• Jun 11, 2025
• Case Studies

5-Ton Gantry Crane for Australia–Enhanced Lifting Efficiency

Discover how our gantry crane transformed lifting operations in Australia. Read our case study on enhanced efficiency, reliability, and safety in industrial lifting.

The client operates a busy distribution warehouse in Australia's industrial heartland. As a logistics and warehousing specialist, they handle steel, machinery parts, and palletized goods. Their existing lifting equipment struggled under heavy loads and repetitive cycles. Downtime and maintenance costs rose. Safety margins narrowed. They needed a robust, high-efficiency material handling solution that met Australia's strict machinery standards and CE certification. Australia has very stringent requirements for material handling equipment. Gantry cranes must meet high standards of load capacity, operational safety and environmental durability. They needed a partner with proven expertise in CE-certified crane design, installation and after-sales support.

Pre-Installation Pain Points

• Overloaded Hoists: Frequent motor trips when lifting near maximum weight.
• Slow Travel Speeds: Manual push trolleys caused operator fatigue and downtime.
• Customs Delays: Packaging and import compliance issues with wood crates.
• Limited Working Height: Existing cranes lacked headroom for bulky loads.
• High Maintenance Costs: Outdated electrics and hoists needed constant repair.

Tailored Gantry Crane Design & Specifications

Yuantai Crane's engineering team proposed a European-style single girder gantry crane. The design balanced low dead weight with high lifting capacity. It matched warehouse clearances and met their throughput targets. Every component carried CE certification to satisfy Australian machinery directives.

1. Key Specifications

2. Advanced Configuration

We selected Siemens lift motors and Schneider electric controls. The France-made wire rope delivered superior bending fatigue resistance. A variable frequency drive provided smooth start-stop control. The lightweight box-section girder reduced crane dead weight by 15%. This freed up valuable headroom and increased effective workspace beneath the bridge.

Structural Advantages

The single girder design lowers manufacturing costs. It simplifies installation and maintenance. The low-profile trolley keeps the hook headroom minimal. Operators can handle bulky goods with full visibility. The compact end beams ensure the crane fits in narrow aisles.

Electrical & Control Features

Integrated Schneider PLC logic enables remote diagnostics. Variable frequency drives on hoist and trolley motors allow precise speed control. Emergency stop pushbuttons and limit switches meet AS/NZS 3854 compliance. The ergonomic pendant control features a dead-man switch for operator safety.

Production, Packaging & Logistics

Once the client issued the advance bank slip, we scheduled production immediately. Cross-department coordination enabled a 50-day manufacturing cycle from drawing approval to final testing. Our Quality Testing Department conducted load tests at 110% of rated capacity. Every weld passed non-destructive testing.

1. Custom Packaging for Australian Customs

Australian biosecurity regulations prohibit untreated solid wood packaging. We used marine-grade plywood crating and heat-treated timber supports. Each component received slippery edge protections. This approach eliminated customs holds and ensured smooth import clearance.

3. Split-Span Shipping Solution

The 15.5 m span exceeded a standard 11.8 m open-top container length. We engineered a two-piece girder: 11.5 m and 4 m sections. Precision flange alignment features allowed on-site bolted reassembly without realignment jigs. Shipping sketches and bolted splice kits accompanied each package.

Installation & Commissioning

The client's in-house crew handled the mechanical assembly using our detailed installation manual. They encountered minor questions on the hoist's electrical connections. Our electrical engineer provided direct phone support and emailed annotated wiring diagrams. Within two days, the crane stood ready for commissioning.

1. On-Site Testing

We guided the customer through multi-point load tests at 110% and emergency stop trials. Travel and hoist speeds met the specified 20 m/min and 25 m/min targets. The crane achieved smooth acceleration and deceleration. Vibration readings remained within ISO 4301-1 class 2.5 limits.

2. Safety & Training

Our service team conducted an operator training session. We covered safe lifting practices, limit switch adjustments, and emergency procedures. The maintenance crew received a preventive maintenance schedule and a digital spare-parts list. This proactive support reduced future downtime risks.

Performance Outcomes

After commissioning, the client reported a 35% reduction in cycle time per lift. Maintenance costs dropped by 40%. Operator fatigue decreased due to precise VFD controls.

Other Application Cases

While this European single-girder gantry crane excels in warehouse settings, its design also adapts to a variety of heavy-lift scenarios across multiple industries:

1. Shipyard Block Assembly and Engine Lifts

The crane's 10 t capacity and smooth trolley travel position hull sections and engine units during block construction. Its low-headroom hook approach works under dockhouse roofs, while precise dual-speed controls eliminate swing when placing large modules.

2. Automotive Production Lines

On chassis and sub-assembly lines, the gantry moves engine blocks, transmissions, and welded frames between workstations. Its adjustable span fits narrow aisles, and the electric chain hoist delivers quick picks with fine positioning for robotic weld cells.

3. Outdoor Maintenance Yards

In vehicle or equipment repair yards, the crane handles heavy machinery parts—such as tractor axles and industrial gearboxes—without fixed rails. Rubber-tyred end-trolley options (or portable rail kits) let you move the crane across concrete pads or compacted gravel.

4. Foundry and Metal-Fabrication Shops

The crane's rigid box girder and high-precision hoist place castings, forged components, and welded assemblies on machining fixtures or inspection stands. Its durable finish and sealed bearings resist hot metal splatter and abrasive dust.

Yuantai 5 Ton Gantry Crane