Generally speaking, in the process of communicating with customers, the more detailed the customer’s requirements are, the more helpful it will be for us to design an efficient customized crane, although this will bring some technical challenges. For example, in many manufacturing plants, one of the requirements we often hear from customers is that the downtime should be short, and it is best not to shut down at all. The case analyzed today is a custom overhead crane for a shipbuilding plant, where the biggest challenge was limited space as the existing building had a truss height of 20 feet 10.5 inches and a crane track height of 18 feet 2.0 inches.

They were working within an existing building with an already tight lifting application. We had to come in and reinforce their building steel along the runways and building columns so that the runways for the cranes could handle the additional capacity. We had to keep our sizing within the existing crane window despite the need for even bigger cranes; we did this by notching the girders and other methods.

Provide lifting solutions for ship manufacturers

This case is about installing a series of bridge cranes and hoists for a shipbuilding factory in Decatur, Indiana, USA. The product is a series of fiberglass powered boats ranging in length from 24 feet to 50 feet, made from raw materials.

The crane manufacturer was called upon to find a solution when the custom wanted to respond to demand to make larger and heavier vessels.

There is a pond out front and pool bays inside. The pools are used to test the motors in the boats; they use the cranes to lift the boats in and out of these pools.

Most of the previously existing cranes were removed, as they had mismatched hoists and speeds, making way for similar but updated cranes. Below-the-hook equipment, such as nylon slings and spreader bars, was retained.

A total of eight bays needed to be covered. The major challenge was confined space, given that the existing building had a 20ft 10.5in truss height and 18ft 2.0in crane rail height.

They were working within an existing building with an already tight lifting application.

We had to come in and reinforce their building steel along the runways and building columns so that the runways for the cranes could handle the additional capacity. We had to keep our sizing within the existing crane window despite the need for even bigger cranes; we did this by notching the girders and other methods.

Additionally, the customer did not want to go through the process of changing out all of their runways for the added capacity, as this would have been expensive and caused downtime.

The first thing to determine is the weight required in terms of capacity for the bow and stern of each ship. The stern, being heavier, required an 8.0-ton crane; and the bow, being lighter, required a 6.0-ton crane. Tandem radio remote controls are utilised to get the two cranes to lift the boat together.

While the lifting equipment is only required to work to moderate duty, they are operated daily, during every shift.

One of our more experienced salespeople had the idea to add intermediate columns in the middle of the runway. This alone allowed them to keep all the runways and have minimal downtime.

During the installation process, we chose standard wire rope hoists and crane kits, using fully side mounted end trucks to keep the crane as close to the narrow window as possible. The span of each crane is equivalent, approximately 47 feet 6 inches. Each bay has an 8.0 ton and a 6.0 ton crane to support the weight of larger ships.

We added a radio remote control with A/B/both selector switch. This allows the company to be able to move the bridges at the same time.

In addition to the larger bay cranes, eight new 2.0-ton capacity underhung R&M cranes were installed in a smaller bay area.

The low headroom of the wire rope hoists allowed the custom to avoid any unnecessary costs that would have been caused by structural alterations.

The entire process lasted from January to September. We can learn a great deal from the experience of our team – from sales to engineering to our field crews.

What details need to be grasped in the process of designing a customized overhead crane?

By providing customized bridge cranes for shipbuilding factories, we can summarize some details that need to be paid attention to in the process of designing customized bridge cranes. These details are not only helpful for our engineers, but also inspiring for customers with purchasing needs.

• Load capacity: The load capacity of the bridge crane should match the actual needs of the shipyard. Considering the heavy components and components that may be involved in the shipbuilding process, the load capacity of the crane should be sufficiently strong.
• Size and span: Customized bridge cranes should have appropriate dimensions and spans based on the working space and specific requirements of the shipyard. Ensure that the crane can move freely within the working area and meet the lifting needs of different positions.
• Operation mode: Considering the operating environment and personnel skill level of the shipyard, customized bridge cranes should be equipped with an easy to operate control system. This can include modern touch screen interfaces, intelligent control systems, etc., to improve operational efficiency and safety.
• Safety: Safety is one of the most important aspects of customized bridge cranes. Cranes should be equipped with necessary safety devices, such as overload protection, limit switches, emergency stop buttons, etc., to ensure safety during operation.
• Durability and Maintenance: Considering the working environment and continuous usage needs of shipyards, customized bridge cranes should have good durability and maintenance. Choosing high-quality materials and manufacturing processes, as well as designs that are easy to maintain and upkeep, can extend the service life of cranes and reduce maintenance costs.
• Customized requirements: Based on the specific needs of the shipbuilding plant, customized bridge cranes may need to have some special functions or configurations. For example, it may be necessary to consider installing special lifting tools or fixtures to meet the lifting needs of specific components.
• Compliance with regulations and standards: During the design and manufacturing process, it should be ensured that the bridge crane complies with relevant regulations and standards, such as the crane standards of the International Organization for Standardization (ISO), national or regional safety regulations, etc. This helps to ensure the safety and compliance of the crane.