When selecting an overhead crane for your facility, one of the most critical factors to consider is overhead crane capacity. Understanding the capacity of overhead cranes ensures not only safe operation but also maximizes productivity and equipment lifespan. Discover the full range of our crane capacities, learn what factors influence the overhead crane weight limit, and get expert advice on how to determine the right lifting capacity for your specific application.
What Is Overhead Crane Capacity?
The overhead crane capacity refers to the maximum load that the crane is engineered to lift safely. This is commonly known as the overhead crane rated capacity or overhead crane maximum capacity. It is the total weight a crane can handle, including the load and any lifting attachments like hooks or grabs.
For example, an overhead crane capacity 5 ton means the crane can safely lift up to 5 tons, including any rigging gear used.
Overhead Crane Load Capacity by Crane Type
Our overhead cranes are available in different types and configurations, and each type has its own typical load capacity range depending on structural design, usage, and application. See below the load capacity ranges of the most common types of our overhead cranes for sale.
General Type Overhead Crane Capacity
Typical Load Capacity: 1 ton to 20 tons (single girder), 5 tons to 500+ tons (double girder)
The general type single girder overhead cranes have one bridge beam and use a hoist that runs on the bottom flange of the girder. They are ideal for facilities with limited headroom and lifting requirements that do not exceed moderate weights. While the double girder overhead cranes consist of two parallel bridge beams, offering greater strength and stability. The hoist typically rides on top of the girders (top-running configuration), maximizing lifting height.
| PARAMETERS OF AQ-HD | |
|---|---|
| Load capacity | 5-20t |
| Span | 7.5-28.5m |
| Lifting height | 6-18m |
| Lifting speed | 0.8/5m/min |
| Hoist running speed | 2-20m/min |
| Crane running speed | 3-30m/min |
| Work duty | A5 |
| Custom designs available | |
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| PARAMETERS OF AQ-QDX | |
|---|---|
| Load capacity | 5-320t |
| Span | 10.5-31.5m |
| Lifting height | 6-24m |
| Lifting speed | 0.2-10.7m/min |
| Trolley running speed | 2.4-33m/min |
| Crane running speed | 4.2-68m/min |
| Work duty | A3-A5 |
| Custom designs available | |
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Explosion Proof Overhead Crane Capacity
Typical Load Capacity: 1 ton to 20 tons (single girder), 5 tons to 75 tons (double girder)
Explosion proof overhead cranes are designed to prevent ignition in explosive environments, commonly used in chemical plants, refineries, paint shops, or any hazardous environment with explosive gas or dust. They feature explosion-proof motors, controls, and wiring systems.
| PARAMETERS OF AQ-LB | |
|---|---|
| Load capacity | 1-20t |
| Span | 7.5-31.5m |
| Lifting height | 6-30m |
| Lifting speed | 0.33-8m/min |
| Hoist running speed | 20m/min |
| Crane running speed | 20m/min |
| Work duty | A3, A4 |
| Explosion-proof grade | ExdⅡBT4、ExdⅡCT4 |
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| PARAMETERS OF AQ-QB | |
|---|---|
| Load capacity | 5-75t |
| Span | 10.5-31.5m |
| Lifting height | 6-20m |
| Lifting speed | 1.9-5m/min |
| Trolley running speed | 10.5-20.5m/min |
| Crane running speed | 15.4-22.3m/min |
| Work duty | A3-A4 |
| Explosion-proof grade | ExdⅡBT4、ExdⅡCT4 |
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Electromagnetic Overhead Crane Capacity
Typical Load Capacity: 5 tons to 50 tons
These magnetic overhead cranes are equipped with electromagnetic lifters to handle ferrous metal materials such as steel plates, billets, and scrap. They often used in high-duty environments and can include backup battery systems to prevent accidental load drop during power failure.
| PARAMETERS OF AQ-QC | |
|---|---|
| Load capacity | 5-50t |
| Span | 10.5-31.5m |
| Lifting height | 6-16m |
| Lifting speed | 7.8-15.5m/min |
| Trolley running speed | 31.3-40.1m/min |
| Crane running speed | 58.5-70.6m/min |
| Work duty | A5-A7 |
| Custom designs available | |
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Grab Overhead Crane Capacity
Typical Capacity: 2 tons to 10 tons (single girder), 5 tons to 20 tons (double girder)
The grab cranes are equipped with grab buckets (clamshell or orange peel types) for lifting loose materials like sand, ore, coal, or waste. The crane is typically heavy-duty with A5–A7 work classification, widely used in waste-to-energy plants, ports, mining, and more.
| PARAMETERS OF AQ-QZ | |
|---|---|
| Load capacity | 5-20t |
| Span | 10.5-31.5m |
| Lifting height | 6-26m |
| Lifting speed | 30.7-39.3m/min |
| Trolley running speed | 31.1-44.6m/min |
| Crane running speed | 76.9-93.6m/min |
| Work duty | A5-A7 |
| Custom designs available | |
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Foundry Overhead Crane Capacity
Typical Capacity: 5 tons to 320 tons (or more)
The foundry overhead cranes are among the most robust and heavy-duty types, designed with reinforced components to withstand extreme heat, dust, and continuous operation. These cranes are used for lifting molten metal, casting ladles, and operating in high-temperature environments in foundries and steel plants.
| PARAMETERS OF AQ-YZ | |
|---|---|
| Load capacity | 5-320t |
| Span | 10.5-31.5 m |
| Lifting height | 6-24m |
| Lifting speed | 6-13m/min |
| Trolley running speed | 36-45.9m/min |
| Crane running speed | 63-118.6m/min |
| Work duty | A6-A8 |
| Custom designs available | |
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Common Application Based on Different Overhead Crane Capacities
From small 5 ton overhead cranes to 500 ton heavy industrial lifting systems, each capacity range serves different industries and tasks. Below are real application examples to show how our customers around the world apply these different overhead crane capacities effectively.
1 – 5 Ton Capacity
Typical cranes: Single girder top running or underhung cranes with light duty cycle
Common Applications:
- Assembly lines
- Small part handling
- Machine shop maintenance
10 – 20 Ton Capacity
Typical cranes: Single or double girder cranes with light to moderate duty cycle
Common Applications:
- Tool & die handling
- Fabrication of steel structures
- Component storage
30 – 50 Ton Capacity
Typical cranes: Double girder top running cranes with moderate to heavy duty cycle
Common Applications:
- Paper mills (handling rollers)
- Mining equipment maintenance
- Mid-size ship component lifting
60 – 100 Ton Capacity
Typical cranes: Double girder top-running systems with heavy duty cycle
Common Applications:
- Steel coil handling
- Furnace component installation
- Heavy machinery assembly
100 – 500+ Ton Capacity
Typical cranes: Extra heavy duty double girder cranes
Common Applications:
- Hydropower equipment lifting (e.g., turbines)
- Shipbuilding
- Reactor installation
- Metal smelting
Ensuring Overhead Crane Load Capacity Safety with Advanced Technologies
Every overhead crane we manufacture is rigorously designed and tested to handle a specific rated load capacity. However, safe lifting isn’t just about staying under a maximum number. Dynamic loads, improper handling, unexpected sway, or mechanical wear can stress the system beyond design limits.
To help our customers avoid these risks and optimize performance, we can equip our cranes with smart systems that monitor, control, and protect both the equipment and the operators.
Intelligent Monitoring System: Real-Time Crane Insight
Our Intelligent Crane Monitoring System is designed to give operators and managers complete visibility into crane performance and condition. Key functions include:
- Real-Time Load Monitoring: Integrated load cells provide continuous feedback on the actual weight being lifted.
- Operational Data Logging: Tracks all crane movements for usage analysis and proactive maintenance.
- Condition-Based Alerts and Diagnostics: Sensors installed throughout the crane monitor the status of motors, brakes, wire ropes, and control systems.
- Integrated Overload Protection: Our cranes come equipped with safety logic that works in tandem with the monitoring system to automatically disengage or lock movement if unsafe conditions arise.
Anti-Sway Technology: Smoother, Safer Lifting
Our anti-sway control systems are engineered to reduce load oscillation and allow for smoother, safer movement. Benefits of our anti-sway technology include:
- Improved Safety: Eliminates sudden load movement and reduces the risk of collisions or dropped materials.
- Higher Precision: Operators can position loads with pinpoint accuracy, even in tight or congested spaces.
- Faster Material Handling: Reduced wait time for sway to settle leads to shorter cycle times and greater throughput.
- Reduced Structural Stress: By limiting dynamic loads, we protect your investment and extend crane lifespan.
Factors Affecting Overhead Crane Load Capacity
Several variables influence the overhead crane load a system can handle:
- Design and Construction: Double girder overhead cranes typically offer higher lifting capacity than single girder cranes.
- Span and Trolley Travel Distance: Load capacity may vary depending on where the trolley is positioned on the bridge.
- Duty Class (Work Duty): Heavy duty overhead cranes (A5, A6, A7, etc.) are designed for heavier or more frequent lifting tasks.
- Rigging and Attachments: These contribute to the total overhead crane weight limit and must be factored into calculations.
- Load Distribution: Uneven loads can stress the crane structure and reduce effective lifting capacity.
How to Determine the Right Bridge Crane Capacity?
Whether you’re working in manufacturing, construction, shipbuilding, steel production, or logistics, ensuring the crane has adequate capacity to handle your loads safely and efficiently is essential to avoid downtime, equipment damage, and safety risks.
As a professional overhead crane manufacturer, Aicrane guides our customers through a whole process to determine the optimal lifting capacity for their specific application. Below are the key considerations and steps involved.
Understand Your Load Requirements
Start by identifying the maximum weight you need to lift. This might sound straightforward, but in practice, it requires careful consideration:
- Maximum Load Weight: What is the heaviest load your crane will need to lift?
- Average Load Weight: If the maximum is rarely handled, you may optimize for average lifting conditions.
- Load Characteristics: Are the loads evenly distributed? Are they bulky, fragile, or flexible? Oversized or irregular-shaped loads may affect the lifting configuration and point loads on the crane.
Tip: Always allow a margin for unexpected weight increases, load miscalculations, or future scalability.
Define Your Operating Environment
The capacity of overhead crane must also match the working environment:
- Indoor vs. Outdoor: Outdoor overhead cranes may face wind loads and environmental stress.
- Temperature Extremes: Low or high ambient temperatures may affect crane performance.
- Corrosive or Dusty Conditions: Additional environmental factors may require crane modifications and could influence capacity limits.
Understanding where and how your crane will operate helps ensure the selected equipment is durable and capable under all conditions.
Evaluate the Duty Cycle and Work Class
Cranes are classified based on work duty or service class, which considers how often and how heavily the crane will be used:
- Light duty: Occasional lifts at low loads (e.g., maintenance shops)
- Medium duty: Frequent lifts at moderate loads (e.g., warehouses)
- Heavy duty: Regular lifts at or near capacity (e.g., steel factories)
- Severe duty: Continuous or near-capacity use in harsh conditions (e.g., shipyards)
Selecting the right work duty classification ensures your crane is rated appropriately for operational longevity and safety.
Consider the Type of Crane and Lifting Configuration
Different crane types have different structural and mechanical constraints. Choosing the overhead crane type – single girder (top running or underhung system), double girder – will influence the load capacity options available.
Also take into account:
- Number of hoists or hooks (single vs. double hoist systems)
- Crane span and lifting height
- Lifting point positions and how the load is distributed between them
For example, a double girder overhead crane may be more suitable than a single girder crane for heavier lifting due to greater load-bearing capabilities.
Factor in Safety Margins and Local Standards
Regulations often require cranes to include a safety margin beyond the maximum anticipated load. These safety factors are determined by local or international standards, such as:
- OSHA (United States)
- ISO (International)
- CE (Europe)
- GB (China)
- GOST (Russia)
Always ensure your crane complies with these standards and includes proper overload protection devices, load limiters, and emergency stops.
Plan for Future Expansion or Increased Load Demands
When budgeting and specifying a crane, consider how your operations might evolve in the next 5-10 years:
- Will you be handling heavier components in the future?
- Is there potential for new production lines or higher throughput?
- Would a higher-capacity crane now reduce the need for a future upgrade?
While over-specifying can increase initial investment, under-specifying can result in costly replacements, downtime, or unsafe operations later.
Get Expert Support From a Crane Manufacturer
A trusted crane manufacturer can help you calculate the right lifting capacity by:
- Analyzing your workflow and load handling needs
- Offering site assessment and 3D layout design
- Recommending crane types, models, and configurations
- Customizing the crane with the appropriate components
At Aicrane, we provide tailored solutions based on the specific lifting application. Whether you need a 5 ton workshop overhead crane or a 100 ton steel mill overhead crane for ladle handling, we engineer each solution to match your load requirements with precision. Choosing the right lifting capacity is not just about picking a number – it’s about understanding your operations, planning for future growth, and ensuring the safety and efficiency of your lifting equipment.
If you’re unsure about what overhead crane lifting capacity is right for your application, our team is here to help. Contact us today for a consultation and let us provide a crane solution that meets your exact lifting needs.
Overhead Crane Capacity – Frequently Asked Questions (FAQ)
What is the difference between Safe Working Load (SWL) and maximum overhead crane capacity?
Can I exceed my overhead crane rated capacity if it’s just for a short time?
How does EOT crane capacity affect cost?
What is meant by ‘design factor’ or ‘safety factor’ in bridge crane capacity?
What happens if an overhead crane is overloaded?
How do I calculate the required capacity for my overhead crane?
For overhead crane load calculation, consider the heaviest load you need to lift, including any rigging or attachments. Always add a safety margin to ensure reliable and safe operation.
Here is a simple formula for overhead crane lifting capacity calculation:
Required Capacity=(Maximum Load Weight+Weight of Lifting Devices)×Safety Factor
