5 ton LD Bridge Crane to Ivory Coast in an Ivorian

Discover the delivery of a 5-ton traditional bridge crane to an Ivorian manufacturing facility, enhancing operational efficiency and productivity in Ivory Coast.

In many industrial sectors, reliable overhead lifting equipment is fundamental to maintaining consistent production schedules, improving workplace safety, and managing materials efficiently. This case study examines the successful delivery and operation of a 5-ton LD traditional bridge crane supplied by Yuantai Crane Company to a manufacturing plant in Ivory Coast. It provides insight into the customer's industrial background, specific lifting requirements, pre-installation challenges, crane design features, and the operational versatility of the equipment.

Industry Background: Material Handling in West African Manufacturing

The client operates a mid-sized manufacturing facility in Ivory Coast, focused on the production and assembly of heavy mechanical components. These include parts for agricultural equipment, industrial machinery, and structural assemblies. In such an environment, daily internal logistics involve the lifting, positioning, and transport of steel parts, castings, and fabricated modules—each weighing several hundred kilograms to several tons.

Given the growing industrialization in West Africa, especially in Côte d'Ivoire, demand for robust and cost-effective lifting systems has increased significantly. Facilities like this one must depend on cranes that can withstand dusty environments, work under fluctuating power conditions, and provide high reliability with low maintenance requirements.

Customer Needs

Prior to the implementation of the Yuantai 5-ton bridge crane, the client used manual hoists and a mobile gantry system to handle materials. This setup proved inadequate for their evolving production scale. The plant faced several operational bottlenecks:

Slow material movement between workstations
Labor-intensive handling processes that posed safety risks
Inconsistent lifting capacity that restricted the handling of larger components
Poor utilization of vertical space, limiting floor efficiency

The customer required a fixed overhead crane system capable of lifting loads up to 5 tons, operating over a wide span of the workshop area. Key expectations included simple installation, minimal maintenance, operator-friendly controls, and compatibility with the existing power supply.

Challenges Faced Before Crane Installation

1. Inefficient Workflow

Manual hoisting methods created workflow delays. Two to three workers were needed to lift a single part, often requiring additional safety supervision. This reduced productivity by an estimated 18% according to internal reports. In addition, tasks such as assembling large components or transferring heavy tools between workstations took longer, leading to bottlenecks in the production line. Operators also had to wait for equipment availability, increasing idle time during peak shifts.

2. Safety Concerns

The plant had encountered two minor workplace injuries in the year preceding the crane purchase, caused by unstable load handling during manual lifting. These incidents occurred while workers were attempting to reposition awkward or imbalanced components by hand or using makeshift lifting methods. While no serious injuries were reported, the risks posed by inconsistent lifting techniques were a growing concern. This highlighted the need for a controlled, mechanical lifting solution to minimize human exposure to hazardous tasks.

3. Limited Load Capacity

Their mobile gantry crane was limited to 2 tons, and could not safely handle certain production components, especially during peak output months when demand rose. Some parts required lifting capacities beyond 3 tons, forcing workers to break them into smaller subassemblies for transport—an inefficient and labor-intensive workaround. At times, production had to be rescheduled or slowed due to the unavailability of appropriate lifting equipment.

4. Wear and Tear on Mobile Equipment

Forklifts and trolleys used inappropriately for vertical lifting suffered frequent mechanical breakdowns, increasing maintenance costs. These tools, not designed for lifting tasks, experienced damage to hydraulic systems, wheel assemblies, and structural frames. Their misuse also led to more downtime for repairs and higher costs for replacement parts. Over time, this created an unplanned maintenance burden and reduced the overall efficiency of the workshop.

Product Overview: Yuantai LD Type Single-Girder Overhead Bridge Crane

The selected product for the client was the LD model single-girder overhead crane, designed and manufactured by Yuantai, a trusted crane manufacturer with extensive experience in heavy-duty lifting systems.

Key Specifications:

Rated Load Capacity: 5 tons
Span: 16 meters (customizable as per facility dimensions)
Lifting Height: 6 meters
Travel Speed: 20 m/min (bridge), 8 m/min (trolley)
Control Mode: Pendant control and remote control
Hoist Type: Electric wire rope hoist
Power Supply: 380V/50Hz/3-Phase (customizable for local requirements)

Design Features That Meet Diverse Industrial Requirements

1. Modular Steel Structure

The crane's main girder is fabricated from Q235B steel, using box beam construction. This ensures high strength while keeping the structure light and easy to install. The modular design reduces site assembly time and supports future expansion. Additionally, the use of standard connection interfaces allows for seamless integration with auxiliary systems such as walkways, maintenance platforms, and auxiliary cranes, making it adaptable to evolving production needs.

2. Reinforced End Trucks

The end carriages are equipped with high-precision wheels and double-speed motors. These enable smooth travel along the rail tracks with minimal vibration, which is crucial for precision positioning of components. The end trucks are also engineered with a load-balancing system and shock-absorbing buffers, which help distribute loads evenly across the track and extend the lifespan of the mechanical and structural components.

3. Durable Wire Rope Hoist

The electric hoist unit features an overload limiter, emergency stop, and upper/lower limit switches, ensuring safe operation under demanding conditions. It is capable of handling repeated lifting cycles with minimal downtime. The hoist drum is precision-machined and grooved for optimal rope alignment, reducing wear on the wire rope and increasing lifting accuracy. The gearbox and motor are designed for continuous duty, meeting FEM and ISO service classifications.

4. Dust and Humidity Resistant Components

Given the region's humid tropical climate, electrical components and motor housings are sealed to IP54 standards, protecting against dust and moisture ingress. This enhances operational reliability and lifespan. Key components such as control panels, limit switches, and brake units are treated with anti-corrosive coatings and equipped with breathable vents to prevent condensation, further safeguarding the internal circuitry.

5. Flexible Operation Modes

The system supports remote wireless control, allowing operators to stay at a safe distance during load movement. An optional cabin control system can also be integrated for future upgrades. The remote control is ergonomically designed for single-handed operation, with customizable buttons and feedback indicators. The control system can also be programmed for semi-automated routines, increasing efficiency for repetitive lifting tasks.

Installation and Onsite Integration

Yuantai provided pre-assembly engineering drawings and installation guidance remotely. The crane system was installed in 7 days, with two local technicians and one remote support engineer coordinating the process. Minimal structural modifications were required due to the crane's customized support bracket design, tailored to the plant's existing steel column layout.

Advantages of Yuantai LD Bridge Crane

1. High Cost-Effectiveness

Compared to double-girder cranes, the LD single-girder system offers lower cost without compromising performance for 5-ton capacity tasks. It requires less structural support, which reduces overall project investment. The simplified design also lowers transportation and installation expenses, making it a practical choice for small to medium-sized manufacturing facilities and maintenance workshops that need reliable lifting capabilities without exceeding budget constraints.

2. Low Maintenance Requirements

The system uses sealed bearings, wear-resistant rails, and a self-lubricating hoist. These features minimize the need for regular mechanical servicing, a major advantage in regions with limited access to technical personnel. Routine inspections can be performed quickly without disassembly, and critical components are designed for long intervals between service checks, reducing downtime and ensuring continuous operation.

3. Long Service Life

Thanks to its corrosion-resistant paint, quality electrical systems, and wear-proof materials, the crane is projected to operate reliably for 10+ years under regular usage conditions. The main structural parts undergo anti-fatigue testing, and the hoist motor is engineered for high duty cycles. All components are selected based on industry-standard certifications, which further ensure long-term dependability even in demanding production environments.

4. Operator-Friendly Controls

The dual-mode control system ensures that inexperienced operators can manage the crane safely after a brief training period. Emergency stop and limit switches provide an extra layer of protection. The intuitive pendant and wireless remote controls feature clear labeling and responsive commands, while system diagnostics and visual indicators assist in identifying any operational anomalies early, promoting safer handling and faster issue resolution.