25-Ton Gantry Cranes for Concrete Beam Yard in the Philippines

This case study highlights how the 25-ton gantry crane improves efficiency, safety, and cost-effectiveness in handling heavy concrete beams.

Overview of the Project

This project involved the installation of a 25-ton double girder gantry crane at a concrete beam yard in the Philippines. The main objective of the project was to provide an efficient and safe solution for handling large concrete beams, which are essential components in the construction industry. The crane was specifically designed to support the yard's operations, ensuring the smooth movement of concrete beams from the production area to storage and further transport.

Given the heavy weight and size of concrete beams, the crane's installation was a critical step toward improving operational efficiency. Prior to the installation, the yard relied on manual labor and less efficient lifting systems. The new gantry crane, with its 25-ton capacity, significantly increased the yard's lifting ability, allowing workers to handle heavier loads more safely and with less effort.

In addition to lifting capacity, the crane was designed with a 20-meter span and a 23-meter lifting height, which provided the necessary reach and clearance for the large beams. This ensured that beams could be moved with precision and safety within the yard, even in tight spaces. 

double girder gantry crane for your reference 

Importance of Gantry Cranes in Concrete Beam Yards

Gantry cranes play a vital role in concrete beam yards by providing a reliable solution for lifting and moving heavy, bulky materials. Concrete beams, often weighing several tons, require specialized lifting equipment that can handle their size and weight. Gantry cranes are well-suited for this task because of their robust design and ability to operate in outdoor environments.

In a concrete beam yard, the use of a gantry crane offers several key advantages:

• Heavy Load Handling:
  Gantry cranes are specifically designed for heavy-duty lifting, making them ideal for moving large concrete beams. Their capacity to lift up to 25 tons, as seen in this project, ensures that the crane can handle the weight of concrete beams without risking structural damage or unsafe lifting operations.
• Efficient Material Movement:
  Concrete beams are not only heavy but also bulky, requiring precise control when being lifted and moved. Gantry cranes provide excellent maneuverability, making it easier to transport beams from the production line to storage areas or directly to trucks for delivery. This improves the overall workflow in the yard and minimizes delays.
• Maximized Yard Space:
  Gantry cranes are designed to work within confined spaces, such as concrete beam yards where maneuvering space can be limited. The crane's 20-meter span allows it to cover a wide area, ensuring that beams can be lifted and moved without the need for extensive yard space. This helps maximize the use of available space for storage and production activities.
• Safety and Precision:
  Handling heavy materials like concrete beams involves inherent risks. Gantry cranes are equipped with safety features such as overload protection, limit switches, and precise controls that minimize the risk of accidents. By automating the lifting and moving processes, the crane reduces the reliance on manual labor, leading to a safer working environment for the employees.

In summary, gantry cranes are essential in concrete beam yards because they provide a high-capacity, reliable, and safe solution for handling heavy loads. Their ability to move concrete beams with precision and speed significantly enhances the efficiency of operations, while also reducing the risks associated with manual handling.

Project Background

Project Location

The concrete beam yard is located in the Philippines, an emerging hub for construction and infrastructure projects. Situated in a coastal area, the yard faces environmental challenges such as high humidity and occasional heavy rains. These factors influenced the design and material selection for the 25-ton gantry crane to ensure its durability and reliability under harsh conditions.

• Coastal Environment: High humidity and saltwater exposure increase the risk of corrosion, requiring the use of weather-resistant materials and coatings.
• Compact Yard Space: The yard's limited space meant the crane needed a 20-meter span and a 23-meter lifting height to maximize efficiency without overcrowding the site.
• Weather Considerations: The region's frequent rain and strong winds necessitated a crane design that could operate safely during adverse weather conditions.

These environmental and logistical factors played a key role in shaping the crane’s specifications, ensuring it could withstand the local conditions while maintaining high operational efficiency.

Client and Purpose

The client is a large concrete production company specializing in the manufacturing of concrete beams used in various construction projects. The yard’s operations involve the production, storage, and movement of concrete beams, which can weigh several tons each. The company faced challenges with lifting heavy beams and relied heavily on manual labor for much of the material handling.

The primary objectives for installing the 25-ton gantry crane were to:

• Increase Efficiency: By automating the lifting and movement of concrete beams, the crane would speed up operations, reducing bottlenecks and improving workflow.
• Improve Safety: The crane’s design includes safety features such as overload protection and limit switches, reducing the risk of accidents during material handling.
• Boost Productivity: The crane’s high lifting capacity and reach allow the yard to handle larger loads and transport beams more efficiently, leading to faster turnaround times.
• Enhance Long-Term Reliability: Given the environmental conditions, the crane was built with corrosion-resistant materials to ensure its longevity and minimize maintenance costs.

By integrating the gantry crane into their operations, the client aimed to streamline their processes, improve safety standards, and enhance overall productivity in the concrete beam yard.

Crane Specifications

• Crane Type: Double Girder Gantry Crane
• Capacity: 25 Tons
• Crane Span: 20 Meters
• Crane Lifting Height: 23 Meters
• Winch Trolley Design

Crane Specifications

Crane Type: Double Girder Gantry Crane

The 25-ton gantry crane installed at the concrete beam yard is an MG double girder gantry crane, which is designed for heavy-duty lifting applications. This type of crane features two parallel girders that support the entire structure, offering greater stability and lifting capacity compared to single girder cranes. The MG double girder design is well-suited for demanding environments, such as concrete beam yards, where heavy loads are frequently handled.

• Stability and Strength: The double girder configuration provides enhanced stability, ensuring that the crane can lift heavy and bulky loads, such as concrete beams, safely and efficiently.
• Durability: With robust construction, the MG crane is built to withstand harsh working conditions, including high humidity and potential exposure to rain, making it a reliable choice for outdoor environments like this concrete beam yard.
• High Load Capacity: The double girder design allows for a higher load-bearing capacity, making it ideal for lifting concrete beams that can be very heavy and difficult to manage without the proper equipment.

This crane type offers the necessary support and strength to ensure that the yard’s operations can be carried out efficiently, even under the strain of constant heavy lifting.

Capacity: 25 Tons

The 25-ton load capacity of this gantry crane is central to its function in the concrete beam yard. Concrete beams, which are large, dense, and heavy, require specialized equipment for safe handling, and the 25-ton capacity ensures that the crane can comfortably handle the yard's most substantial loads.

• Meeting Yard Requirements: The 25-ton capacity is perfectly suited for lifting concrete beams, which often weigh several tons each. This allows the crane to easily move beams without risk of overload.
• Comparison with Other Cranes: Compared to other cranes commonly used in concrete yards—such as jib cranes or smaller gantry cranes—this 25-ton crane offers a significantly higher capacity. Many smaller cranes might struggle with the size and weight of these beams, but the 25-ton capacity allows for smoother, more efficient operations.
• Handling Heavy and Bulky Loads: The crane’s capacity ensures that it can handle not only standard concrete beams but also oversized or extra-heavy beams that are occasionally produced, providing flexibility for various operational needs.

The 25-ton capacity directly impacts the yard’s ability to meet high demands for concrete beam handling, ensuring that productivity is maintained without compromising safety.

Crane Span: 20 Meters

The 20-meter span of the crane refers to the horizontal distance between the crane's supporting legs. This dimension is crucial because it determines the range within which the crane can move loads.

• Maximizing Yard Coverage: With a 20-meter span, the crane can cover a substantial portion of the yard, enabling it to lift concrete beams from different production zones and move them to storage or loading areas.
• Accommodating Various Lifting Configurations: The 20-meter span provides the flexibility to handle beams of different lengths and sizes. Whether beams need to be picked up from one side of the yard or moved across large storage areas, this span allows for smooth, uninterrupted operations.
• Space Optimization: In a yard with limited space, having an appropriately sized span means the crane can work efficiently without requiring excessive clearance, maximizing available storage and working areas.

With this span, the crane effectively supports the yard’s workflow, ensuring that concrete beams are handled with precision, regardless of their positioning in the yard.

Crane Lifting Height: 23 Meters

The 23-meter lifting height is another crucial specification of this gantry crane, allowing it to handle large concrete beams with ease. Lifting height is an essential consideration when moving concrete beams, as it ensures that there is sufficient vertical clearance for handling beams that may be stored at elevated positions or stacked in high-rack storage systems.

• Safe and Efficient Handling of Large Beams: Concrete beams often require lifting to significant heights for proper placement in storage or for loading onto trucks. The 23-meter lifting height allows the crane to easily accommodate these operations without risking interference with overhead structures or other equipment.
• Vertical Clearance: Adequate lifting height ensures that the crane can lift beams high enough to clear other objects in the yard, such as storage racks, other equipment, or potential obstacles like safety barriers.
• Optimizing Workflow: With this lifting height, the crane can easily retrieve beams from higher positions, ensuring that the entire yard is accessible, and improving the overall flow of operations.

The 23-meter lifting height not only meets the physical needs of the yard but also enhances overall operational flexibility, particularly when dealing with taller stacks of concrete beams.

main girder of double girder gantry crane 


gantry crane supporting legs 

electric hoist for the gantry crane double girder 

Crane Performance and Application

Operational Efficiency

The 25-ton MG double girder gantry crane has significantly enhanced operational efficiency in the concrete beam yard. Its design allows for smooth and quick handling of large, heavy concrete beams, which directly contributes to the yard's productivity. The crane’s features have led to noticeable improvements in:

• Faster Load Handling: With its 25-ton lifting capacity, the crane efficiently moves concrete beams from the production area to storage and dispatch zones, cutting down the time required to handle each load.
• Increased Throughput: The ability to lift and move heavier loads without strain means that more beams can be processed within a shorter time frame, increasing overall output.
• Reduced Manual Labor: The automated lifting system reduces the need for manual labor, which not only speeds up the handling process but also minimizes the risk of worker fatigue and injuries.

In essence, the crane optimizes the workflow, ensuring that the yard can handle higher volumes of concrete beams with greater speed and efficiency.

Safety Features

Safety is a critical concern in heavy-duty operations like the concrete beam yard, and the 25-ton gantry crane is equipped with several advanced safety features to ensure secure operation:

• Overload Protection: The crane is fitted with overload detection systems that automatically prevent lifting beyond its rated capacity. This ensures that the crane does not operate beyond its safe limits, preventing potential structural damage or failure.
• Limit Switches: The crane includes limit switches that restrict the movement of the crane's trolley and hoist, preventing them from exceeding safe operational ranges. This ensures the crane operates within its designated area, reducing the risk of accidents.
• Emergency Stop Systems: In the event of an emergency, the crane is equipped with a rapid-response emergency stop system. This system halts all crane movements immediately, allowing operators to react quickly in case of any unforeseen issues or safety concerns.
• Operator Training and Controls: The crane's control system is designed for ease of use, reducing the likelihood of human error. Combined with operator training, the system ensures safe operation even under the pressure of heavy-duty tasks.

These safety features work together to create a secure work environment, protecting both the crane's operators and the materials being handled.

Maintenance Considerations

Proper maintenance is crucial to ensuring the crane remains operational and efficient over its long service life. The 25-ton gantry crane has been designed with maintenance in mind, with several features that reduce wear and ensure longevity:

• Routine Inspections: Regular inspections are vital to keeping the crane in good working order. Key components such as the hoist, winch, trolleys, and lifting gear should be checked frequently for wear and tear. These inspections help identify issues before they become major problems, reducing downtime.
• Environmental Adaptations: Given the high humidity and coastal conditions in the Philippines, the crane is equipped with anti-corrosion coatings and weather-resistant materials to prevent rust and degradation. This reduces the frequency of maintenance and helps prolong the crane's lifespan.
• Lubrication and Cleaning: The crane’s moving parts, such as the trolley wheels and winch systems, require periodic lubrication to ensure smooth operation. Additionally, regular cleaning helps to prevent the buildup of debris, which could interfere with the crane’s functionality.
• Spare Parts and Support: The crane’s design includes easy access to essential parts for replacement or repair. In regions like the Philippines, where climate conditions can be challenging, having readily available spare parts and local support is key to minimizing downtime.

With the right maintenance practices, the 25-ton gantry crane is expected to deliver consistent performance, supporting the yard’s operations for many years to come while minimizing the need for costly repairs.

Benefits to the Concrete Beam Yard

Increased Efficiency and Productivity

The installation of the 25-ton gantry crane has had a significant impact on the efficiency and productivity of the concrete beam yard. Before the crane’s installation, the yard faced challenges with handling the large, heavy concrete beams using manual labor and less efficient equipment. The 25-ton crane has streamlined operations in several key ways:

• Faster Lifting and Transport: The crane’s high lifting capacity and ability to move loads quickly have drastically reduced the time required to lift and transport concrete beams across the yard. Tasks that once took considerable time and effort are now completed in a fraction of the time, enabling the yard to handle more beams per day.
• Reduced Material Handling Bottlenecks: The crane’s 20-meter span and 23-meter lifting height allow it to cover a wide area of the yard, eliminating bottlenecks that previously occurred when trying to move beams from one location to another. With greater reach and maneuverability, beams are moved quickly and efficiently between production, storage, and loading zones.
• Optimized Workflow: The crane’s automated movements have optimized the flow of materials within the yard. Workers can now focus on other tasks, such as overseeing operations and managing beam quality, rather than being directly involved in the physically demanding lifting processes. This improves overall workflow and reduces delays in the yard.

By reducing handling time and increasing throughput, the gantry crane has directly contributed to a marked increase in productivity, allowing the yard to meet growing demand and improve operational efficiency.

Enhanced Safety and Reduced Downtime

Safety is a top priority in any industrial environment, particularly in concrete beam yards where heavy lifting and manual labor can pose risks. The 25-ton gantry crane has contributed significantly to improving safety and reducing downtime in several ways:

• Minimized Risk of Accidents: With the crane now handling the heavy lifting, the reliance on manual labor for beam movement has been reduced, thereby lowering the risk of injuries due to overexertion or improper lifting techniques. The crane’s advanced safety features, such as overload protection, limit switches, and automatic braking systems, ensure that the lifting operations are carried out safely.
• Precise Control for Safe Handling: The open winch trolley design enables smooth and precise movement of heavy beams. This control ensures that beams are lifted and positioned without jerking or accidental drops, reducing the likelihood of accidents or damage to both the equipment and the beams themselves.
• Reduced Equipment Failures and Downtime: By replacing outdated equipment with a modern gantry crane, the yard has reduced frequent breakdowns and malfunctions. The crane’s robust design, built to withstand harsh working conditions, has minimized operational disruptions and downtime. This means the yard can maintain a consistent pace of work without costly delays due to equipment failure.
• Worker Safety: With the crane handling the heaviest lifting tasks, workers are no longer exposed to the risks of handling large concrete beams manually. This has made the yard a safer place to work, with fewer risks of accidents or injuries from moving heavy materials.

The improved safety and reduced downtime have contributed not only to a more secure working environment but also to enhanced operational consistency, allowing the yard to meet deadlines and production goals without interruptions.

Cost-effectiveness and ROI

The 25-ton gantry crane has proven to be a cost-effective investment for the concrete beam yard, delivering substantial operational savings and a strong return on investment (ROI) for the client. Here’s how:

• Reduction in Labor Costs: With the crane handling the majority of the lifting tasks, the yard has been able to reduce its reliance on manual labor. Fewer workers are required for physically demanding lifting operations, resulting in significant savings on labor costs. Workers can now be redeployed to other, less strenuous tasks, further improving productivity across the yard.
• Decreased Maintenance Costs: The new crane’s reliable, durable design has reduced the frequency of maintenance required compared to older, less efficient lifting equipment. The reduced downtime due to fewer equipment failures also translates into savings, as the yard can maintain higher operational uptime, increasing output without interruption.
• Long-term Durability: The crane’s design, built to withstand the environmental conditions of the Philippines, including high humidity and frequent rains, ensures that the investment will provide long-term value. Corrosion-resistant materials and durable components mean the crane will last longer, resulting in a lower cost of ownership over time.
• Faster Project Turnaround: The increased lifting speed and efficiency provided by the crane enable the yard to handle more concrete beams in less time. This directly impacts the yard’s ability to meet client demands and deliver projects faster, which in turn increases revenue and strengthens customer satisfaction.
• Return on Investment (ROI): Given the reduced labor costs, decreased maintenance expenses, and increased production rates, the ROI for the client has been substantial. The crane's ability to increase productivity while lowering operational costs ensures that the initial investment will be recouped within a relatively short time frame, further solidifying its cost-effectiveness.

In conclusion, the 25-ton gantry crane has provided significant financial benefits to the concrete beam yard, from reducing labor and maintenance costs to boosting production and revenue. The long-term ROI of the crane ensures that the client’s investment continues to pay off, making it a financially sound decision for the yard’s operations.

Conclusion

The installation of the 25-ton gantry crane at the concrete beam yard in the Philippines has proven to be a highly successful project, achieving all of its primary objectives. Key outcomes include:

• Successful Installation: The crane was successfully installed, meeting the yard’s requirements for heavy-duty material handling. It has since become an integral part of the yard's daily operations, allowing for efficient and reliable lifting and transporting of large concrete beams.
• Improved Operations: The crane’s high capacity, 20-meter span, and 23-meter lifting height have significantly boosted the yard's productivity. It has reduced handling times, streamlined material transport, and optimized the workflow, allowing the yard to meet production targets with greater ease and speed.
• Enhanced Safety: By automating the heavy lifting tasks, the crane has dramatically improved safety standards within the yard. With fewer manual lifting operations, the risk of accidents has been greatly reduced, and the crane’s advanced safety features ensure smooth and secure operation, providing a safer working environment for all employees.

Overall, the crane has had a transformative impact on the yard’s efficiency, safety, and productivity, making it a valuable addition to the operation and a successful implementation of advanced crane technology.

In conclusion, the 25-ton gantry crane has not only delivered immediate benefits but has also laid the foundation for future growth and potential expansions, both within this yard and for similar projects in the Philippines . The successful installation and operation of this crane position the yard for continued success in the competitive concrete manufacturing industry.