When selecting a gantry crane for your application, the capacity of the crane is one of the most critical factors to consider. Here, we will explore the range of gantry crane capacity, the factors that influence it, and how to determine the right capacity for your needs.
What Is Gantry Crane Capacity?
The capacity of gantry crane refers to the maximum load that it can safely lift. This capacity is determined by several factors, including the design of the crane, the material used in construction, and the power of the crane’s lifting mechanism. Gantry cranes are often used to lift and move heavy materials such as steel, concrete, or machinery, making it crucial to select a crane with an appropriate lifting capacity to ensure safe and efficient operation.
Range of Gantry Crane Capacities
Small Capacity Gantry Crane (Up to 10 Ton)
Small capacity gantry cranes are designed to handle lighter loads, making them ideal for smaller operations and facilities where heavy lifting is not required. These cranes typically have a lifting capacity of up to 10 tons and are often used in workshops, garages, and warehouses for routine tasks such as material handling, maintenance, and assembly.
Applications:
- Workshops & Garages: Small capacity cranes such as 3 ton, 5 ton, 6 ton and 10 ton, are commonly used in mechanical workshops, garages, and small factories for lifting equipment, tools, and components. They offer flexibility for tasks like maintenance, repairs, and assembly.
- Warehouses & Distribution Centers: In warehouses, these 1 ton to 10 ton gantry cranes can move boxes, packages, and light materials across short distances, making them invaluable for inventory management.
- Construction Sites: For small construction projects, such as building sheds, small bridges, or smaller concrete components, small capacity cranes can be used for lifting and placing materials.
Medium Capacity Gantry Crane (10 to 50 Ton)
Medium capacity gantry cranes are designed to handle more substantial loads and are commonly used in industries that deal with moderately heavy materials. With lifting capacities ranging from 10 to 50 tons, these cranes are a versatile option for a variety of industrial, manufacturing, and construction applications.
Applications:
- Manufacturing Plants: In factories, medium capacity cranes, such as 15 ton, 20 ton, 25 ton, 30 ton and 40 ton, are used for lifting large machines, heavy parts, and production components during assembly or maintenance.
- Construction Sites: For medium-sized construction projects, such as building larger structures or lifting precast concrete components, these 10 ton to 50 ton gantry cranes provide the required lifting power.
- Steel Mills & Metal Fabrication: Medium capacity cranes are commonly found in steel mills and metal fabrication plants, where they move large metal components and heavy materials from one stage of production to another.
- Port Terminals: In ports, these cranes can handle shipping containers, heavy cargo, or materials used in shipbuilding.
High Capacity Gantry Crane (50 Ton and Above)
High capacity gantry cranes are designed for heavy-duty operations, capable of lifting loads well over 50 tons. These cranes are indispensable in industries that require the movement of extremely heavy or bulky materials, such as shipbuilding, steel production, and large construction projects. Some high capacity cranes can handle weights of 100 tons, 200 tons, 300 tons, 500 tons, or even more.
Applications:
- Shipyards: In shipbuilding, high capacity gantry cranes are essential for lifting and moving large ship components, such as hull sections, engines, and other heavy materials. These cranes are also used for launching and dry-docking ships.
- Steel Mills & Heavy Industry: In steel mills, these cranes move heavy steel ingots, coils, and structural components. They are also used in power plants and large manufacturing facilities for lifting turbines, boilers, and other large equipment.
- Heavy Construction Projects: High capacity cranes are used in large construction projects where extremely heavy loads such as steel beams, concrete segments, and industrial machinery need to be moved. They are also essential for lifting materials used in the construction of bridges, tunnels, and high-rise buildings.
Project Cases with Different Gantry Crane Capacities
45 Ton For A Railway Logistic Station
- Project Location: Kazakhstan
- Type: RMG
- Span: 38 meters
- Lifting Height: 15 meters (4+1 container)
- Cantilever: 7 meters + 9 meters
- Application: Lifting 20-foot, 40-foot, and 45-foot containers at railway logistics stations
50 Ton For A Tunnel Construction Project
- Project Location: Russia
- Type: Double Girder
- Span: 40 meters
- Lifting Height: 80 meters
- Single Cantilever: 5 meters
- Application: Lifting materials from the tunnel
40 Ton for A Wood Processing Plant
- Project Location: Russia
- Type: Double Girder
- Span: 32 meters
- Application: Lifting wood at a wood processing facility
10 Ton for A Precast Concrete Production Facility
- Project Location: Indonesia
- Type: Single Girder
- Span: 18.9 meters
- Lifting Height: 5.4 meters
- Work Duty: A3
- Application: Lifting precast concrete components
32/20 ton for An Automotive Parts Manufacturing Facility
- Project Location: USA
- Type: Rubber Tyred Double Beam
- Span: 11.7 meters
- Lifting Height: 7.7 meters
- Application: Lifting large injection molds for automotive parts production
40 Ton for A Steel Tank Manufacturing Plant
- Project Location: USA
- Type: Rubber Tyred Single Beam
- Lifting Height: 40 feet
- Width: 60 feet
- Application: Transferring processed tanks and loading/unloading onto trucks
10 Ton for A Steel Processing Plant
- Project Location: Russia
- Type: Rubber Tyred Single Beam
- Span: 8 meters
- Lifting Height: 6 meters
- Application: Lifting and transporting steel pipes within the factory’s open yard.
Factors Influencing Gantry Crane Lifting Capacity
The crane lifting capacity is determined by several critical factors that influence how much weight it can safely lift and handle. These factors include:
Design and Structure:The crane’s design, including the strength of the main girder, legs, and hoisting mechanism, is crucial. Stronger materials and structural integrity allow for higher lifting capacities.
Load Distribution:Even load distribution is essential. Unevenly distributed loads can strain the crane, reducing its effective capacity and stability.
Work Duty and Usage:Cranes with higher work duty classifications (e.g., A5-A7) are designed for more frequent, heavy-duty operations, enabling them to lift heavier loads.
Environmental Conditions:Factors like temperature, wind, and seismic activity affect a gantry crane load capacity. Extreme conditions may require design adjustments to maintain safe operation.
Power Source and Efficiency:Electric and hydraulic systems influence the crane’s lifting power. Higher motor power and efficient systems enable heavier lifting.
Safety Features:Anti-sway systems, load sensors, and limit switches enhance safety and allow cranes to handle heavier loads more effectively.
How to Determine the Right Gantry Crane Capacity
Determining the right capacity is crucial for ensuring safety, efficiency, and the long-term performance of your operations. Here’s a step-by-step guide on how to choose the appropriate gantry crane capacity:
Understand the Load Requirements
The first and most important factor to consider is the weight of the heaviest load the crane will be required to lift. You should:
- Identify the maximum load weight that the crane will be handling in typical operations.
- Consider dynamic load factors, as lifting, lowering, and moving the load can cause stresses beyond the load’s static weight.
Account for Load Distribution
If your crane will handle multiple loads at once or move heavy equipment with uneven weight distribution, ensure you account for the maximum distributed weight during operation. A crane with an appropriate capacity must be able to support not just the maximum weight of individual items but also any variation in weight during handling.
Consider the Span and Lift Height
The span (distance between the supports) and lifting height are key factors in determining gantry crane lifting capacity:
- Longer spans and higher lifting heights often require cranes with more robust lifting mechanisms and higher capacity.
- If the crane must reach higher or farther, additional capacity may be needed to lift the load safely and efficiently at different points along the span.
Factor in Environmental Conditions
- Wind speed and other environmental conditions like temperature and humidity can affect crane performance, particularly for outdoor gantry crane. Cranes used in exposed or extreme conditions may require a higher capacity to handle unforeseen stresses.
- Ground conditions also play a role – softer or uneven ground may require more robust designs to ensure stability when lifting heavy loads.
Understand Duty Cycle and Usage Frequency
Duty cycle refers to how often the crane will be used during a typical workday. Cranes operating continuously at or near their rated capacity will experience more wear and tear and require more frequent maintenance.
You may want to consider a higher capacity crane if the crane will operate in heavy-duty conditions (i.e., frequent lifts of heavy loads).
Choose the Right Safety Margins
It’s important to build in a safety margin to ensure that the crane can handle unexpected overloading or shock loading events. Typically, a 25%-50% safety margin is used above the maximum expected load, though this may vary depending on your application.
If you’re unsure about which crane capacity is ideal for your needs, we can help you select the right solution. Contact Aicrane today to discuss your requirements and get expert advice on choosing the perfect gantry crane capacity for your operation.
