What is an Overhead Crane?

Overhead cranes are transport equipment used for material handling, especially in large industrial plants, steel production centers, workshops and storage areas. The most distinctive feature of these cranes is that they move on long concrete columns or metal frames with two lanes. Thanks to this structure, it is known as "traveling bridge crane".

Overhead cranes can be used in various sectors thanks to their different lifting capacities and flexible designs. These cranes, which can work efficiently both indoors and outdoors, are indispensable for jobs that require especially heavy loads.

Overhead Crane (Overhead Travelling Crane)

Overhead cranes are powerful lifting systems that can safely carry loads weighing tons in large working areas. By moving on a fixed mechanism, it provides easy and efficient relocation of materials. Widely used in industrial installations, they are also known as overhead cranes.

How is an Overhead Crane Made?

The production of overhead cranes starts with detailed analysis according to the brands. General design drawings are created by taking into account the measurements in the project, the intended use and the customer's demands.

Overhead cranes (overhead cranes) are built on steel construction bridges and designed for L/1000 deflection. The manufacturing process is determined according to FEM/ISO standards according to the working conditions of the crane and production varies according to these times.

Lftkon Crane develops its designs with R&D and project teams consisting of engineers from the region. In addition to standard crane solutions, components are also offered on a custom basis.

Overhead Crane Design Stages

Key steps to consider when designing an overhead crane:

• Requirements Analysis: Critical factors such as the maximum weight the crane must lift, the distance it must travel and the environment in which it will operate are determined. In this way, the most suitable crane type and capacity are clarified.
• Calculation of Load Factors: The lifting capacity of the crane is calculated, taking into account both current and possible future loads. This ensures that the system is reliable and long-lasting.
• Selecting the Crane Type: Depending on the needs of the business single girder, double girder or gantry crane the appropriate type of overhead crane is determined. Each option is optimized according to the load handling requirements of the operation and the site conditions.
• Determination of Span and Runway Length: The distance between the support structures is measured to determine the span and runway length over which the crane will move. In this way, the crane is designed to fully adapt to the operation area.
• Selection of the Lifting Mechanism: Suitable for load capacity, lifting speed and operation precision lifting motor and trolley system is selected. The right equipment is used for efficient and controlled operation.
• Calculation of Structural Requirements: The materials and dimensions of load-bearing components such as crane beams, columns and runway beams are determined to ensure that the structure can safely carry the expected loads.
• Adding Security Features: System, limit switches, overload protection, emergency stop buttons and precision control panels such as advanced security measures. User safety is maximized.
• Design of Electrical and Control System: Vincin precise and smooth movement motor types, control panels and cabling are optimally designed. Depending on the automation requirement, remote control or manual operation options are integrated.
• Regulatory Compliance and Consultancy: The entire design and production process, national and international security standards is realized accordingly. Our expert engineers advise businesses to provide the best solution.
• Production, Installation and Testing: Once the design is approved, the crane components manufactured and assembled in accordance with high quality standards. Our professional team meticulously installs and verifies the safe operation of the system through extensive testing.

 

Bridge Crane Lifting Capacities

Our double girder overhead crane models offer a standard lifting capacity of 1 ton to 80 tons, while our single girder models have a lifting capacity of 1 ton to 32 tons. Our products are manufactured with domestic and imported solutions in accordance with FEM, DIN and TSE/EN compliance; They are designed to reach the desired extension distances with single speed, double speed or stepless speed options.

Multiple lifting groups can be integrated on the same cranescape, and fixed auxiliary lifting group solutions are also available in addition to the main grouping.
Overhead cranes manufactured with standard rope lifting group can be manufactured with chain lifting group according to customer demands.
In standard tonnage cranes, crane bridge girders are manufactured from box-ended constructions, while standard profiles are preferred in lower tonnage models.

Overhead Crane (Overhead Crane) Types

Our overhead cranes are divided into two main categories:

• Double Beam Models: It is preferred for installations with long bridge axle spans and offers large turning capacities.
• Single Beam Models: The bridge is used in areas where the wheelbase is short. These models can also be referred to as monorails and are supported by cantilever type options that take advantage of space.

In accordance with the customer, our gantry cranes can be produced in 6 directions in 3 axes, with the desired lifting distances and speed step settings or stepless speed options.
In addition, these cranes are equipped with the possibility of remote control in technological developments, providing high load carrying and movement lifting capacity thanks to the use of all-steel material.
While the remote control feature increases the professionalism in the working environment; Thanks to the instant brake system, safe operation and functionality come to the fore.

What is Guse?

Guseis a support, also called short cantilever, designed to support the rail system on which cranes operate. It is generally used in industrial areas such as factories, production facilities and structures with heavy loads. This support increases the stability of the crane system by being placed at the junction of two beams.

If there is not enough working space between the roof truss and the crane, single girder overhead cranes are preferred. In addition, our bottom-hung type single girder cranes move under the crane walkway, taking up less space on site and offering an economical solution in applications with high lifting requirements.

The standard lifting capacity of our double girder overhead cranes ranges from 1 ton to 80 tons and from 1 ton to 32 tons for single girder models. Our products are offered with control type pendant button control, remote control and optional cabin controlled options.

 

How to Install an Overhead Crane?

The process of installing an overhead crane consists of several steps that need to be carefully planned and implemented by specialized teams.

Here is a general installation guide:

1. Assess the Requirement:
   • Basic parameters such as the lifting capacity, span and height needed for the crane are determined.
   • The building structure, available load capacity and special requirements are taken into account.
2. Expert Collaboration:
   • It is important to work together with structural engineers for site assessment, proper design and implementation.
   • Consultancy should be obtained from professionals such as lıftkon Crane who are experts in their field.
3. Connect with Professionals:
   • All necessary permits and approvals are obtained to ensure compliance with local regulations and building codes.
4. Get the Necessary Permissions:
   • Make sure that the area where the crane will be installed is clean, flat and organized in a way that does not interfere with crane movements.
   • The ground must be strong enough to support the weight of the crane.
5. Prepare the Field
   • The runway beams, columns and brackets to support the crane are placed and fixed in accordance with engineering calculations.
6. Assembly Operations:
   • The main beam, trolley, crane and other components are assembled in accordance with the manufacturer's installation instructions.
   • With the use of the right tools and equipment, a robust installation is realized.
7. Electrical and Mechanical Connections:
   • The electrical cables and control elements required for the operation of the crane system are meticulously connected.
   • Additional mechanical and electrical safety equipment such as limit switches, anti-collision sensors are installed.
8. Load Tests and Inspections:
   • Once the installation is complete, detailed load tests are carried out to ensure safe and efficient operation of the crane system.
   • In case of any defects or incompatibilities, necessary corrections are made.
9. Training and Certification:
   • Crane operators receive detailed training on the use of the system.
   • If necessary, certification of operators is ensured.

At every step of the installation process, it is of utmost importance to comply with safety standards and manufacturer's instructions. For this reason, getting support from professionals such as Lıftkon Crane, who are experts in their field in complex installation processes, provides both a safe and efficient working environment.

Types of Overhead Cranes

 

Single Girder Overhead Cranes

Single girder overhead cranes offer lifting capacities from 1 ton to 32 tons as standard.

These models are manufactured in accordance with FEM, DIN and TSE/EN norms and are designed with single speed, double speed or stepless speed options to reach the desired lifting heights.

• Area of Use:
  Preferred for installations with short bridge spans, single girder models offer an ideal solution, especially when there is not enough space between the Guse and the roof truss.
• Monorail Crane :
  Single girder cranes are also referred to as "monorail cranes". In this system, more than one lifting group can be located on the same crane bridge or fixed auxiliary lifting group solutions can be integrated in addition to the main lifting group. In addition to the use of rope hoists as standard, chain hoist options are also available according to customer requirements.
• Single Girder Overhead Crane Features:
  • Lifting capacity: 1-32 tons.
  • It is suitable for use in both indoor and outdoor areas of industrial facilities.
  • Suitable for below-the-hook equipment integration.
  • It has a lighter structural feature compared to double beam models.
  • Loadcell support is required for overload protection.
  • Economical, reliable and efficient solution for handling and stacking
• Control Options:
  Standard cable control and radio frequency remote control technologies are also used in these crane models.

Double Girder Overhead Cranes

                                                                                                    
Double girder models have a standard lifting capacity from 1 ton to 80 tons and are manufactured in accordance with international norms such as FEM, DIN, TSE/EN.

• Area of Use:
  These cranes, which are preferred in facilities where the bridge axle span is wide, can be applied with more than one lifting group on the same crane bridge, as well as offering fixed auxiliary lifting group options to the main lifting group.
• Installation and Maintenance Advantages:
  Thanks to the maintenance platform on the crane bridge, both assembly and periodic maintenance operations are easier.
• Highlights:
  • Lifting capacity: 1-80 tons
  • Especially ideal for facilities with large axle spans
  • Possibility to design below-the-hook equipment according to your process
  • Loadcell integration for overload protection
  • Improved ease of maintenance and installation
  • Higher lifting height and capacity than overhead cranes

 

Cantilever Type Overhead Cranes

Cantilever type cranes offer significant advantages in terms of the width of their area of use. Thanks to their one-sided walkways, they provide the opportunity to work without occupying space in other areas and are usually positioned under overhead crane systems.

• Production and Technology:
  Lftkon Crane manufactures cranes with high working class and long service life by using world-class production technologies in industrial cantilever crane systems. Cantilever crane solutions are applied in many sectors such as machine manufacturing, mold, metal, marble, chemical, energy, construction, casting, shipyard.
• Production Process and Features:
  In the production process, all stages from the smallest part to the final product are designed and manufactured by Lıftkon Crane and supported by comprehensive service. In the design of cantilever type overhead cranes, the required FEM/ISO values are determined according to the working conditions of the enterprise. The bridge traveling group can be manufactured as double girder or single girder (monorail). Although cable control is standard in the system, radio frequency remote control option is also available. Safety equipment such as limit switch, overload sensor, light and audible warning are standard in all systems.

Overhead Crane Maintenance:

Regular maintenance is essential for the smooth, safe and efficient operation of overhead cranes. You can find some basic steps to be considered in the maintenance process below:

1. Establish a Maintenance Program:
2.  Establish a detailed program specifying each maintenance activity and the frequency of checks. This program should cover regular inspection, lubrication and periodic maintenance.
3. Perform a Visual Inspection:
   Periodically inspect all components on the crane. Look for potential problems such as worn or loose bolts, damaged cables or wires, worn parts, etc.
4. Lubrication Operations:
   Regular lubrication of moving parts in the crane, such as bearings, gears and chains, with lubricants recommended by the manufacturer helps to reduce friction and prevent premature wear.
5. Control of the Electrical System:
   Verify that electrical components such as control panels, cables and connections are in good condition. Checking for loose connections or signs of overheating can prevent malfunctions.
6. Perform Load Tests:
   Conduct regular load tests to verify that the crane capacity and performance are operating as expected. Evaluate the response and stability of the system by testing with a known load.
7. Inspect Safety Equipment:
   Test safety devices such as limit switches, emergency stop buttons and overload protection systems for correct operation and calibrate them if necessary.
8. Rope and Cable Inspection:
   Wire ropes or cables used in the crane should be checked regularly for wear, breakage or damage. Replacing damaged parts immediately prevents accidents.
9. Provide Documentation:
   Keep detailed records of all maintenance, inspections, repairs and modifications. This documentation allows you to track maintenance history and serves as a reference for solving future problems.
10. Staff Training and Expertise:
    Make sure maintenance teams are familiar with the procedures for overhead cranes. If necessary, seek the support of specialized companies for special maintenance operations or repairs.
11. Compliance with Standards and Regulations:
    During crane maintenance operations, make sure that the safety standards and regulations applicable to your industry or region are strictly followed.

Overhead crane maintenance requirements may vary depending on the model and type used. It is important to act in accordance with detailed instructions and manufacturer's guidelines.

Where is Bridge Crane Used?

Double and single girder overhead cranes are preferred in many areas such as iron and steel plants, foundries, steel mills, shipyards, mines, ports and railway stations as well as industrial production facilities. Thanks to the developing technology, stainless steel or aluminum body models are also included in our production in accordance with the requirements of sterile environments. In this way, it can be used safely in areas such as pharmaceutical, food and meat integrated facilities.

• Areas of Use:
  • Iron and steel plants
  • Foundries
  • Steelworks
  • Shipyards
  • Mine sites
  • Ports
  • Railway stations
  • Food production facilities

Overhead Crane Pricing

Prices of overhead cranes vary depending on features such as lifting capacities, axle span and lifting height. Different pricing models are applied according to the technical specifications of the cranes. To access price information and get a detailed offer liftkon.com.tr/ you can reach from our website.

How Does an Overhead Crane Work?

Overhead crane systems can be controlled by the operator and can move in 3 axes - forward, backward, right, left, up and down - in a total of 6 directions on the rails on which they are mounted. This system is suitable for different applications with its single or double rail operation feature.

• Basic Components and Functioning:
  • Monorail System: It allows small loads to be transported on a single rail, while components such as the main winch motor, hook block, sub-assemblies and groupings facilitate load handling.
  • Electronic Control The electronic system sets the crane in motion, while the remote control provides load guidance and motion control.
  • Cab/Wireless Controller: The control levers in the cabin of cranes offer ease of use with wired control or wireless remote control options.
  • Load Lifting Mechanism: Loads lifted using steel ropes can change direction thanks to pulleys. Hook blocks are designed to carry the load safely.
  • Sling and Fasteners: The sling from which the load is suspended has a certain capacity depending on the knotting pattern and the arm angle. The harmonized use of fasteners such as cross bars, clamps, sling rings, etc. ensures that the load is transported safely and to the right place.

Overhead Crane (Overhead Crane) Transfer Process

After the production stages of overhead cranes (overhead cranes) are completed, the process of placing the crane on the truck for transfer begins.

• Loading and Transportation:
  Loads exceeding 12 meters in length and 2.5 meters in width may be transported using trucks with extended trailers or lowbed type vehicles, after obtaining the necessary special road permits.
• On-site Download:
  At the arrival point, the crane is lowered to the holding area to be used with the help of a mobile crane and a hyap crane.
• Installation:
  Lftkon Crane's experienced technical team ensures that the crane is positioned correctly on the rails after the transfer. During this process, occupational health and safety (OHS) measures are meticulously supervised by Lıftkon Crane representatives and customer officials.

Overhead Crane (Overhead Crane) Operating Instructions

The following operating instructions must be followed for safe and efficient operation of the cranes:

• Pre-Operation Controls:
  • Before using the crane, make sure that no one is present in the working area; if visibility is limited, an observer must be present.
  • The strength of the ropes should be checked and the connection between the rope and the hook should be examined. Do not work with deformed ropes.
  • Check that the rope is properly seated on the drum bearings; observe the functioning of the brakes by lifting the load about 5-10 cm.
  • The normal operation of the crane should be verified by running it idle.
• Control and Movement Instructions:
  • When pressing the lift button, the lower button must not be pressed at the same time.
  • It should be noted that the crane hook is at the exact center of the load to be lifted.
  • In forward-backward, right-left movements, buttons in opposite directions should not be pressed at the same time.
  • The emergency stop (red button) must be switched off after use and normal operation resumed.
• Cargo Transportation and Unloading Rules:
  • The cranes must not touch each other, and care must be taken to ensure that the lifting drum does not hit its own drum.
  • In the event of any malfunction, the operator must not attempt to intervene, but must immediately report the situation to the Electrical or Maintenance group.
  • Loads must be lifted and lowered vertically; pulling loads is prohibited.
  • Check that the load to be lifted is completely free and make sure that no one is under it during lifting.
  • Carrying people with cranes should be strictly prohibited; unauthorized access to the work area should not be allowed.
  • Necessary safety precautions (e.g. safety latch on the hook) must be taken to ensure that loads are lifted evenly and slings do not slip off the hook.
  • Loads that cannot be lifted with a sling should be transported using a special basket or special hook.
  • In transportation, assembly and disassembly operations with the crane vehicle, the crane must not be moved without the instruction and sign of the responsible personnel.
  • Loads of unknown weight must never be loaded or lifted by the crane.
  • During lifting, it must be checked that the hook moves vertically in all directions; excessive sideways movements must not be allowed.
  • Once the load is suspended, the crane must not be abandoned and the lifted load must not be kept suspended for a long time.
• Environmental and Emergency Measures:
  • Work should not be carried out if the wind speed exceeds 30 km/h.
  • Personal protective equipment such as hard hats, gloves, boots, steel-toed shoes and overalls must be used in all operations.
  • It must be ensured that the light signal and audible warning systems are in working condition.
  • No person other than the operator should use the crane.
  • Periodic maintenance and control periods must be ensured to be fulfilled completely.
  • In non-dusty environments, it is important to check that the ropes are greasy, this is important for safety.
  • In the event of a malfunction, personnel carrying out repair or maintenance must take all necessary precautions by obtaining a hot permit and reading the instructions for working at height.
  • Protective equipment on the machine must never be removed.
  • In case of any emergency, the nearest authority must be notified immediately.

Liftkon increases the productivity of businesses by offering innovative and reliable systems in industrial lifting solutions. Thanks to its solutions integrated with overhead crane systems, it optimizes production processes by ensuring safe and precise handling of heavy loads.

Crane systems equipped with modern technology stand out with their durability and long-lasting use. Liftkon's specially designed overhead cranes facilitate operational processes by providing maximum performance and safety for factories, logistics centers and industrial facilities.