involved hoisting a 45-ton, 14-meter-long steam drum to a height of 30 meters—an operation that demanded precision, high load capacity, and complete synchronization. However, the customer's existing setup was not designed to handle such demanding conditions. Space limitations, safety concerns, and inadequate lifting tools all contributed to significant project delays and operational risks. These challenges highlighted the need for a customized hoisting solution that could guarantee safety, efficiency, and stability during installation.
1. Inadequate Lifting Equipment
The customer initially tried to complete the lift using their old crane and a manual chain block system. This equipment was suitable for lighter tasks but completely insufficient for a 50-ton steam drum. The available hoists could not bear the full load safely, and their limited lifting height and slow speed made the process inefficient and risky. Every attempt to lift the drum strained the equipment, creating dangerous working conditions and raising the possibility of structural damage.
2. Limited Overhead Support
Another major challenge came from the site's structural limitations. The installation area used double-truss steel beams spaced only five meters apart, which made it impossible to install traditional overhead cranes or large gantry systems. The narrow spacing restricted the use of conventional lifting frames, while ground-mounted gantries lacked the reach to achieve the 30-meter lifting height required. This left the team without a stable support system to suspend or position heavy lifting machinery safely. The spatial constraints demanded a compact, lightweight yet powerful lifting solution that could fit within the narrow truss spacing while maintaining full lifting height and load stability.
3. Safety and Stability Concerns
Lifting such a long, heavy drum through 30 m of vertical space required a highly stable, synchronized dual-hoist setup. Any misalignment or unsynchronized hoisting could lead to oscillations, causing potential collisions with the supporting trusses or damage to the drum.
Yuantai's Customized Solution
Yuantai's engineering team designed a specialized lifting system using two 45-ton electric wire rope hoists mounted on custom H-beams. This arrangement provided the necessary capacity, stability, and vertical reach for the 45-ton steam drum. Key design elements included:
Custom H-Beam Support Structure
- Two H-beams sized H800×W300 mm, with a 40 mm bottom plate and 26 mm top plate.
- H-beams positioned on either side of the 5 m-wide truss gap, ensuring each hoist carried approximately 25 tons during the lift (45 tons total).
- Reinforced welding and gusset plates to guarantee rigidity and prevent deflection under load.
45T Electric Wire Rope Hoists
- Rated Lifting Capacity: 45 metric tons per hoist, providing a safety margin beyond the required 25 ton-per-hoist load.
- Lifting Height: 30 meters, meeting the vertical clearance needs to reach the truss beams.
- Synchronization Capability: Both hoists electrically synchronized to lift the drum in unison, preventing twisting or uneven lifting.
- Dual-Speed Control: Slow speed for precise positioning during the final lift phases and faster speed for initial vertical travel.
- Safety Devices: Overload limiter, upper and lower limit switches, emergency stop functions, and a mechanical brake system to hold load securely under power loss.
Hoist Integration and Installation
Proper hoist integration is essential for ensuring long-term performance and operational safety, and the installation of the two 45-ton electric hoists was carried out through a series of carefully planned steps. At Yuantai's factory, both hoists were fully assembled with motors, drums, gearboxes, and control units, and each unit underwent a rigorous load test at 125% of rated capacity to verify structural integrity, brake function, and lifting precision. For safe international transport to Manila, the hoists were securely packaged in reinforced plywood crates with internal supports and moisture-resistant linings to protect against shock and corrosion during sea shipment. Upon arrival, Yuantai's field engineers provided expert on-site support, including precise beam alignment, hoist mounting, and trolley rail adjustments using laser instruments to ensure perfect level and straightness across the crane span. The final commissioning phase involved completing all electrical connections, testing safety systems, and performing supervised full-capacity load tests to confirm synchronized hoist operation. Functional checks of travel, braking, and emergency stop systems verified that all performance and safety standards were fully met.
Yuantai Wire Rope Hoists
Advantages of Yuantai's Electric Hoist Solution
Yuantai's dual 45 ton electric hoist setup offers a blend of capacity, precision, and safety tailored for heavy lifts. Here are the key benefits:
1. High Load Capacity with Safety Margin
By pairing two 45 ton hoists for a 45 ton steam drum, each unit operates well below its maximum rating. This load sharing reduces mechanical stress on gears and ropes. The result is lower wear rates and improved long-term reliability for high-demand lifting cycles.
2. Precise Dual-Hoist Synchronization
A dedicated control system keeps both hoists lifting in perfect unison. Throughout the 30 m travel, the steam drum stays level and free of swing. This prevents binding or contact with overhead truss members and reduces the risk of damage to both load and structure.
3. Simplified Structural Requirements
Rather than erecting a full gantry, engineers mounted a custom H-beam support directly to existing truss members. This retrofit saved on civil works and cut installation time. It also avoided major modifications to the building's frame, minimizing disruption to ongoing operations.
4. Enhanced Safety Features
Each hoist includes overload protection, upper and lower limit switches, and an emergency-stop circuit. If power fails, mechanical brakes engage to hold the load securely. These safeguards give operators clear, reliable control over every lift.
5. Extended Service Life and Low Maintenance
Critical parts—such as heat-treated wire ropes, greased bearings, and reinforced gears—are designed for longevity. Routine upkeep requires only visual inspections and periodic rope lubrication. This maintenance regimen keeps downtime to a minimum and extends the hoists' operational life.
Performance and Adaptability in the Field
During the installation, Yuantai's electric hoists performed across challenging conditions:
- Heavy Vertical Lift (30 m): Hoists maintained stable, controlled movement over the full height without overheating or load drift.
- Constrained Workspace: The truss-mounted H-beams and hoists fit within existing structural confines, requiring only minimal workspace for beam placement.
- Minimal Horizontal Movement: Hoist trolleys locked in place to prevent lateral travel, matching the requirement of lifting without shifting the steam drum side-to-side.
Customer Feedback
Yuantai's 45-ton electric wire rope hoist system provided a robust, safe, and adaptable lifting solution for a critical boiler installation project. By addressing high capacity, vertical height, and structural constraints, our hoists delivered reliable performance under challenging conditions. This case highlights Yuantai's expertise in designing customized industrial lifting solutions that serve a variety of heavy-duty applications across industries.
Conclusion
Yuantai's 45-ton electric wire rope hoist system provided a robust, safe, and adaptable lifting solution for a critical boiler installation project. By addressing high capacity, vertical height, and structural constraints, our hoists delivered reliable performance under challenging conditions. This case highlights Yuantai's expertise in designing customized industrial lifting solutions that serve a variety of heavy-duty applications across industries.
