Every lifting requirement is unique, and a one-size-fits-all crane solution often falls short. Aicrane custom overhead crane is specifically engineered to match your workspace layout, lifting capacity, and operational demands, ensuring maximum efficiency, safety, and long-term reliability.
Custom Overhead Crane Types for General and Specialized Applications
Aicrane offers custom overhead cranes designed to fit general or highly specialized lifting operations. From light-duty workshops to heavy industrial environments, each crane is tailored to meet your specific workflow, load requirements, and working conditions, combining reliable performance with enhanced safety and ease of operation.
Custom Overhead Cranes for General Applications
Single Girder Overhead Cranes – Customized for Light-Duty Applications
Perfect for light to medium loads and shorter spans, these single girder cranes offer a reliable, cost-effective solution for workshops, warehouses, and general manufacturing facilities. Their compact design makes them ideal for facilities with limited headroom.
- Load Capacity: 5-20 tons (customized)
- Span: 7.5-28.5m (customized)
- Lifting Height: 6-18m (customized)
Double Girder Overhead Cranes – Tailor-Made for Heavy Duty Lifting
Designed for heavier loads and longer spans, double girder cranes offer greater stability, higher lifting heights, and the ability to handle demanding industrial workflows. They are commonly used where frequent lifting and heavy-duty performance are required.
- Load Capacity: 20-500 tons (customized)
- Span: 10.5-31.5m (customized)
- Lifting Height: 6-24m (customized)
Customized Overhead Cranes for Specialized Applications
For operations with unique requirements or challenging working conditions, our overhead cranes can be tailored with specialized designs:
Explosion-Proof Overhead Cranes – Built for Hazardous Environments
Explosion-proof cranes are engineered for hazardous environments where flammable gases or dust are present, ensuring safe and compliant operation.
- Load Capacity: 5-75 tons (customized)
- Span: 10.5-31.5m (customized)
- Lifting Height: 6-20m (customized)
Electromagnetic Overhead Cranes – Tailored for Precision Steel Handling
Electromagnetic overhead cranes are equipped with electromagnetic lifting systems, perfect for handling steel plates, scrap metal, and other ferrous materials efficiently.
- Load Capacity: 5-50 tons (customized)
- Span: 10.5-31.5m (customized)
- Lifting Height: 6-16m (customized)
Grab Overhead Cranes – Customized for Bulk Material Handling
Grab overhead cranes are ideal for bulk material handling, such as coal, grain, or aggregates, providing high-capacity and precise lifting.
- Load Capacity: 5-20 tons (customized)
- Span: 10.5-31.5m (customized)
- Lifting Height: 6-26m (customized)
Metallurgical Overhead Cranes – Custom-built for Extreme Conditions
Metallurgical overhead cranes are built to withstand extreme temperatures and heavy loads, typically used in steel mills or foundries, with reinforced structures and heat-resistant components.
- Load Capacity: 5-320 tons (customized)
- Span: 10.5-31.5m (customized)
- Lifting Height: 6-24m (customized)
With the right overhead crane type selected – whether for general material handling or specialized industrial tasks – you’ve laid the foundation for a custom lifting solution that truly fits your operation. The next step is tailoring the specifications to your exact needs, from load capacity and span to hoisting mechanisms and control systems.
Key Customization Options for Your Overhead Cranes
Once the right crane type is selected, the next step is tailoring every detail to your unique operational needs. At Aicrane, each overhead crane can be customized to fit your workflow, materials, and environment, delivering optimal performance, safety, and reliability.
Custom Load Capacity and Span
- Engineered from light-duty 5-ton units to heavy-duty 500-ton systems.
- Span and lifting height are designed around your facility layout and workflow, ensuring safe, smooth, and efficient operation.
- Specialized configurations, such as multi-girder setups, can be implemented for unique lifting requirements.
Personalized Hoisting Mechanisms
- Choose from wire rope hoists, electric chain hoists, or fully custom lifting systems suited to your loads.
- Multi-point synchronized lifting is available for long or delicate items, such as molds, turbines, or steel beams.
- Variable-speed drives provide smooth, precise movement, reducing wear and enhancing control.
Tailored Control Systems
- Pendant control, wireless remote control, operator cabin, or fully automated operation can be selected.
- Advanced features such as anti-sway, automated positioning, and smart monitoring enhance safety and accuracy.
- Control systems can be integrated with existing facility automation for seamless workflow.
Customized Safety Features
- Overload protection, travel and hoist limiters, and emergency stop systems are standard.
- Optional real-time monitoring provides insights into crane performance, alerting operators to maintenance needs or unusual conditions.
- Additional safeguards can be added for hazardous environments or industry-specific requirements.
Engineered Structural Design and Materials
- High-strength steel structures are designed for your building constraints and operational demands.
- Structural components consider runway loads, wheel distribution, and workspace layout.
- Materials and coatings can be tailored for corrosion resistance, high-temperature operation, or other environmental challenges.
Operation-Specific Customization
- Speeds: Hoisting and travel speeds can be configured for efficiency or precision, with multi-stage or variable frequency options.
- Work Duty Level: Cranes can be designed for different duty classes (A3, A5, A6, etc.) to match lifting frequency and load variation.
- Attachments and Accessories: Hooks, grab buckets, electromagnets, or specialized clamps can be designed for your materials.
- Environmental Adaptation: For outdoor, marine, high-humidity, low-temperature, or dusty conditions, components and coatings can be customized for durability.
With every detail of your overhead crane tailored to your operational needs, you are equipped with a solution built for efficiency, reliability, and safety. Next, let’s explore real-world examples of how these customized overhead cranes perform in diverse industrial environments.
Tailored to Perform: Real Projects of Custom Overhead Cranes
At Aicrane, every overhead crane we deliver is tailored to meet the exact requirements of our clients. Here are a few examples that illustrate how customization ensures optimal performance and efficiency:
Custom Double Girder Bridge Crane for A Russian Manufacturing Facility
A Russian manufacturer needed a double girder overhead crane to handle molds in their existing workshop. Their key requirements were:
- Full adaptation to the workshop layout and operational workflow.
- Optimization for the specific mold-handling process to ensure efficiency and safety.
- Achieving the best performance within a strict budget.
Aicrane’s Custom Solution:
- Crane Specifications: 64-ton (32+32 ton) double girder crane, 22.5-meter span, 11-meter lifting height, precisely engineered to fit the workshop without structural modifications.
- Hoisting and Operation: Dual synchronized hoists customized for smooth, precise lifting of molds, integrated with a control system tailored for safe, efficient operation.
- Cost Optimization: Configuration designed to maximize performance while staying within the client’s budget.
Custom Electromagnetic Overhead Crane for A Russian Steel Plant
A steel plant in Russia required a custom overhead crane capable of handling both steel plates and steel coils. Their key challenges included:
- Efficiently switching between different lifting methods.
- Ensuring operational safety while handling heavy and variable loads.
- Integrating smoothly into their existing production workflow.
Aicrane’s Custom Solution:
- Crane Specifications: 16-ton electromagnetic overhead crane, 25-meter span, 8.1-meter lifting height, precisely engineered to meet the plant’s operational requirements.
- Trolley Configuration: Equipped with a rotating trolley to allow flexible positioning of materials across the work area.
- Dual-Purpose Lifting Attachments: The crane features a removable electromagnetic lifting beam for steel plates. When removed, it can handle steel coils with slings, providing maximum operational flexibility for different load types.
- Safety Monitoring: Integrated modern safety monitoring system ensures reliable operation and enhances operator confidence during all lifting tasks.
More Custom Bridge Crane Projects
These examples highlight how Aicrane’s custom overhead cranes are engineered to meet specific operational needs, facility constraints, and workflow challenges. Click here to explore more real-world custom overhead crane projects.
Ready to design an overhead crane tailored to your project? Let’s take a closer look at how the custom design process works.
Aicrane Custom Overhead Crane Design Process
At Aicrane, every crane we deliver is a result of a detailed, collaborative design process, ensuring that your overhead crane perfectly fits your operational needs, workflow, and facility conditions. Here’s how we turn your requirements into a fully customized solution:
Understanding Your Lifting Needs for a Custom Overhead Crane
We begin by understanding your facility layout, lifting requirements, operational workflow, and environmental conditions. Special considerations, such as load types, lifting frequency, safety requirements, and spatial constraints, are thoroughly evaluated.
This step ensures the design addresses all operational challenges before any engineering work begins.
Developing a Tailored Overhead Crane Design Concept
Based on your requirements, our engineers develop preliminary design concepts, including overhead crane type, span, lifting height, hoist configuration, and optional attachments. These concepts are presented with rough sketches and technical specifications for collaborative review.
The goal is to identify the most efficient, safe, and cost-effective solution while ensuring compatibility with your facility and workflow.
Detailed Engineering and Optimization for Custom Overhead Cranes
Once the concept is approved, detailed structural and mechanical designs are created. Crane components, materials, hoist mechanisms, control systems, and safety features are engineered specifically for your operational conditions.
Design simulations and load analyses verify performance, safety, and reliability before fabrication begins.
Final Validation and Approval of Your Custom Crane Design
The final design package is reviewed with your team to ensure all requirements are met. Optional features, speed configurations, and duty classes are finalized based on your operational priorities.
This phase results in a fully approved, custom design that serves as the blueprint for fabrication and subsequent project stages.
Aicrane’s custom design process ensures that every overhead crane is perfectly aligned with your unique operational requirements, delivering maximum efficiency, safety, and value.
To further ensure your project’s success, Aicrane not only delivers fully custom bridge cranes but also provides comprehensive EPC services, taking your project from planning and design through to procurement, installation, and commissioning.
Integrated EPC Services for Customized Steel Structure and Crane Projects
To further ensure the success of your lifting project, Aicrane offers complete EPC (Engineering, Procurement, and Construction) services that cover both custom engineered steel structure facilities and overhead crane systems. This integrated approach provides a turnkey solution – from design to commissioning – ensuring efficiency, reliability, and long-term value.
Integrated Planning and Deterministic Delivery
Our professional engineering team develops coordinated layouts for both the factory building and crane systems, ensuring seamless compatibility between the crane runway, structure, and production flow. By deeply integrating the crane’s operating envelope into the building design, we eliminate layout conflicts and efficiency losses.
Aicrane’s strict progress management and risk control guarantee on-time delivery, giving customers confidence in project certainty and predictable outcomes.
Rapid Construction and Early Commissioning
Through parallel scheduling of factory construction and equipment design, we enable cranes to be installed as soon as the steel structure is completed.
This ”construction + trial operation” linkage shortens the overall project timeline by 2-3 months, allowing earlier production and faster return on investment.
Quality and Cost Assurance from the Source
Aicrane ensures quality and cost advantages right from the source. Within the framework of strict local import quota compliance, we collaborate closely with leading industrial giants such as SANY Heavy Industry and Baosteel to establish an integrated industrial supply chain.
Through large-scale, centralized procurement, we secure premium raw materials at competitive prices while maintaining full traceability and quality consistency.
One-Stop Integrated Solutions for Efficiency and Sustainability
Aicrane’s EPC model supports ”Construction + Digitalization + Green Energy” integration, combining smart factory design, IoT-based crane monitoring, and renewable energy systems.
This enables the creation of intelligent, low-carbon industrial parks that reduce energy consumption and operating costs while improving production efficiency.
Financial and Policy Support
We collaborate with export-import banks and development funds, including the Silk Road Fund, to offer customers favorable financing solutions and flexible payment options.
EPC projects are often aligned with national infrastructure and industrial development plans, helping clients secure policy incentives and priority resource allocation.
Long-Term Value Beyond Construction
Beyond project delivery, Aicrane provides clients with supply chain integration, operational support, and tax incentives through its global network.
Our EPC projects deliver more than just infrastructure – they create sustainable industrial ecosystems that continue to generate value long after commissioning.
With Aicrane EPC capabilities, you gain a complete, end-to-end solution – from the design and construction of your steel structure factory to the installation of custom overhead cranes – ensuring your project is efficient, compliant, and built for long-term success.
Ready to elevate your project with a fully customized overhead crane and integrated EPC solution? Contact our team today to discuss your requirements and get a tailored design proposal that perfectly fits your operational needs.