Custom Design 100 Ton Railway Container Handling Gantry Crane

Product Description

Product Description

Seagull Custom 5-200t Single/double Girder Shipyard Harbour Container Electric Mobile Gantry Crane with Electric Hoist

Gantry cranes are heavy-duty lifting equipment shaped like a "gate," with two legs supporting the main beam. They are widely used in factories, ports, construction sites, logistics warehouses, and other locations. They are primarily used for vertical lifting and horizontal transport of heavy objects, and are a core piece of equipment in industrial production and logistics. From a structural perspective, a gantry crane consists of five core components: First, the main beam, serving as the core load-bearing structure, is typically constructed of box-type steel or truss structures to ensure sufficient strength and rigidity. Second, the outriggers, which come in two types: rigid and flexible, support the main beam and connect to the operating mechanism, ensuring overall stability. Third, the trolley operating mechanism, mounted at the bottom of the outriggers and typically consisting of a motor, reducer, and wheel assembly, drives the equipment longitudinally along the track. Fourth, the trolley operating mechanism, mounted on the main beam track, moves laterally, driving the lifting mechanism to achieve horizontal displacement of the load. Fifth, the lifting mechanism, consisting of a winch, wire rope, and hook (or a grab bucket, electromagnetic suction cup, or other lifting device), is the key component for lifting and lowering heavy objects. Gantry cranes can be categorized by structural type, including single-girder, double-girder, truss, and box-type. based on their mobility, they can be further divided into rail-mounted gantry cranes (operating along fixed rails) and rubber-tire gantry cranes (flexibly maneuverable and adaptable to trackless sites). Different types are suited to varying operating environments and requirements.

Advantages

(1) Strong Load Capacity and Wide Range of Applications

Gantry cranes offer a wide range of load capacities, from 1-5 tons for small equipment to hundreds of tons for large, specialized port equipment. They can meet the handling needs of both light and heavy cargo in diverse scenarios. Whether assembling heavy parts in factories, loading and unloading containers at ports, or transporting rebar and prefabricated components at construction sites, they can operate reliably. Especially for large-span, heavy-load applications, they offer significant advantages over bridge cranes, truck cranes, and other equipment.

(2) High Operational Flexibility and Large Coverage

Rail-mounted gantry cranes can achieve longitudinal coverage of hundreds of meters by extending the track length. The trolley mechanism can move horizontally along the main beam, and combined with the lifting function of the hoist mechanism, this creates a three-dimensional working space with no blind spots. Rubber-tyred gantry cranes, without relying on fixed tracks, are equipped with a steering system, allowing for flexible movement in open areas and adapting to frequently changing temporary work locations (such as construction sites and open-air storage areas), significantly improving operational efficiency.

(3) Reliable Safety and Easy Operation

Modern gantry cranes are generally equipped with multiple safety features, including a lift height limiter (to prevent the hook from over-winching), a travel limiter (to prevent equipment collisions), an overload protection device (to prevent overload damage to the structure), a buffer (to reduce operational shock), and an emergency braking system, effectively mitigating safety risks during operation. The equipment also offers a variety of operating methods, including ground operation (handle control), cab operation (excellent visibility, suitable for complex operations), and remote control operation (suitable for high-risk environments, ensuring personnel safety). The user interface is simple and intuitive, requiring minimal training.

 (4) Convenient Installation and Maintenance, High Cost-Effectiveness
 
Compared to bridge cranes, which rely on plant columns or specialized brackets, gantry cranes require no complex overhead support structures. Installation simply requires leveling the site and laying tracks (for track-based cranes) or directly commissioning the tire travel system (for tire-based cranes), resulting in a short installation cycle and low cost. Regarding maintenance, the neatly arranged layout of its core components (such as the motor, reducer, and wheel assembly) facilitates disassembly, replacement, and maintenance by maintenance personnel. Furthermore, the high commonality of consumable parts reduces maintenance costs. Long-term, the gantry crane has a service life of 10-20 years, and the depreciation costs of the equipment are amortized over daily operations, offering significant cost-effectiveness.

TECHNICAL PARAMETER

DETAIL

(I) Structural Details: Balancing Strength and Lightweight

Main Beam Design: The box-type main beam is constructed from Q345B low-alloy, high-strength steel and formed through CNC cutting and automated welding robots. The welds undergo non-destructive testing (UT) to ensure they are free of defects such as cracks and pores. The truss-type main beam utilizes an optimized member layout to reduce deadweight and lower operating energy consumption while maintaining load-bearing strength. The main beam surface is shot-blasted to Sa2.5 grade, followed by a two-coat anti-corrosion primer and a topcoat. This ensures longevity and withstands harsh environments such as humid, dusty, and salt-spray environments (such as ports and open-air construction sites).
Outrigger Structure: The rigid outriggers feature a box-section and are rigidly connected to the main beam, ensuring longitudinal stability. The flexible outriggers are connected to the main beam via pins, allowing for slight lateral deformation to accommodate track installation errors or ground subsidence, thereby avoiding structural stress concentration. Reinforced ribs are installed at the connection between the bottom of the outriggers and the running mechanism to increase load-bearing capacity. A leveling device is also included, allowing the outrigger height to be adjusted using shims to ensure the main beam is level.

(II) Running Mechanism Details: Stable and Precise

The trolley running mechanism utilizes a "three-in-one" drive unit (motor, reducer, and brake integrated into one unit), boasting a compact size and high transmission efficiency (over 95%). The wheels are forged and tempered from 45# steel (hardness HB220-250), and the wheel treads are precision-ground for smooth contact with the rails and minimal wear. The brake utilizes electromagnetic power-off braking, instantly engaging upon power failure. This results in a short braking distance (≤0.5m at a speed of 10m/min), ensuring precise stopping of the equipment. Trolley Operating Mechanism: The trolley frame utilizes a lightweight steel structure and is equipped with a high-precision planetary reducer, ensuring smooth and impact-free transmission.

The trolley wheels utilize polyurethane-coated wheels (or steel wheels). Polyurethane wheels reduce wear on the main beam rail and lower operating noise (≤70dB), while steel wheels are suitable for heavy-load applications. The trolley is equipped with a variable frequency speed control system, enabling stepless speed adjustment from 0.5-10m/min to meet varying operating tempos.

(III) Safety and Control Details

Safety Protection: In addition to basic limit and overload protection features, some high-end equipment also features a wind speed sensor (which automatically alarms and shuts off power when wind speeds exceed 15m/s), an anti-sway device (using hydraulic or electronic control to reduce hook swing amplitude to ≤5%), and a video monitoring system (for real-time monitoring of the hook operating area to avoid blind spot collisions). The electrical system utilizes a waterproof and dustproof design (with an IP54 protection rating) to prevent dust and rain intrusion and potential malfunctions. Control system: Utilizes a PLC programmable controller (PLC) with self-diagnosis (automatically displays fault codes when a fault occurs, facilitating quick troubleshooting). The ergonomically designed operating handle is comfortable to hold, with a strategically arranged button layout, enabling single actions (such as lifting or trolley operation) or combined actions (such as simultaneous lifting and trolley operation). Remote control utilizes 2.4G wireless communication, offering a control range of up to 100 meters and stable, latency-free signals, making it suitable for high-risk operations.

Project Cases

Customization Solutions

Gantry crane customization is based on the user's specific operating scenario, load requirements, site conditions, and other factors. We provide a comprehensive service process, encompassing "demand analysis - solution design - manufacturing - installation and commissioning - and after-sales training." Typical customization options are as follows:

(I) Industry-Specific Customization

Port Container Customization: To meet the needs of port container loading and unloading, we offer custom double-girder gantry cranes with girder spans of 20-40 meters (accommodating 2-4 containers stacked side by side), lifting heights of 12-18 meters (accommodating 3-5 stacking of containers), and lifting capacities of 40-80 tons (accommodating 20-foot and 40-foot containers). These cranes are equipped with specialized container spreaders (with twist-lock devices for quick container locking) and boast trolley speeds of 30-40 meters per minute, improving loading and unloading efficiency. Furthermore, these cranes are treated with salt spray corrosion protection (surface sprayed with fluorocarbon paint and electrical components with anti-corrosion sealing) to adapt to port and coastal environments. Customization for Construction Sites: Targeting the irregular terrain and flexible work locations of construction sites, we offer custom rubber-tyred gantry cranes. These cranes utilize off-road tires (suitable for gravel and dirt surfaces), have a lifting capacity of 10-30 tons, a lifting height of 8-12 meters, and a main beam span of 12-18 meters. They are equipped with foldable outriggers (which reduce their size for transport and facilitate relocation), a diesel generator (which allows for independent operation without an external power source), and wireless remote control, allowing workers to flexibly control the crane within the construction area.

Customization for Factory Workshops: Targeting the assembly of heavy equipment within factories, we offer custom single-girder gantry cranes with a main beam span of 8-15 meters, a lifting capacity of 5-50 tons, and a lifting height of 6-10 meters. The trolley is equipped with a precision variable frequency speed control system, achieving a positioning accuracy of ±5mm, meeting the precise alignment requirements of equipment assembly. Furthermore, the outrigger height is optimized to avoid conflict with the factory building's roof structure, based on workshop height restrictions. The electrical system is compatible with the factory power grid (e.g., 380V/50Hz three-phase five-wire system) to ensure stable power supply.

(II) Customization for Special Functions
 
Customization for Low-Temperature Environments: We offer custom low-temperature gantry cranes for operations in cold regions. Core components (motor, reducer, hydraulic system) are constructed of low-temperature-resistant materials (capable of normal operation in temperatures between -30°C and -40°C). Lubricants are specialized low-temperature oil (freezing point ≤ -45°C). The cab is equipped with a heating system, and operating handles are fitted with insulation covers to ensure stable operation in low temperatures.
Customization for Explosion-Proof Environments: We offer custom explosion-proof gantry cranes for explosion-proof environments such as the chemical, oil and gas industries. Electrical components (motor, controller, and buttons) utilize Ex d IIB T4 Ga explosion-proof design to prevent sparks. The hoisting mechanism utilizes non-sparking steel wire rope (galvanized), and the wheels are made of copper alloy to prevent sparks from friction. Static-prone paints are prohibited from being applied to the equipment surface to ensure safe operation in flammable and explosive environments.

(III) Customized Service Process
 
Requirements Communication: The technical department will develop a requirements list based on the user's core requirements, including lifting capacity, lifting height, span, operating speed, site dimensions, environmental conditions (temperature, humidity, corrosiveness, etc.), and industry-specific requirements (such as explosion-proof and container-specific).

Scheme Design: based on the requirements list, structural calculations (using finite element analysis software to verify the strength and rigidity of the main beam and outriggers) and 3D modeling (using software to visualize the equipment's appearance and structural details) are performed. A technical plan is then developed, including equipment parameters, structural drawings, safety protection configurations, and a price list. The plan is then optimized after confirmation with the user.
Manufacturing: Raw materials are procured according to the confirmed plan (including steel, motors, and reducers that meet national standards). Production is carried out using CNC machining equipment (CNC cutting machines, welding robots, lathes, etc.). Quality inspections are conducted at each process (such as steel material testing, weld flaw detection, and component dimensional inspections) to ensure that the product meets design requirements. Installation and Commissioning: Depending on the customer's country and region, if a professional installation team is available, we will arrange on-site installation. We will lay the track (for track-based installation) or commission the tire-based travel system (for tire-based installation), depending on site conditions, and install the electrical system and safety devices. After installation, we will conduct no-load commissioning (to test the smooth operation of various mechanisms) and full-load commissioning (to simulate actual operating scenarios and test load capacity and accuracy) to ensure that all equipment performance meets specifications. If a professional installation team is not available, we will provide a detailed installation guide and online installation guidance until the equipment is installed.

After-sales Training and Service: We provide user operators with operational training (covering equipment operation, safety precautions, and common troubleshooting), as well as operating and maintenance manuals. We will establish an after-sales record, provide a one-year free warranty (free repairs and replacement of parts during the warranty period), and lifetime technical support (regular on-site inspections and spare parts supply services).

Established in 1986, Changshu Seagull Crane&Hoist Machinery Co., Ltd. is a leading manu-facturer of lifting tools and equipments, including hand chain hoists, lever hoists, electric hoists, lifting clamps and more. With ISO9001:2015certification and TUV CE/GS approvals, we ensure top-quality products for global markets like the USA, Germany, Japan, and others. As a trusted OEM partner for international brands, we export 95% of our products worldwide. Our advanced testing facilities and strict quality control guarantee reliable performance. Over 50% of our clients have collaborated with us for more than 10 years, thanks to our consistent quality and excellent service.
SEAGULL is your reliable partner for innovative lifting solutions.