In modern industrial production, the lifting and movement of heavy goods have become easier and more efficient thanks to mechanical equipment—especially overhead cranes used in factories. These cranes help optimize labor productivity while ensuring the safety of both operators and goods during handling.
In this article, KTG Industrial will provide a comprehensive overview of the benefits, structure, and most common types of overhead cranes used in manufacturing facilities today.
What is an overhead crane in a factory?
An overhead crane is a mechanical system installed above the working area, designed to lift and move heavy loads horizontally and vertically within the workspace. This equipment is particularly useful for handling large and heavy items such as steel, concrete, and industrial machinery.
With load capacities ranging from 1 to 500 tons and powered by electric motors, overhead cranes are widely used across various industrial manufacturing sectors. They significantly enhance material handling efficiency and ensure safety during operation.
An overhead crane is a piece of equipment used to lift and move heavy loads within a factory or workshop.
Advantages of using overhead cranes in factories
The application of overhead cranes in factories brings a range of significant benefits, helping businesses optimize production, ensure worker safety, and reduce operational costs. Key advantages include:
- Labor savings: Overhead cranes handle lifting tasks efficiently, significantly reducing the need for manual labor and lowering workforce-related costs.
- Increased productivity: With precise and flexible movement, overhead cranes help shorten handling time, maintain workflow continuity, and improve overall operational efficiency.
- Enhanced worker safety: Designed to meet technical safety standards, overhead cranes minimize the risk of accidents when handling heavy materials, ensuring safer working conditions.
- Cost-effective installation and easy upgrades: The crane’s structure allows for easy installation across various types of factory layouts. Maintenance, replacement, or upgrades can also be carried out quickly when needed.
What types of overhead cranes are used in factories?
There are two main types of overhead cranes commonly used in factories:
Single-girder overhead crane
This is a type of crane with a simple design, featuring a single main girder, usually constructed in a box (assembled) form or as an I-beam. The system includes components such as the main girder, end carriages, hoist for lifting and lowering, power supply systems for both the hoist and crane, control cabinet, and accompanying safety devices.
Single-girder cranes have a lifting capacity ranging from 0.5 to 10 tons, making them suitable for light to medium-duty material handling needs in factories. Thanks to their compact design and space-saving advantages, they are particularly well-suited for production facilities with limited space and moderate scale.
Single-girder overhead crane
Double-girder overhead crane (double girder crane)
This type of crane uses two parallel main girders, typically in a robust box beam form. The system includes a trolley with a hoist that moves along the girders, a maintenance walkway, power supply and control systems, along with specialized safety devices.
Lifting capacity can vary depending on the design—from several tons to over 100 tons. The biggest advantage of a double-girder crane is its ability to handle heavy loads efficiently, with high durability and operational stability. However, it comes with higher initial investment costs and requires more installation space.
This type of crane is commonly used in large-scale factories such as metallurgy, steel manufacturing, industrial packaging, and thermal power plants.
Double-girder overhead crane
What is the structure of an overhead crane in a factory?
- Main girder:
The main girder is the primary load-bearing component of the overhead crane, typically designed as a box girder or using I-beam steel. It also serves as the track for the hoist or trolley to move along. When designing the main girder, it is essential to consider the lifting capacity and the span of the factory to ensure structural rigidity, elasticity, and operational stability.
- End girders (end trucks):
End girders are rectangular box-shaped steel structures, commonly 6 to 10 meters in length. Each end is equipped with a drive mechanism and rubber bumpers to reduce impact when the crane reaches travel limits. The end girders are connected to the main girder using bolts, flanges, or fillet welds depending on the design.
- Wheels:
Depending on the load and span, cranes use wheels of various diameters such as D200, D250, D300, D350, D400, D500, or axle-mounted wheels. These wheels ensure stable and smooth movement.
- Lifting mechanism:
The lifting system may include electric chain hoists, electric wire rope hoists, or trolleys. Chain and wire rope hoists are typically integrated with single-girder cranes, while trolleys are used in double-girder cranes for handling heavier loads.
- Control system:
Overhead cranes can be operated via different methods such as wired pendant control, wireless remote control, or integrated operator cabins—depending on the operating conditions and work environment.
- Crane runway (rails):
The crane operates on specialized steel rails, typically made from standard types such as P11, P15, P18, P24, P30, P38, or P43, selected based on load and system scale.
- Bumpers (shock absorbers):
Bumpers are critical components designed to absorb impact when the hoist or crane reaches its travel limit. Made from engineered rubber, they offer high elasticity and excellent wear resistance. These components come in various sizes and shapes to suit a wide range of operational requirements.
- Travel motors and drives:
The travel system includes the motor housing, gear transmission, electromagnetic brakes, pinion gears, and brake diodes. The crane moves along the rails using four wheel assemblies—each end truck includes one powered and one idle wheel. Motors typically use 3-phase, 380V – 50Hz AC power.
- Electrical system:
There are two main power supply systems: the transverse system for the hoist and the longitudinal system powering the entire crane. This setup ensures continuous and safe operation during all working phases.
General structure of an overhead crane
Operating mechanism of an overhead crane in a factory
The overhead crane system operates based on power transmission from an electric motor to a gearbox via couplings and drive shafts. This setup drives the wheels, which move the entire main girder of the crane along its designed travel path. Simultaneously, the trolley—where the lifting mechanism is installed—moves along a rail system mounted on the main girder.
In certain situations, the braking system is activated to slow down or safely stop the crane’s movement. The entire operation is controlled by a central control system, ensuring synchronized and precise coordination between all electrical and mechanical components of the crane.
What factors should be considered when installing an overhead crane in a factory?
Unlike standard mechanical equipment, overhead cranes are used to lift and move heavy loads within factories. Therefore, the selection, design, and installation of cranes require a high level of technical accuracy to ensure safety, efficiency, and to avoid unnecessary costs. Below are key factors to consider when installing an overhead crane:
Load capacity
Maximum lifting capacity is a critical factor that determines the crane’s technical configuration and overall cost. The greater the capacity, the more complex the structure and the higher the investment. It’s important to clearly define the actual weight of goods and frequency of use to select a crane with suitable power—avoiding both underuse and overload risks.
Span
Span refers to the distance between the two parallel rails, corresponding to the crane’s operational width. A larger span requires more robust steel structures and detailed technical planning, which can increase production and installation costs. Accurately determining the required span early on helps streamline cost estimates and system optimization.
Lifting height
Lifting height (also known as hook travel) influences the selection of the hoist and the required length of chain or wire rope. To ensure efficient operation, installers typically conduct an on-site survey, measuring parameters like column height and roof clearance to recommend the most suitable crane configuration.
Crane runway length
This defines how far the crane will travel along the runway inside the facility. Runway length directly impacts the scale of rail installation, power supply system design, and overall project cost. Providing this specification early to the contractor enables faster and more accurate design and pricing.
Lifting and travel speed of the crane
The lifting and travel speed of an overhead crane is another important factor to consider. Each type of crane can be designed with one or multiple speed settings and may include an inverter (VFD) for flexible speed control based on operational needs. Cranes with higher speeds or more advanced maneuverability often come with higher investment costs.
Installing an overhead crane in a factory involves careful consideration of multiple key factors.
Important notes when operating overhead cranes in factories
During operation, factory overhead cranes may encounter technical issues that affect performance. Therefore, businesses should provide thorough training for workers on safe and efficient crane operation procedures.
Maintaining a regular cleaning and maintenance schedule also helps reduce the risk of equipment failure and extends the crane’s lifespan.
In addition, the lighting system—especially LED lights in the workshop—should be installed below the crane’s travel height and away from its operating range. This ensures adequate lighting is maintained while minimizing the risk of collisions that could damage the lights during crane operation.
Related article: Lighting standards for factory in Vietnam
Installation process of an overhead crane in a factory
To ensure efficient operation, the installation process must strictly follow technical procedures through the following steps:
Step 1: Select the appropriate crane type
Identify usage requirements to choose the right type of crane—single girder, double girder, suspension, semi-gantry, etc.—based on load capacity and working environment.
Step 2: Prepare installation infrastructure
Inspect and complete the rail system, column foundations, and electrical system to ensure compliance with design and safety standards.
Step 3: Fabricate, paint, and prepare components
Fabricate crane parts, apply anti-rust coating, and gather all components and equipment at the construction site.
Step 4: Assemble the mechanical structure
Install the main girder, end trucks, railings, and platforms. Use a crane to lift the entire structure and place it onto the rail tracks.
Step 5: Install the lifting system
Set up the hoist, hook block, conductor rail, and safety components in their designated positions.
Step 6: Install the electrical and control systems
Lay out electrical wiring, mount the control cabinet, and connect the hoist and remote control system.
Step 7: Test run and safety inspection
Perform test runs with and without load, check all functions and safety devices before handing over the equipment for use.
Conclusion
With the information provided above by KTG Industrial, we hope you now have a solid understanding of overhead cranes in factory settings. These cranes are essential equipment across various industrial sectors, especially in facilities that require heavy lifting and material handling.
By understanding the structure, advantages, and different types of overhead cranes, businesses can make informed decisions and select the most suitable solution for their production needs—ultimately improving operational efficiency and optimizing investment costs.
