50 Ton Gantry Crane for Precasting Concrete Yard Philippines

Heavy-duty gantry crane designed for precast concrete yards, offering 50 Ton capacity, efficient material handling, and durable performance.

Case Study: 50 Ton Gantry Crane for Sale in the Philippines – Precasting Concrete Yard

Overview of the Project

Crane Type: Double Girder Overhead Crane with Electric Hoist Trolley

The crane chosen for this project is a double girder overhead crane, paired with an electric hoist trolley. This combination was selected for its capacity to handle heavy loads, provide high lifting heights, and cover a wide operational span.

• Double girder design: Provides increased lifting capacity, enhanced stability, and greater lifting heights.
• Electric hoist trolley: Ensures smooth and efficient lifting operations, reducing operational strain and increasing precision.

The double girder structure offers more robust support, making it ideal for lifting the large and heavy concrete elements typical in a precast concrete yard. The electric hoist trolley, powered for precision movements, makes the crane ideal for repetitive, high-volume lifting tasks.

Crane Capacity: 50 Tons

The crane was designed with a 50 Ton capacity, which aligns with the facility’s requirements to handle large and heavy precast concrete components.

• Heavy lifting capabilities: The 50 Ton capacity allows for the safe handling of concrete components such as beams, columns, and slabs.
• Reliability: The crane’s design ensures it can operate consistently and efficiently under heavy loads, minimizing downtime and boosting productivity.

This weight capacity allows the crane to manage the most demanding tasks in the precast yard without compromising on safety or performance.

Crane Span: 20 Meters

A 20-meter crane span was selected to provide optimal coverage of the precast yard, enabling the crane to reach different work areas and move large components effortlessly across the site.

• Wide coverage: A 20-meter span allows the crane to serve multiple production lines and cover large production areas.
• Operational flexibility: The span ensures the crane can maneuver over various production zones and lift heavy concrete elements without interference.

The wide span improves workflow efficiency, reducing the need for multiple cranes or additional equipment in the yard.

Project Location: Precasting Concrete Yard, Philippines

The project is located in a precasting concrete yard in the Philippines, a region characterized by a tropical climate with high humidity and heat. The crane design had to be customized to withstand the local environmental conditions.

• Tropical climate considerations: Anti-corrosion coatings and weather-resistant materials were used to ensure long-term performance.
• Local environmental challenges: The crane was built to withstand tropical storms and extreme heat, ensuring it operates smoothly even in tough conditions.

The design of the crane took these local environmental factors into account, ensuring durability and reliability.

Objective: Enhance Material Handling Efficiency and Productivity

The primary objective of this installation was to improve material handling efficiency and productivity in the precast concrete production process.

• Reduced labor costs: The crane’s efficient material handling system reduces the need for manual lifting, cutting down on labor requirements.
• Increased output: Faster lifting and movement of precast components means quicker production cycles and reduced project timelines.
• Enhanced safety: Automated lifting minimizes human error and safety risks associated with manual handling of heavy materials.

This crane installation significantly boosts the yard’s operational efficiency, helping the facility meet the growing demands of the construction industry in the Philippines while ensuring worker safety and reducing production delays.

Project Background

Industry Overview: Importance of Efficient Material Handling in the Precast Concrete Industry

Efficient material handling is vital in the precast concrete industry because of the large and heavy components involved. Precast concrete yards produce elements like beams, columns, slabs, and walls that need to be lifted, moved, and positioned with precision. Without reliable lifting equipment, moving these materials can become slow and labor-intensive, which reduces productivity and increases costs.

• Time-sensitive operations: Precast yards often have tight deadlines, so the ability to quickly move materials is crucial to staying on schedule.
• Improved productivity: Efficient handling reduces downtime, prevents damage to materials, and keeps production flowing smoothly.
• Safety: Proper lifting equipment helps prevent accidents, injuries, and damage to products, creating a safer work environment.

In the precast concrete industry, having the right crane or lifting system is essential for moving heavy items efficiently, reducing costs, and keeping operations running smoothly.

Overview of the Philippines' Precast Concrete Market and Demand

The precast concrete market in the Philippines has grown steadily, driven by the country's expanding construction industry. There is an increasing demand for precast components in residential, commercial, and infrastructure projects.

• Rising demand for precast elements: As urban development continues to grow, more precast components are needed for buildings, bridges, and other structures.
• Government infrastructure projects: The Philippine government's investments in infrastructure have boosted the demand for precast concrete products.
• Move towards automation: To stay competitive, precast yards are adopting more automated systems, including advanced cranes, to boost productivity and cut labor costs.

The growing need for precast concrete and larger construction projects has made heavy-duty lifting equipment even more important in the Philippines.

Client Needs and Requirements

The client, a precast concrete yard in the Philippines, had several specific needs when choosing a crane:

Need for heavy-duty lifting equipment: The yard produces large concrete components that can weigh several tons. They needed a crane that could safely and efficiently handle these heavy loads without compromising on performance.

Key specifications:

• Capacity: The crane needed to lift up to 50 tons to handle the heaviest concrete elements.
• Span: A 20-meter span was required to cover the yard and move materials efficiently across the production area.
• Lifting height: The crane had to have enough lifting height to move large components and clear other equipment and obstacles in the yard.

The goal was to improve efficiency, reduce manual labor, and handle larger precast components quickly and safely.

Challenges

The project faced a few key challenges that needed to be addressed in the crane design:

• Limited space in the yard: The yard had a constrained layout, making it difficult to move large precast components without causing congestion. The crane needed to be designed to maximize space while still being flexible enough to handle materials across the yard.
• Harsh environmental conditions: The Philippines has a tropical climate with high humidity, heat, and occasional storms. These weather conditions can affect equipment, so the crane had to be built to withstand the local environment. It needed anti-corrosion features and weather-resistant materials to ensure long-lasting performance and reliability.

The combination of tight space and challenging weather conditions required careful planning to ensure the crane would operate safely and effectively while meeting the yard’s specific needs.
 

 50 ton gantry crane for precasting conceret yards for your reference 

Crane Design and Specifications

Crane Type: Double Girder Overhead Crane

The crane chosen for this project is a double girder overhead crane, which is ideal for heavy-duty applications like those in a precast concrete yard. This design provides several key benefits:

• Increased Strength and Stability: The double girder setup allows for a stronger, more stable structure, enabling the crane to handle heavy loads without compromising performance or safety. This is particularly important in environments where large and dense concrete components are frequently lifted.
• Enhanced Lifting Height and Span: With the double girder design, the crane offers greater lifting heights and spans, which helps maximize the coverage area of the yard. It allows the crane to lift materials to higher elevations and reach a wider area, which is critical when moving large precast concrete components.

These features make the double girder overhead crane ideal for the demanding tasks in precast concrete yards, where heavy lifting and efficient material handling are essential for smooth operations.

Capacity: 50 Ton

The crane has a 50 Ton lifting capacity, which is directly tied to the heavy lifting requirements of the precast concrete yard.

Relevance to Precast Concrete Operations: The 50 Ton capacity allows the crane to handle the large, heavy components typical of precast production, such as beams, columns, and slabs. These elements often weigh several tons, and without a crane with such a high lifting capacity, moving these items would be slow and inefficient.

• Beams: Long, heavy structural elements used in building construction.
• Columns: Vertical supports for buildings and bridges.
• Slabs: Large, flat precast components used for floors, roofs, and walls.

The 50 Ton capacity ensures that the crane can safely handle these heavy loads, reducing the need for multiple lifts and minimizing delays in the production process.

Crane Span: 20 Meters

The crane has a 20-meter span, which plays a crucial role in optimizing material handling across the yard.

• Significance for Yard Coverage: A 20-meter span allows the crane to cover a larger area of the precast yard, making it possible to move materials across different production zones without the need for additional cranes or equipment. This improves efficiency by reducing the time it takes to transport components between work areas.
• Design Considerations for Maneuvering Large Components: The crane’s span was carefully designed to ensure that it could reach all corners of the yard while maintaining flexibility to maneuver heavy and oversized concrete components. The wide span helps avoid congestion in the yard, which is important for ensuring smooth workflows and reducing delays.

With this 20-meter span, the crane can serve multiple production lines at once, increasing the overall capacity of the yard.

Electric Hoist Trolley

The crane is equipped with an electric hoist trolley, a system that is essential for precise, smooth, and efficient lifting operations.

• Smooth and Precise Lifting: The electric hoist trolley system is designed for smooth movement along the crane’s beams, providing precise control over the lifting and lowering of heavy loads. This precision is critical in a precast concrete yard, where even small errors in positioning can result in accidents or damage to the concrete components.
• Motorized Travel and Efficient Lifting Mechanics: The hoist trolley is powered by motors that allow it to travel smoothly along the crane’s rails, improving the overall lifting speed and reducing the time required to transport heavy components. The efficient lifting mechanics of the system ensure that the crane can move loads quickly and safely, which is vital in a high-demand environment like a precast yard.

The combination of motorized travel and precise lifting control makes the electric hoist trolley an essential component of the crane, contributing to the overall efficiency and safety of operations in the precast concrete yard.


Supporting legs of 50 ton gantry crane for sale Philippines 
supportng legs of  50 ton gantry crane for sale Philippines 

main girder of 50 ton gantry crane for sale Philippines 
cable drum of 50 ton gantry crane for sale Philippines 

Site Analysis and Installation

Site Layout and Crane Positioning

Mapping the precast concrete yard and determining the optimal placement for the crane was a critical part of the project. The layout needed to ensure that the crane could efficiently cover all production areas while considering space limitations.

• Space Optimization: The yard had a limited footprint, so the crane had to be positioned to maximize its reach without causing congestion. The 20-meter span was carefully considered to ensure it could cover key areas, such as the production lines and storage zones, while minimizing obstructions.
• Crane Access to Various Parts of the Yard: The crane’s location needed to provide access to all parts of the yard where heavy precast components are moved. The positioning allowed for smooth flow of materials between different production areas, including casting zones and storage areas.

By carefully planning the crane’s position, the layout ensures the crane can efficiently service the yard while maintaining safety and accessibility.

Crane Installation Process

The installation of the 50 Ton double girder overhead crane involved several crucial steps, starting with site preparation and followed by a detailed step-by-step installation process.

Site Preparation and Foundation Requirements:

• Ground assessment: The site needed to be prepared to accommodate the crane’s weight and size. This involved evaluating the ground’s stability and strength to ensure the crane’s foundation could handle the load.
• Foundation design: A strong foundation was built to anchor the crane’s support beams and girders. This foundation was specifically designed to handle the 50 Ton capacity and ensure the crane’s long-term stability.

Step-by-Step Installation Procedure:

• Assembly of Components: The installation began with assembling the crane’s individual components, including the girders, hoist trolley system, and electrical systems.
• Positioning the Crane Structure: Once the parts were ready, the crane structure was carefully positioned on its foundation, ensuring that all components aligned correctly.
• Testing and Calibration: After the crane was assembled, it went through a series of tests to ensure everything was operating as expected. The crane’s lifting capacity, span, and hoisting system were all tested to meet the client’s specifications.
• Final Adjustments: Any necessary adjustments were made to ensure the crane was operating smoothly before the final handover.

The installation process was done in stages to ensure that each phase was completed efficiently and safely.

Safety Considerations

Ensuring safety during the installation and operation of the crane was a top priority. The crane was designed with safety in mind, and all installation work adhered to local and international safety standards.

Compliance with Safety Regulations: The installation followed local safety guidelines as well as international standards such as:

• ASME (American Society of Mechanical Engineers): Ensuring the crane met rigorous safety and performance standards.
• IEC (International Electrotechnical Commission): Compliance with electrical safety standards, especially for the hoist trolley and motorized systems.

Design Features Ensuring Worker Safety:

• Emergency Stop Mechanism: The crane is equipped with an emergency stop system that immediately halts operation in case of a malfunction or emergency.
• Overload Protection: Sensors are in place to prevent the crane from lifting loads beyond its rated capacity, reducing the risk of equipment failure or accidents.
• Safety Barriers: Protective barriers around key areas help prevent accidental access to dangerous zones during crane operation.

Equipment Protection: The crane’s components, especially the hoist system and motors, are designed with features like overload protection and corrosion-resistant coatings to prevent damage from prolonged exposure to harsh environmental conditions.

Customization and Features

Customized Features for Precast Concrete Yard

The crane system was specially customized to meet the specific needs of the precast concrete yard and ensure optimal performance under the demanding conditions of lifting large, heavy concrete components.

• Tailored Lifting Mechanisms: The crane features custom lifting mechanisms designed to safely handle the heavy and oversized precast concrete elements, such as beams, columns, and slabs. Specialized slings and hooks ensure that these components are lifted securely, reducing the risk of damage during transport.
• Anti-Corrosion Coatings for Tropical Climate: Given the tropical climate in the Philippines, the crane was equipped with anti-corrosion coatings and weather-resistant materials. This prevents rust and deterioration caused by high humidity, frequent rain, and exposure to salt in the air, ensuring the crane remains in top condition for years.
• Enhanced Stability Features: To further enhance stability and performance, the crane system includes reinforced hoist trolleys capable of supporting heavy loads with minimal sway or vibration. Limit switches were also installed to prevent over-travel and protect both the crane and its load from damage, ensuring smooth and controlled operations.

These customized features ensure the crane can handle the specific requirements of the precast concrete yard, including lifting heavy, large components safely and reliably in challenging environmental conditions.

Control Systems

The crane’s control system was designed for ease of use and maximum safety, integrating advanced features to improve operational efficiency.

Overview of Control Panel and Remote Control Systems: The crane features a user-friendly control panel and remote control systems, allowing operators to maneuver the crane with precision and minimal effort. The remote control provides greater flexibility, enabling operators to control the crane from a safe distance, enhancing their ability to manage operations without being in direct proximity to the heavy lifting.

Integration of Safety Features:

• Overload Protection: The crane is equipped with overload sensors that immediately alert operators if the crane is lifting a load beyond its rated capacity, preventing potential damage or accidents.
• Emergency Stop: An emergency stop button is installed on both the control panel and remote control, ensuring that the crane can be halted instantly in the event of an emergency, protecting both the operators and the materials being handled.
• Automatic Limit Switches: These switches are integrated into the system to automatically stop the crane’s motion if it reaches the set limits, preventing damage to the crane, the load, and the surrounding equipment.

The control system’s design ensures that operators can work confidently and safely, knowing the crane is equipped with the latest safety and automation features.

Energy Efficiency

Energy efficiency was a key consideration in the crane's design, reducing both operational costs and environmental impact.

• Energy-Efficient Motors and Hoisting Systems: The crane utilizes high-efficiency motors and advanced hoisting systems that consume less energy while maintaining high lifting speeds and power. This helps reduce the overall energy usage of the crane, leading to lower electricity costs for the facility.
• Low Maintenance and Operational Downtime: The crane's components were selected for durability and low maintenance requirements. This includes sealed bearings, high-quality wiring, and durable anti-corrosion coatings that reduce wear and tear. As a result, the crane requires fewer maintenance interventions, which translates to lower operational downtime and greater productivity.

By focusing on energy efficiency and low maintenance, the crane system helps the precast concrete yard maintain cost-effective operations while minimizing disruptions to production schedules.

Performance and Operational Benefits

Efficiency Gains

The new 50 Ton double girder overhead crane has significantly improved productivity in the precast concrete yard, enhancing the overall efficiency of the production process.

• Improved Productivity: The crane’s ability to lift heavy precast components quickly and efficiently has streamlined production workflows. It reduces delays in material handling and allows for a faster turnaround time from casting to storage or shipment. This results in higher throughput and a quicker completion of projects.
• Reduced Material Handling Time: The crane’s powerful lifting capacity and smooth operation minimize the time spent moving large components between production zones. This helps reduce the time it takes to prepare materials for the next stage of production, accelerating the entire process.
• Labor Cost Savings: By automating the lifting and transportation of heavy components, the need for manual labor is reduced. Fewer workers are needed for physically demanding tasks, allowing the yard to reallocate resources to other critical areas and reduce labor costs.

The efficiency gains from the crane system help the yard handle increasing demand while keeping costs manageable.

Operational Flexibility

The crane’s design provides substantial operational flexibility, allowing it to meet the diverse needs of the precast concrete yard.

• Ability to Lift and Transport a Wide Range of Precast Components: The crane’s 50 Ton lifting capacity and 20-meter span make it versatile enough to handle a variety of precast components. Whether it’s large beams, columns, slabs, or custom-shaped items, the crane can easily move them around the yard, ensuring materials are available where they are needed without delay.
• Handling Heavy Weights Safely: With its reinforced hoist trolleys and anti-corrosion coatings, the crane can lift heavy weights reliably without compromising safety or equipment durability. The system’s design ensures that even the largest and heaviest components can be handled with precision, preventing strain on the crane and minimizing the risk of accidents.

This flexibility allows the yard to efficiently manage different types of precast concrete products, improving the overall flow of operations.

Durability and Maintenance

The crane is built to last, with a focus on minimizing downtime and ensuring long-term reliability in tough working conditions.

• Low Maintenance Requirements: The crane was designed with durability in mind, using high-quality materials and components that require minimal maintenance. Sealed bearings, corrosion-resistant coatings, and robust structural elements reduce the need for frequent repairs and maintenance checks, ensuring the crane remains operational without constant attention.
• Long-Term Reliability in Challenging Conditions: Built to withstand the humid, high-heat environment of the Philippines, the crane’s weather-resistant features ensure reliable performance over time. Anti-corrosion coatings protect against rust, while high-quality components endure the harsh conditions of the precast yard, including heavy use and exposure to dust, moisture, and occasional storms.

The crane’s durability and low maintenance requirements make it a reliable asset for the yard, ensuring that it can continue to perform at high levels over its lifespan, even in challenging environmental conditions.

Challenges Faced and Solutions Implemented

Space Constraints

One of the main challenges faced during this project was the limited space available in the precast concrete yard. The yard's layout required careful planning to accommodate the large 50 Ton crane while ensuring that it could efficiently maneuver across the facility and handle heavy loads.

Solutions for Fitting a 50 Ton Crane in Limited Space:

• Compact Design: To address the space constraints, the crane was designed with a compact configuration, optimizing the available footprint while still offering the necessary lifting capacity. By positioning the crane strategically in the yard, it was able to cover the most critical areas without encroaching on other parts of the facility.
• Maximizing Yard Space: Special consideration was given to the crane's span and lifting height to ensure it could move materials efficiently while taking up the least amount of space possible. The 20-meter span was chosen to balance coverage across the yard with the available clearance, allowing the crane to serve a wide range of production areas without interfering with other equipment.

These design adjustments ensured that the crane could operate efficiently in the constrained space of the precast yard, helping optimize material handling without sacrificing performance.

Weather Conditions

The tropical climate in the Philippines, with high temperatures, high humidity, and occasional rain, posed a significant challenge for crane operation and longevity. The crane needed to be able to withstand these harsh environmental conditions while maintaining peak performance.

Addressing the Impact of High Temperatures, Humidity, and Rain:

• Anti-Corrosion Design: To mitigate the impact of the Philippines' tropical weather, the crane was fitted with anti-corrosion coatings on all exposed parts, including the girder beams, hoists, and trolley systems. These coatings prevent rust and degradation caused by moisture, extending the crane’s service life.
• Weather-Resistant Materials: High-strength materials resistant to heat and humidity were used throughout the crane’s construction, ensuring that all components function well in the tropical climate. Components such as motors, electrical systems, and gears were selected for their resistance to corrosion and their ability to operate smoothly even in humid conditions.
• Rain Protection: The crane’s electrical systems and control panels were housed in weatherproof enclosures, protecting them from rain and moisture. This ensures that the crane remains fully operational even during wet conditions, which are common during the rainy season in the Philippines.

By implementing these weather-resistant features, the crane was able to handle the harsh tropical climate, ensuring reliable performance and minimizing the need for frequent maintenance or repairs due to weather-related wear and tear.

Client Feedback and Results

Client Satisfaction

The precast concrete yard manager provided positive feedback regarding the crane’s performance and its impact on daily operations.

Testimonials from the Yard Manager: The yard manager emphasized how the new crane system has made a significant difference in both efficiency and safety. According to the manager:

• “The 50 Ton double girder crane has transformed how we handle heavy components. It’s not only faster but also safer for our workers. The precision and ease with which we can move materials across the yard have significantly reduced downtime.”
• “The anti-corrosion features have proven invaluable in the humid environment, and we’ve had minimal maintenance issues since installation, which helps keep our production running smoothly.”

Improvement in Production Rates and Worker Satisfaction: The crane has directly contributed to a smoother workflow in the yard. By reducing the time spent moving heavy components and lowering the risk of accidents, worker morale has improved, as employees now work in a safer and more efficient environment. The ability to meet production deadlines more easily has led to higher overall satisfaction in the team.

Quantifiable Results

The introduction of the crane system led to measurable improvements in both material handling and overall production efficiency.

Reduction in Material Handling Time: The time required to move large precast components has been significantly reduced. Prior to the crane, workers spent much more time manually shifting materials, often requiring multiple operators. With the new crane, materials are lifted and transported quickly with minimal manpower, streamlining the overall process.

Increase in Operational Efficiency and Production Throughput: The crane’s ability to handle large loads quickly has had a direct impact on production rates. With fewer delays and faster movement of materials, the yard has seen an increase in its throughput, allowing more precast components to be produced within the same timeframe.

For example, the average time to move a heavy slab has been reduced by 30%, leading to a higher output without needing additional labor or shifts.

Long-Term Reliability of the Crane System: The crane has been running reliably since its installation, with minimal downtime. This has resulted in improved planning and scheduling, as the yard no longer needs to account for frequent maintenance disruptions. The anti-corrosion coating and durable design have proven effective in maintaining crane performance despite the humid and rainy climate in the Philippines.

The results speak for themselves: the crane has significantly improved operational efficiency, reduced material handling time, and enhanced the yard’s production capacity, making it a valuable asset for the business in both the short and long term.

Conclusion

The installation of the 50 Ton double girder gantry crane has been a significant success for the precast concrete yard in the Philippines. The crane’s advanced design and custom features have helped the yard streamline its operations, improve productivity, and ensure safe handling of large, heavy precast components.

• Enhanced Efficiency: The crane has significantly reduced material handling times, enabling quicker production cycles and minimizing labor costs. It has provided the necessary lifting capacity to handle large precast components with precision and speed.
• Durability and Adaptability: Designed to withstand the harsh environmental conditions in the Philippines, including high temperatures, humidity, and occasional rain, the crane has performed reliably with minimal maintenance.

Final Assessment of the 50 Ton Double Girder Gantry Crane’s Impact

The 50 Ton crane has had a positive impact on the yard’s overall performance:

• Improved Material Handling: With its high lifting capacity and 20-meter span, the crane can lift and transport a wide variety of precast concrete components, improving the yard’s operational flexibility.
• Increased Productivity: The efficient crane operation has led to faster production timelines, reducing delays and enhancing throughput.
• Reduced Maintenance: The crane’s robust design and anti-corrosion features have ensured that downtime is kept to a minimum, contributing to ongoing operational efficiency.

Overall, the crane has not only enhanced the material handling capabilities of the yard but also played a pivotal role in increasing overall productivity.

Key Takeaways for Similar Projects in the Region

For other precast concrete yards in the Philippines and similar regions facing similar operational challenges, the following key takeaways from this project can be applied:

• Tailor Solutions to Local Conditions: Customizing cranes to meet local environmental conditions, such as incorporating anti-corrosion features for tropical climates, is crucial for long-term performance and reliability.
• Maximize Space Efficiency: Even in limited spaces, careful crane positioning and layout design can maximize operational flexibility and yard coverage, ensuring that space constraints do not hinder productivity.
• Focus on Safety and Reliability: Integrating advanced safety features, such as overload protection and limit switches, ensures that crane operations are both efficient and secure.