Long Span, High Costs? Beam Cutting & Installation Guide

Learn about beam cutting and installation challenges for long-span, single & doulble girder cranes, and ways to manage costs effectively.

If you're in the market for a long-span crane, whether it's a box girder crane or an overhead girder crane, you probably already know that these cranes come with some unique challenges. They are powerful machines built to handle heavy loads over large areas, but that size and strength come at a price.

In this guide, we’ll break down the costs involved in beam cutting and installation. We’ll explain why crane girder beams and box girders add to the overall price tag and what factors make the costs higher.

By the end, you'll understand exactly why long-span cranes are more expensive and how the crane girder you choose can impact your budget.

The Big Question:

So, why do long-span cranes cost so much? It's a fair question. The truth is, span length, tonnage, and the materials used all affect the price. Here's what you need to know:

• Longer spans mean you need bigger and stronger crane beams, whether they are box girders or girder cranes.
• The cutting process for larger beams requires more work, and that adds to the cost.
• Higher tonnage cranes need even stronger crane girder beams, and the heavier materials add up quickly.

Now, let’s dive deeper into how these factors play a role in your overall costs. It’s not just the size of the crane, but also how the beam cutting process works and how long it takes to install.

What Is Beam Cutting and Why Does It Matter?

What Is Beam Cutting?

Beam cutting refers to the process of dividing crane girder beams or box girders into smaller, more manageable sections. This is a crucial step for making transportation and installation easier, especially when working with long-span cranes.

Why Is Beam Cutting Done?

• Handling Large Spans: Long spans are difficult to transport as a single piece. Cutting crane girder beams into smaller sections makes them more manageable for transport.
• Easier Delivery: By cutting the beams into sections, they can be moved using standard-sized vehicles, avoiding the need for oversized transport equipment.

How Does Beam Cutting Work?

• Cutting Process: The crane beams are cut into multiple smaller sections before transportation. Once they arrive at the site, these sections are reassembled to create the full-length beam, ensuring a seamless installation.

Why Does Beam Cutting Matter?

• Efficiency: The ability to cut crane beams and box girders into sections ensures that even the largest and heaviest components can be moved and installed effectively and efficiently, reducing the complexity and cost of transportation.

This process helps simplify the logistics, ensuring that long-span cranes can be assembled on-site without any unnecessary delays or difficulties.


 

When Do You Need Beam Cutting?

Longer Spans

If your crane girder beam needs to span more than 18 meters (or even 31 meters), beam cutting is typically required. The longer the span, the larger and heavier the beam becomes, making it difficult to transport and install as one piece.

Transportation Limitations

• Road and Bridge Restrictions: Even if your crane's span isn’t extremely long, transportation issues such as road restrictions or weight limits on bridges can require you to cut the beams. Smaller sections are much easier to move and fit through these limitations.

Ease of Installation

• Faster Assembly: Cutting the crane girder beams into smaller sections makes installation quicker and more flexible. The sections can be easily transported to the site and assembled on location, speeding up the overall installation process.

In short, beam cutting is necessary whenever your crane girder or box girder needs to span long distances or faces transportation challenges. It’s the key to ensuring everything fits together and is installed properly.

Why Do Long-Span Cranes Cost More?

Bigger Beams, Higher Costs

Long-span cranes are more expensive because they require larger, stronger beams. These crane girder beams or box girders are designed to carry heavy loads, and that’s reflected in their cost.

Material Costs

• More Material Needed: Larger spans demand more material to ensure the beam can support the weight. This means more steel, aluminum, or other materials are required, which increases the overall cost.

Increased Work

• Manufacturing and Assembly: Heavier beams require more labor to manufacture, cut, and assemble. It’s not just about making a bigger beam, but making it strong enough to safely support the crane’s load.

Higher Cutting, Welding, and Reinforcement Costs

• Specialized Equipment: Cutting thicker beams requires specialized machinery like CNC or laser cutters.
• Additional Reinforcement: Welding and reinforcing these beams takes more time and skilled labor, adding to the final cost.

In essence, the heavier and more robust the crane girder beams, the higher the production, cutting, welding, and reinforcement costs, which all contribute to the higher price of long-span cranes.

Complicated Cutting and Transport

Precision Cutting

When dealing with long-span cranes, precision is key. To ensure that the crane girder beams are strong and fit perfectly, cutting must be done with great accuracy. This requires advanced techniques like CNC cutting or laser cutting, which need specialized equipment and skilled operators. The use of these high-precision methods adds to the overall cost.

Multiple Sections

• More Sections, More Costs: For longer spans, crane girder beams often need to be cut into multiple sections to make transportation easier. While this helps with handling and delivery, it can increase the logistics costs as the separate sections need to be moved individually. The time taken for delivery also increases.

Logistical Challenges

• Specialized Transport: Depending on the size and weight of the beams, specialized transportation may be necessary. Larger beams may require special trailers or vehicles for transport, further adding to the cost. Additionally, the need for more planning and coordination can delay the delivery and installation timeline.

In short, the complexity of cutting long-span crane beams and the logistics involved in transporting them significantly increase the overall costs and time required for installation.

Reinforcements for Strength

Structural Integrity

As crane girder beams or box girders get larger and heavier, the need for reinforcements grows. Reinforcements are essential to ensure the beams maintain their structural integrity and can handle heavy loads without failure. This often involves adding extra material or reinforcing the beams during the production process.

Additional Work and Material

• Increased Costs: The more reinforcements needed, the higher the cost. Reinforcing crane beams requires both additional materials and more labor time, which directly increases the overall price.
• Labor and Material Requirements: These extra steps are necessary to ensure the beams are strong enough for their intended purpose, but they do add to both the material and labor costs.

Final Impact on Price

In summary, the larger and heavier the crane girder or box girder, the more cutting, transportation, and reinforcement it requires. These factors contribute significantly to the higher costs associated with long-span cranes.

How Span Length and Tonnage Affect Beam Cutting Fees

Span Length

The length of the crane span has a direct impact on the cost of beam cutting. Here’s how:

Longer Spans Require More Sections

• More Cuts: As the span length increases, the crane girder or box girder generally needs to be divided into more sections. These smaller sections make transportation and installation easier, but the cutting process itself can be costly. More sections also mean more time and labor to reassemble on-site.

Complexity of Cutting and Reassembling

• More Complex Process: The longer the span, the more intricate the cutting and reassembly process becomes. Longer spans require more equipment, more labor, and more time to get everything back together at the installation site, which increases the overall cost.
• Additional Labor and Equipment Costs: These extra steps involve specialized tools and more skilled workers, contributing to the higher costs of long-span cranes.

Price and Length Go Hand in Hand

• Direct Correlation: The relationship between span length and cost is straightforward. Longer spans require more material, more cutting, and more labor to transport and install, which means higher costs at each stage of the process.

In short, longer span lengths lead to higher beam cutting fees due to the need for more sections, increased complexity in the cutting and reassembly process, and additional resources for transportation and installation.

Tonnage

The tonnage of your crane is a key factor in determining the size, strength, and cost of the crane girder beams or box girders. Here's why tonnage plays a major role:

Stronger Beams for Higher Tonnage

• Larger, Stronger Beams: Higher tonnage cranes, such as a 50-ton crane, require beams that are thicker and stronger. These beams are necessary to safely support the heavier loads that come with a high-tonnage crane.
• Increased Strength Requirements: The higher the crane's tonnage, the more strength the crane girder beams need to ensure they can carry heavy, challenging loads.

More Material, More Work

• Increased Material and Labor Costs: Thicker, stronger beams demand more material and take more labor to cut and assemble. The cutting process for these larger beams is more labor-intensive and requires specialized tools, all of which contribute to higher costs.
• Labor-Intensive Cutting: The complexity of cutting thicker beams means more effort and time, pushing up the overall price.

Example of the Difference

• Smaller Cranes (10-Ton): For a 10-ton single girder crane, the beams are relatively smaller and easier to handle. The cutting and installation process is straightforward, meaning lower costs.
• Larger Cranes (50-Ton): For a 50-ton double girder crane, the beams are significantly larger and require more work to cut and assemble. The larger the beams, the more expensive the entire process becomes, from cutting to transportation to installation.

In short, the higher the tonnage of the crane, the stronger and more complex the beams need to be, resulting in higher material and labor costs for both cutting and installation.

 long girder crane 

Cost Examples

Understanding the relationship between span length, tonnage, and beam cutting costs can help you plan and budget more effectively. Here are a few examples to give you a clearer picture:

Shorter Span & Lower Tonnage

• Example: For a 10-ton single girder crane with a span length of 18 meters, the beam cutting process is relatively simple. The beams are smaller and lighter, requiring less material and less labor to cut and assemble.
• Result: This makes the cutting and installation process more affordable. It’s a straightforward process, with fewer sections and less complex logistics.

Longer Span & Higher Tonnage

• Example: For a 50-ton double gider crane with a span length of 31 meters, the beam cutting process becomes significantly more complex. The beams are larger, heavier, and require additional reinforcements to ensure structural integrity.
• Result: This increases costs due to the need for more material, labor, and specialized cutting. The transportation and assembly process also becomes more intricate and expensive.

Single Girder Crane (LD, LX, HD, MH)

Double Girder Crane (LH, QD/MG, QDX/MGO)

Price Range Explanation:

Single Girder Cranes (LD, LX, HD, MH): These cranes are generally more affordable due to their simpler design. Prices vary based on tonnage and span length, with smaller tonnages and shorter spans being cheaper. Larger spans and higher tonnages increase costs.

• Low Range ($140 - $220): Typically for small cranes (0.5T - 10T) with shorter spans.
• Higher Range ($220 - $290): For heavier cranes (16T - 20T) or longer spans (31 meters).

Double Girder Cranes (LH, QD/MG, QDX/MGO): Double girder cranes are more complex and require more material and labor to construct, making them more expensive. Prices increase with both tonnage and span length.

• Low Range ($280 - $400): Suitable for smaller cranes (5T - 16T) and shorter spans.
• Higher Range ($400 - $750): Suitable for larger cranes (20T and above) or longer spans (31 meters).

Custom Pricing: For cranes with tonnages over 50T or highly customized designs, pricing will need to be calculated based on specific requirements.

This table should make it easier for you to understand the price ranges for different crane types, tonnages, and spans. Let me know if you need further clarification!

 Overhead crane girder assembled and installed in workshops

Installation: What You Need to Know

Installing long-span cranes, such as box girder cranes or overhead girder cranes, presents several challenges. Here’s a breakdown of what to expect during the installation process:

Challenges of Installing Larger Cranes

Heavier, Bigger Beams

• More Equipment Needed: Larger crane girder beams require specialized equipment like cranes, hoists, and other heavy machinery to lift and position them accurately. These components are far heavier than smaller crane beams, making handling more difficult.
• Skilled Labor: Due to the size and weight, it’s important to have skilled operators who can safely manage the lifting and positioning of these large beams.

Complexity of Installation

• Size and Weight Issues: The installation process becomes significantly more complicated when dealing with larger, heavier beams. Not only do you need the right equipment, but you also need to ensure that each beam is aligned perfectly. Misalignment can lead to operational issues once the crane is in use.
• Precision Matters: Installing the beams with precision is crucial for the overall functionality of the crane. This takes more time and effort, as the crane beams need to be fitted perfectly into place.

Increased Labor Costs

• More Hands on Deck: With larger cranes, more workers may be needed on-site to handle the heavy lifting, assist with the beam installation, and ensure that the crane is put together properly.
• Higher Labor Costs: More workers, longer working hours, and increased complexity all contribute to higher labor costs. This can make installation significantly more expensive for long-span cranes.

Installing long-span cranes with large crane girder beams or box girders is no small task. It requires specialized equipment, skilled labor, and precise planning. As a result, the overall installation process is more time-consuming and costly. Make sure to factor these elements into your overall crane project budget.

Space and Logistics

The amount of space available at your workshop or construction site is a key factor in how smoothly your crane installation will go. Here’s what you need to consider:

Limited Space

• Challenges in Moving and Positioning Beams: If your site is cramped, it becomes much more difficult to move and position large crane girder beams or box girders. Tight spaces often require extra effort to maneuver these heavy beams, which can slow down the installation process.
• Specialized Equipment Required: Limited space may require the use of specialized equipment, such as compact cranes or hoists, to safely move and position the beams. This extra equipment adds to the complexity and cost of the installation.

Complicated Delivery and Assembly

• Multiple Phases for Delivery: In a tight space, you might need to move the crane girder beams or box girders in stages. This can complicate the delivery process, as it may require additional trips or temporary storage before assembly begins.
• Increased Risk of Delays: Limited space can also cause delays in getting the crane up and running. The more careful the movement and positioning, the longer the installation process may take, which could result in extended timelines and higher costs.

Logistics Costs

• Specialized Equipment and Coordination: With tight spaces, there’s a greater need for specialized equipment and more careful coordination to move and install the crane girder beams. These additional requirements contribute to higher logistics costs.
• Increased Labor Effort: The complexity of managing logistics in a constrained space often means more labor is needed to handle the equipment and oversee the installation process, further driving up costs.

Limited space at your installation site creates a range of challenges, from moving and positioning large crane components to coordinating the delivery and assembly process. All of these factors increase installation complexity and logistics costs, so it’s important to plan accordingly and account for these additional expenses when budgeting for your crane project.

Safety and Compliance

When installing crane girder beams or box girders, safety is crucial. Here’s why:

Handling with Care

• Heavy Beams Require Proper Handling: Larger crane girder beams or box girders are extremely heavy and can be easily damaged if not handled correctly. Careful planning and following strict safety protocols are necessary to lift, transport, and install the beams without damaging the equipment or putting workers at risk.
• Safety Measures: Proper lifting techniques and equipment, such as hoists, cranes, and slings, should always be used to ensure a safe working environment during the installation process.

Inspection and Compliance Costs

• Industry Standards: To meet safety and industry standards, your crane installation may require additional inspections and certifications. These inspections ensure that everything from the beam quality to the installation process is in compliance with legal requirements.
• Compliance Costs: Inspections, testing, and certification add to the overall cost of the installation. However, these expenses are necessary to ensure the crane’s safe operation and to avoid potential penalties or accidents in the future.

Ensuring Structural Integrity

• Meeting Standards for Safety: The structural integrity of the crane largely depends on the proper installation of the crane girder beams and box girders. Even a small error during installation can lead to serious issues with the crane’s safety, including failure under load or operational hazards.
• Avoiding Future Problems: Ensuring that all components meet the required standards and specifications from the beginning reduces the risk of structural failures, maintenance problems, or accidents that could be costly and dangerous down the line.

Safety and compliance are integral parts of the installation process for long-span cranes. From handling the beams carefully to passing necessary inspections, ensuring structural integrity is critical for the long-term safety and effectiveness of the crane. Proper planning for these safety measures and compliance costs can help avoid delays and ensure a smooth installation process.

5 Tips to Minimize Costs in Long-Span Girder Crane Procurement

1. Choose the Right Span

Selecting the right span length for your crane is a key decision that directly impacts your costs. Here's how to approach it:

• Match Span to Need: Select a span length that meets your operational requirements without unnecessarily increasing costs. While longer spans offer more flexibility, they significantly raise costs due to cutting, transportation, and installation.
• Balance Cost and Functionality: Avoid choosing a span length that exceeds your operational needs. Opt for a span that allows efficient performance while keeping costs manageable.

2. Consider Pre-Engineered Solutions

Opting for pre-engineered crane girder beams and box girders can save time and money. Here's why:

• Pre-Designed Beams: These are already designed for standard span lengths and proven for typical uses, reducing the need for custom fabrication. This standardization can result in cost savings.
• Less Customization: Choosing pre-engineered beams means fewer customizations are needed, which reduces cutting and material costs.
• Faster Delivery and Installation: Pre-engineered beams often come with faster delivery times and easier installation due to their standard design, making the entire process more efficient.

3. Plan for Efficient Installation

Planning your installation process effectively can result in significant cost savings. Here's how to streamline it:

• Pre-Assembly of Parts: Pre-assemble components before they arrive on-site. This can reduce installation time and the labor required, ultimately lowering installation costs.
• Smooth Logistics: Ensure efficient logistics, especially if space is limited. Coordinating timely deliveries and organizing tasks in the right sequence prevents delays, keeping costs down.
• Coordinated Effort: Having a solid plan ensures all installation tasks are done smoothly, reducing unexpected costs and keeping the project on track.

4. Look Beyond the Initial Price

The upfront cost of your crane girder beams or box girders is just part of the total expense. Here’s what to consider for the bigger picture:

• Total Cost of Ownership: Consider all costs beyond the initial purchase, including cutting, transportation, installation, and long-term maintenance.
• Long-Term Maintenance: Factor in the ongoing maintenance costs, including repairs and replacement parts. Sometimes a cheaper option may come with higher maintenance costs over time.
• Get Comprehensive Quotes: When comparing quotes, ask for a breakdown that includes all associated costs. This ensures you’re comparing the full financial picture, not just the lowest upfront price.

By following these tips, you can make smarter decisions and minimize costs when procuring a long-span crane. From selecting the right span to planning ahead for installation, each step can have a major impact on your overall expenses.

Conclusion

Key Takeaways

In conclusion, the costs associated with beam cutting and installation for long-span cranes, such as box girder cranes or overhead girder cranes, are influenced by several key factors:

• Span Length: Longer spans mean more complexity in cutting, transportation, and installation, driving up the costs.
• Tonnage: Higher tonnage requires stronger and thicker beams, leading to higher material and labor costs.
• Beam Handling: The larger and more intricate the crane girder or box girder, the more specialized the cutting and handling processes, which further increases costs.

To keep your costs in check, here are some actionable steps:

• Collaborate with Suppliers:Work closely with crane suppliers to get an accurate cost estimate and ensure you're getting the best value for your investment.
• Plan Your Span Lengths Carefully:Be mindful of the span length you choose. Only opt for longer spans if absolutely necessary to avoid unnecessary costs.
• Explore Pre-Engineered Options:Where possible, go for pre-engineered crane girder beams or box girders that are designed for standard applications to reduce customization and cutting expenses.
• Consider Total Costs: Don’t just focus on the initial price. Factor in all the additional costs, such as cutting, transportation, and installation, to get the full picture.

Ready to explore further? Contact us for a detailed cost breakdown or to discuss your specific needs for crane girder beams and box girders. We’re here to help you make an informed decision and keep your crane procurement process efficient and cost-effective.