- Oct 09, 2025
- Case Studies
Overhead and Gantry Crane for Russian Cement Factory
Yuantai Crane provided overhead and gantry cranes for a cement factory in Russia, primarily used for handling heavy equipment and loading cement for delivery.
The customer is a cement factory from Russia who has been supplying cement to various industries for a long time. In recent years, there has been a greater demand for cement due to the need to build more and more new factories and buildings in their country. In order to increase the production of cement, they have recently expanded their premises with new workshops and grounds. So they were looking for cranes suitable for the new site.
Client Need
The client needed a reliable crane system to support multiple stages of their cement production process. They required cranes to handle raw materials such as limestone, slag, and coal, to speed up material transport and reduce manual handling. They also needed lifting equipment to transport, install, and maintain large machines like mills, dryers, and pulverizers, to improve maintenance efficiency and worker safety. During daily production, the crane must move heavy loads to keep the production line running smoothly without downtime. For finished cement, the customer needed fast and efficient loading, bagging, and truck shipment to cut labor costs and meet delivery schedules. However, they faced major challenges. Their existing outdoor gantry cranes could not handle all equipment needs, and indoor overhead cranes were located in another workshop and could not be used in the new facility. They also needed to lift small and irregular stones into the plant. In addition, cement had to be loaded onto trucks quickly after production, so a high-efficiency crane solution was essential to support continuous operations and logistics.
Challenges Before Using Yuantai Cranes
1. Inefficient Equipment Handling
Prior to Yuantai's intervention, the plant relied on smaller, low-capacity jib cranes and manual methods. Workers used forklifts and chains for heavy lifts. This led to slow installations and high safety risks. Moving large kilns required multiple pieces of temporary scaffolding. Installation errors and equipment damage occurred frequently. Clear risks to worker safety and schedule delays were serious issues.
2. Limited Loading Capacity
Trucks waited hours for cement loading. The existing gantry cranes were not rated for heavy load cycles. The single older gantry often broke down under continuous use. It could not handle the bulk cement volume needed to meet delivery schedules. This bottleneck impacted customer orders and plant revenue.
3. Inadequate Safety Features
The customer's old cranes lacked modern safety devices. Overload alarms, limit switches, and emergency stops were missing. There was no effective load monitoring. This increased the risk of accidents during heavy equipment handling and bulk material loading. Compliance with industrial safety regulations was a growing concern.
Yuantai's Custom Crane Solution
After confirming the customer's usage requirements, we confirmed that the customer needed overhead cranes and gantry cranes. Overhead cranes and grab cranes in the workshop are a must. In addition, the lack of a roof or girders at the yard precludes the use of bridge cranes. Therefore, a gantry crane is required to load the cement. The crane must straddle the yard, pick up the bulk cement and place it in the truck hopper.
Design of the 10T Double Girder Overhead Crane (A5)
This 10-ton double girder crane is built for heavy, continuous work. It runs on a plant-mounted runway and serves production, maintenance, and material handling tasks. Designers focus on strength, uptime, and operator safety. The layout balances lift height, span, and headroom. Parts are chosen for long life and easy maintenance. Controls and safety systems match industrial standards. The goal is reliable service with predictable maintenance needs.
1. High Duty Class (A5)
A5 duty means the crane works often and under heavy loads. Expect frequent starts, stops, and direction changes. Components must handle higher duty cycles. Select motors, brakes, and gears rated for continuous operation. Plan for shorter preventive maintenance intervals than light-duty cranes. Use higher grade bearings and lubricants. Provide a clear inspection schedule. This reduces unexpected downtime and keeps performance steady.
2. Robust Double Girder Structure
The double girder design gives more lifting height and better stiffness. Two parallel girders spread the load. This lowers deflection and reduces sway. It lets you fit a larger wire rope hoist and a bigger hook block. Fabricate girders as box or plate sections for strength and torsional rigidity. Include a walkway and handrails for safe access. Design connections for easy replacement of worn parts. Check welds and bolt patterns during inspections. The robust frame improves accuracy during heavy lifts.
3. Advanced Wire Rope Hoist
Use a heavy-duty wire rope hoist rated for 10 tonnes with dual-speed or VFD control. Dual speeds let operators choose slow precision or faster transit. Smooth acceleration cuts shock to the load. Select a hoist with a robust drum, quality rope reeving, and a secure rope anchor. Include rope guides and a lubrication plan. Fit thermal protection on motors and a reliable braking system. Inspect rope for wear, kinking, and corrosion. Replace rope per discard limits and after any damaging event.
4. Safety Devices
Equip the crane with proven safety hardware and clear indicators. Fit an overload limiter, upper and lower travel limits, and slack-rope detection. Use mechanical and electrical brakes with emergency stops at local and remote stations. Add anti-collision systems for multi-crane zones. Install audible alarms and visible warning lights for travel and hoisting. Provide load indicators and a clear operator display. Perform proof load tests, periodic inspections, and functional checks after major repairs. Keep test and inspection records on file.
Design of the 10T Single Girder Overhead Crane (A3)
This 10-ton single-girder crane is built for light to moderate shop work. It meets Duty Class A3, so it handles regular maintenance lifts and small production duties without over-specifying the system. The single girder keeps the headroom low and the structure compact. That saves vertical space in areas with low ceilings. We fit a robust end-truck assembly and engineered wheels to ensure smooth travel and long runway life. The electric chain hoist upgrade gives accurate load positioning and simpler servicing than some wire-rope systems. Controls include a pendant and a radio remote, both with an emergency-stop, dead-man function, and two-speed travel for safer moves. Design details focus on easy maintenance: accessible lubrication points, replaceable wear parts, and straightforward electrical panels. We specify corrosion-resistant paint and IP-rated enclosures for reliability. Before handover, we perform factory inspections and a load test at standard proof load to confirm performance and safety.
Design of the 5T Single Girder Overhead Cranes
The 5-ton single girder overhead crane is a compact, cost-effective lifting solution for light to medium industrial work. It handles maintenance lifts, moves spare parts and motors, and manages frequent, lower-capacity tasks across workshops and storage areas. The single-girder layout keeps weight and cost down while still giving reliable performance. Key components include the main girder, end trucks, a travelling trolley, and a hoist (wire-rope or electric chain). Design factors such as span, duty cycle, hook path, and lifting speed determine girder size and hoist selection. Standard safety items include upper/lower limit switches, overload protection, emergency stop, and redundant braking. Controls can be pendant, radio remote, or a cabin, chosen for operator visibility and workflow. Engineers must check runway alignment, support loads, and deflection limits to ensure smooth travel and accurate positioning. Regular inspection, lubrication, and periodic load testing keep the crane safe and extend service life. Optional upgrades include VFD speed control, anti-sway features, and corrosion-resistant coatings for outdoor use. Overall, this crane type balances economy with functionality for routine shop and light production handling.
Advantages of Yuantai's Crane Solutions
1. Enhanced Operational Efficiency
The new cranes cut equipment installation time by 40%. Bulk cement loading time dropped from three hours to under one hour per truck. Faster cycle times increased plant output and reduced labor costs.
2. Improved Safety and Compliance
All cranes feature modern safety devices. Overload protection and limit switches prevent accidents. Wireless remote controls keep operators at a safe distance. These upgrades helped the plant comply with Russian industrial safety standards.
3. Robust and Reliable Components
Yuantai uses high-grade steel for girders and heavy-duty wire ropes. Crane wheels have heat-treated bearings. These robust components reduce wear and tear. Preventive maintenance intervals extended from monthly to quarterly.
4. Customization for Site Conditions
Crane spans and height clearances were tailored to the plant's specific layout. Gantry rail supports were anchored on concrete piers cast around existing storage bins. This avoided expensive structural modifications.
Yuantai Overhead Crane and Grab Overhead Crane
Implementation and Quality Control
Yuantai's production flowed through tightly controlled stages. Steel cutting used CNC machines and material certificates were logged. Welders worked to qualified procedures and inspectors checked weld size and penetration. Assembly took place in jigs to ensure alignment. Hoists, trolleys, and gearboxes were fitted and balanced. Electric panels were assembled, wired, and bench-tested. During factory acceptance, the team ran a static load test at 125% of rated capacity for a specified hold time. We also performed dynamic runs to check start/stop behavior, travel speeds, acceleration, and smooth, vibration-free motion. Safety devices got functional checks: emergency stops, upper/lower limit switches, load indicators, and anti-collision interlocks. The team calibrated instruments and recorded all results in a final FAT report. After successful tests, we disassembled major assemblies as needed, applied corrosion protection coatings per specification, and packaged parts for transport with sea-fastening and cushioning. Each shipment included spares, lifting and assembly instructions, wiring diagrams, test certificates, and a commissioning checklist.
Packing, Delivery, and Installation
From packing to handover, this project followed a strict and well-managed schedule. Yuantai handled logistics, quality checks, and on-site support to ensure a smooth delivery. All components were packed carefully to prevent corrosion and impact damage. Steel girders were wrapped in protective plastic film, while hoists and electrical panels were packed in fumigation-free wooden crates. The customer received full technical documentation in English and Russian, including installation manuals, operation and maintenance guides, spare parts lists, and quality certificates with test reports. Yuantai's field engineers traveled to Russia to guide the customer's technical team during installation. They assisted with positioning runway beams, assembling crane girders and hoist trolleys, mounting gantry crane rails, and aligning wheels for smooth travel. Synchronized load tests were performed on both the 10-ton double girder crane and the 10-ton gantry crane. The installation was completed on time. Yuantai also provided on-site operator training, focusing on safe lifting practices and emergency procedures.
Conclusion
This case study demonstrates Yuantai's expertise in designing and delivering specialized overhead and gantry cranes for cement plants. By addressing the Russian client's specific challenges—high lifting capacities, continuous operation, and precise load control—we provided a comprehensive material handling solution. These cranes also serve other industries, such as steel fabrication, power generation, mining, and shipbuilding, proving their versatility. For reliable, safe, and efficient crane systems, Yuantai remains a trusted partner in industrial lifting solutions. If you need a crane solution, you can always contact us for a customized solution.
Contact Yuantai Crane
If you require customized lifting solutions for cement production, steel workshops, or other heavy industries, please visit our website or contact us for a consultation.
