- Apr 29, 2022
- Case Studies
10 ton Overhead Crane Serving in Bangladesh Steel Coil Plant
Discover how Yuantaicrane's 10-ton double girder overhead crane streamlined steel coil handling for a Bangladesh plant, reducing downtime by 40%. Explore our heavy-duty crane solutions today!
The customer operates a large-scale steel mill in Chattogram, Bangladesh, producing rebars, angles, channels, and steel coils. In steel manufacturing, moving heavy materials—such as raw billets, coils, and scrap—is crucial. These tasks depend heavily on reliable overhead crane systems to maintain production flow, already established within regional industry norms such as safety regulations and high-capacity handling needs.
Customer Needs and Operational Challenges
The plant relied on older single-girder cranes (up to 8 t capacity) and mobile forklifts. These systems fell short of current production demands. Key challenges included:
1. Insufficient Load Capacity
Steel coil bundles usually weighted between 8 t and 10 t, exceeding the 8 t capacity of existing cranes. Teams had to divide bundles into smaller loads or call in mobile cranes. Each time coils were re-rigged, additional processes were required, handling time increased, and safety concerns were raised.
2. High-Duty Operation Requirement
The facility ran two shifts, five days a week with minimal downtime. Equipment that wasn’t designed for continuous cycles suffered rapid wear. Frequent breakdowns and maintenance slowed production and eroded on-time delivery rates.
3. Need for Precision Placement
Coils had to sit within ± 50 mm of their target position to feed the rolling mill correctly. Misalignment caused mill jams.
4. Safety Compliance
New regulations required overload protection, anti-collision sensors, and emergency stop systems on all lifting equipment. The plant's older cranes lacked these features. Upgrading to contemporary safety gear became vital for avoiding fines and protecting employees.
5. Energy Efficiency
Rising electricity costs put a strain on the plant's operational budget. The existing cranes used direct-online starters that required significant inrush currents. To reduce energy consumption and electricity expenses, a system incorporating variable-frequency motors and regenerative braking was required.
Solution: 10 Ton Double‑Girder QDX Overhead Crane
Yuantai Crane offered a custom-designed 10 ton double-girder QDX overhead crane. This solution addressed all operational needs and exceeded local safety standards:
1. Structure and Rigidity
The crane employs a double-girder bridge to reduce deflection under its full 10 t weight, even on spans exceeding 10 m. Box-style girders increase the hook's headroom by about 300 mm, allowing you to clear overhanging ducts or furnace hoods. The welded Q345B steel box sections resist bending and torsion, ensuring load stability during high-cycle lifts.
2. Hoist and Motion Control
The lifting is accomplished with a heavy-duty wire-rope hoist. It has an electronic drum brake and a gearbox built to handle frequent starts and stops. The 16 mm diameter rope meets DIN tensile criteria and withstands thousands of cycles. The bridge and trolley motors use variable-frequency drives to smooth out acceleration and deceleration. This reduces inrush current by 30% and saves approximately 12% on energy consumption when compared to across-the-line starters.
3. Safety and Operator Ergonomics
Load sensors on the hoist output shaft measure weight in real time. If you surpass 100% of the rated capacity, the device will cease power immediately. When another crane or obstacle approaches a predetermined zone, the bridge and end trucks' infrared collision detectors slow or stop the crane. Emergency stop buttons are located in the operator cabin and on the remote. The optional climate-controlled interior features 360° tempered-glass views and an adjustable, vibration-damped seat.
4. Additional Features
The bridge comes in modular sections that bolt together on site, reducing freight costs and speeding assembly. End trucks ride on forged-steel wheels rated for 150 000 cycles, with precision bearings that resist wear. LED floodlights mount under the trolley to light up the hook area, improving accuracy when placing loads in low-light conditions.
5. Custom Adaptation to Facility Conditions
We matched a 14 m span and 10 m hook height to the plant’s furnace-to-rolling-mill transfer requirements. The crane carries an FEM M6 duty rating, handling up to 4 000 start-stop cycles per year. Its epoxy-polyurethane finish withstands dusty, high-temperature (up to 120 °C) environments. Sound-insulated motors and gearboxes keep noise below 75 dB(A) at 5 m, meeting local plant noise regulations.
Custom Adaptation to Facility Conditions
- 14m span / 10m hook height: aligned with furnace-to-rolling mill transfers.
- FEM M6 duty rating: supports up to 4,000 starts per year.
- Durable coatings: epoxy + polyurethane for high-temperature, dusty conditions (~120°C ambient).
- Noise reduction: 75dB(A) at 5m, via sound-insulated motors and gearboxes.
Advantages Delivered to the Customer
Productivity Boost
Replacing tandem 8ton lifts with a single 10 ton crane reduced handling cycles by ~30%. Coil loading went from 4min to 2.5min per bundle.
Enhanced Safety
Real-time overload detection and collision suppression eliminated near-miss loads. Compliance with Bangladesh safety regulations improved significantly.
Reduced Downtime
With M6-rated systems and VFD technology, daily run time extended to 16hours without overheating. Maintenance intervals went from 500 to 1,000 hours, reducing pipeline repairs by 55%.
Lower Operating Costs
Energy efficiency savings of ~12%, combined with regenerative braking, yielded annual savings of ~8,500kWh.
Improved Working Conditions
Driver cabin with 360° view reduced the need for floor spotters by 40%, easing operations.
Simplified Maintenance
Standardized components across QDX cranes reduced spare parts inventory by 15%. Integrated PLC monitoring enabled predictive maintenance with early alerts.
Broader Applications of Double-Girder QDX Cranes
- Shipyards: Lifting hull sections and engines.
- Automotive manufacturing: Transporting engine blocks, chassis kits.
- Power generation: Installing turbine rotors, generators.
- Chemical plants: Handling reactors and heat exchangers (with optional explosion-proof modifications).
- Steel service centers: Bundling, unpacking, moving coils.
- Precast concrete factories: Lifting beams, panels.
- Maintenance workshops: Facility equipment repairs (e.g. large HVAC units).
- Mining workshops: Heavy parts handling in dust-prone environments.
Project Implementation Steps
Site Survey
Technical team measured existing runway alignment, power supply (400V/200A), and structural foundations in August 2024.
Fabrication and QA
ISO 9001 workshop welding with ultrasonic testing and ±1mm tolerances. Factory Acceptance Tests ensured load accuracy and safety function.
Installation and Commissioning
January 2025: crane erected, aligned, wired (laser alignment within 2mm). Functional testing at 125% load. February 2025: certified by Bangladesh Bureau of Industry Quality Control.
10 Ton Bridge Crane Yuantai Provided
Conclusion
This case of the 10 ton double-girder QDX overhead crane shows how tailored design and high-quality engineering can transform heavy-material handling processes in steel coil plants. The combination of capacity, precision, safety, and energy efficiency addresses critical operational challenges and delivers sustained ROI. This crane model is versatile across industries such as shipbuilding, power plants, chemicals, and precast concrete, offering a reliable choice wherever large loads and industrial safety matter.
Contact Yuantai for Custom Overhead Crane Solutions
Learn more about our double girder overhead crane and request technical consultation or quotation via our contact us page.
