1. Boom in Infrastructure Projects Driving Demand for Advanced Lifting Solutions

The Indian government’s push for infrastructure development is fueling the demand for heavy-duty cranes and hoists. The Smart Cities Mission, with a budget of Rs 100 lakh crore, aims to develop 100 smart cities across India. These projects require cranes for tasks like building construction, bridge erection, and laying pipelines. Similarly, dedicated freight corridors spanning thousands of kilometers necessitate a robust fleet of cranes for track laying and maintenance.

The renewable energy sector is another key driver. India has set an ambitious target of achieving 450 GW of installed renewable energy capacity by 2030. This translates to a massive increase in wind farms and solar parks, which require cranes for installing turbines and solar panels. According to a report by Allied Market Research, the global mobile crane market is expected to reach a value of USD 22.47 billion by 2027, and India is expected to be a major contributor to this growth.

2. Focus on Safety and Efficiency: Technological Advancements

With the rise of large-scale projects and the increasing emphasis on worker safety, hoist and crane manufacturers in India are incorporating advanced technologies. Telematics, which involves integrating data from sensors with cloud-based platforms, is playing a crucial role. Sensors on cranes can monitor factors like load weight, wind speed, and equipment health. This data is transmitted wirelessly, allowing for real-time remote monitoring and preventive maintenance. This not only reduces downtime but also helps prevent accidents by identifying potential issues before they escalate.

There’s also a growing adoption of electric and hybrid cranes.  A report by Mordor Intelligence suggests that the Asia Pacific electric hoist market will witness a Compound Annual Growth Rate (CAGR) of 5.2% during 2020-2025. These cranes offer significant advantages over traditional diesel-powered models. They produce lower emissions, making them ideal for indoor applications and environmentally sensitive projects. Additionally, electric cranes have lower operating costs due to reduced fuel consumption and maintenance needs.

Advanced safety features are becoming an essential part of modern cranes. Anti-collision systems use sensors and cameras to prevent cranes from colliding with each other or with obstacles. Load limiting devices ensure that cranes don’t exceed their safe lifting capacity, preventing accidents and equipment damage.

3. Localization and Make in India Initiative

The Indian government’s Make in India initiative is encouraging domestic production of cranes and hoists. This initiative aims to reduce dependence on imported equipment and boost local manufacturing capabilities.  The government has introduced various policies, including tax breaks and subsidies, to incentivize domestic production. This creates a significant opportunity for Indian hoist and crane manufacturers to cater to the growing demand within the country.

Localization also fosters skill development in the crane and hoist sector. By manufacturing cranes in India, there’s a need for skilled professionals who can design, fabricate, operate, and maintain these complex machines. This not only creates job opportunities but also ensures a skilled workforce that can meet the evolving needs of the industry.

4. Emerging Rental Market and Rise of Flexible Ownership Models

The traditional model of owning cranes and hoists might not be feasible for all construction companies, especially smaller ones. This has led to the emergence of a robust crane and hoist rental market in India. Companies can now rent cranes and hoists for specific projects, eliminating the need for large upfront investments and the burden of storage and maintenance. This flexibility allows construction companies to optimize their budgets and access the latest equipment for specific lifting needs.

The rise of online rental platforms is further streamlining the rental process. These platforms connect construction companies with crane and hoist rental providers, making it easier to find the right equipment at competitive rates. With the increasing popularity of online platforms, the crane and hoist rental market in India is expected to grow significantly in the coming years.

5. Data-Driven Design and Customization for Enhanced Performance

The future of crane and hoist manufacturing lies in data-driven design and customization. Manufacturers are increasingly using big data to analyze operational data from existing cranes. This data helps them understand how cranes are being used, identify areas for improvement, and optimize crane design for better performance and efficiency.

Customization is another key trend. Gone are the days of one-size-fits-all cranes. Today, manufacturers are offering cranes and hoists tailored to specific site and lifting requirements. This can include factors like

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This article explores five key quality control techniques that Indian hoist crane manufacturers can implement to guarantee flawless production and deliver equipment that meets the highest safety standards.

1. Building a Robust Quality Control Framework (QCF) for Cranes and Hoists in India

A robust Quality Control Framework (QCF) serves as the foundation for achieving flawless crane and hoist production. Here’s why it’s particularly important in the Indian context:

Stringent Safety Regulations:

 India enforces strict safety regulations for lifting equipment, as outlined by the Bureau of Indian Standards (BIS) and the Directorate General of Factory Advice and Boiler Plants (DG-FABP). A strong QCF ensures compliance with these regulations, minimizing legal liabilities for manufacturers.

Focus on “Make in India”:

 The Indian government’s “Make in India” initiative emphasizes domestic manufacturing of high-quality equipment. A well-defined QCF allows manufacturers to demonstrate their commitment to quality and compete effectively in the global market.

Developing a QCF involves several key steps:

Alignment with Indian Standard (IS) Codes:

 Several IS codes define specific requirements for cranes and hoists, such as IS 1878 (Specification for Electric Overhead Travelling Cranes), IS 2147 (Specification for Wire Ropes), and IS 3002 (Code of practice for Erection of Cranes and Hoists). The QCF should ensure adherence to these relevant codes.

Integration Throughout Manufacturing:

 Quality control shouldn’t be an isolated activity. The QCF should integrate seamlessly into every stage of the manufacturing process, from raw material procurement to final testing. This allows for early detection and rectification of potential issues.

2. Implementing Effective Inspection Techniques

Inspections are crucial for identifying and eliminating defects at various stages of production. Here are some key inspection techniques:

Pre-production Material Inspection:

 Before entering the production line, raw materials like steel plates and wire ropes undergo rigorous inspection. This includes checking chemical composition, mechanical properties, and manufacturer certifications to ensure they meet the required specifications. Statistics from the Central Institute for Research on Cotton Textile (CIRCOT) indicate that a staggering 20% of textile machinery failures can be attributed to poor-quality raw materials. Implementing robust pre-production inspection can significantly reduce this risk in crane and hoist manufacturing as well.

In-process Inspections: 

Throughout the production process, components like welds and fabricated sections are meticulously inspected. Weld quality is critical for crane and hoist structural integrity. Visual inspections, along with techniques like Ultrasonic Testing (UT) and Radiographic Testing (RT), ensure welds meet the highest standards.

Final Assembly and Load Testing:

 Once assembled, the complete crane or hoist undergoes comprehensive load testing. This verifies its ability to safely handle the rated lifting capacity. Failing to conduct proper load testing can have disastrous consequences. A study by the National Safety Council of America (NSC) revealed that overloading is a major factor in crane accidents. Stringent load testing within the QCF helps prevent such incidents.

Non-Destructive Testing (NDT) Methods: 

NDT techniques like UT and Magnetic Particle Testing (MT) are employed to assess critical components for hidden defects without causing damage. This ensures the internal integrity of crucial parts like hooks and shafts.

3. Leveraging Technology for Improved Quality Control

Technology offers powerful tools to enhance the effectiveness of quality control practices:

Computer Aided Design (CAD) Software:

 Utilizing CAD software allows for the creation of detailed digital models of cranes and hoists. These models facilitate design verification, enabling engineers to identify and rectify potential issues before physical production begins. Studies by the Aberdeen Group show that companies leveraging CAD experience a 30% reduction in engineering errors.

Automation in Welding and Assembly:

 Integrating automation in welding and assembly processes minimizes human error and ensures consistency in critical operations. This translates to higher quality welds and a more uniformly assembled final product.

Digital Data Collection and Reporting:

 Implementing digital systems for collecting inspection data and generating reports streamlines the QCF process. This improves traceability, allowing manufacturers to track materials, inspections, and test results for each crane or hoist.

Exploring 3D Printing for Prototyping and Quality Checks:

 3D printing technology has the potential to revolutionize prototyping for cranes and hoists. Creating 3D-printed models allows for early assessment of designs and identification of potential assembly or functionality issues before large-scale production commences

4. Skilled Workforce and Training for Quality Assurance

A well-trained and qualified workforce is essential for upholding high quality standards. Here’s how to empower your team:

Welder Certification and Inspector Training:

 Welders play a critical role in crane and hoist construction. In India, welders must be certified by organizations like the Welding Research Institute (WRI) or the Society for Non-Destructive Testing (SNDT). Similarly, inspectors require training in relevant inspection techniques and adherence to IS codes. Investing in such certifications and training programs ensures a skilled workforce capable of consistently delivering high-quality work.

Continuous Improvement Programs: 

The quality control landscape is constantly evolving. Implementing continuous improvement programs for quality control personnel keeps them updated on the latest inspection techniques, industry best practices, and advancements in technology. This ensures their skills remain sharp and adaptable to changing requirements.

Culture of Quality Awareness: 

Fostering a culture of quality awareness among all employees is vital. This can be achieved through regular training sessions, communication campaigns, and employee incentive programs that recognize and reward a commitment to quality. When everyone takes ownership of quality, the entire manufacturing process benefits.

5. Maintaining Documentation and Records for Traceability

Comprehensive Documentation:

 Every crane and hoist should have a dedicated file containing material certificates, inspection reports, and test results. This documentation serves as a historical record, providing valuable information in case of future reference or warranty claims.

Data Security:

 With the increasing use of digital data collection, ensuring robust data security protocols is essential. This protects sensitive information from unauthorized access or manipulation.

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Understanding Your Needs:

Load Capacity:

 This is the most crucial factor. Identify the heaviest load you plan to lift and add a 10-15% buffer for unforeseen situations. According to the Indian Steel Association, the Indian steel sector alone produced over 118 million tonnes of crude steel in 2023, highlighting the need for robust cranes in numerous industries.

Lift Height and Reach:

 Determine the maximum vertical distance (lift height) and horizontal coverage (reach) required for your lifting operations. Consider future expansion plans that might necessitate a larger range of movement.

Frequency of Use:

 Cranes are categorized based on duty cycle, which refers to the percentage of time the crane is operational in a given period. Here’s a breakdown to help you choose:

Light Duty (Class A):

 Up to 20% usage, ideal for occasional lifting tasks.

Moderate Duty (Class B):

 20-40% usage, suitable for regular lifting in production environments.

Heavy Duty (Class C):

 40-50% usage, designed for frequent lifting of moderately heavy loads.

Severe Duty (Class D):

 Over 50% usage, ideal for continuous lifting operations in demanding environments.

Facility and Application Considerations:

Building Infrastructure: 

Evaluate your building’s ceiling height, support structures, and available space for crane installation. Ensure your chosen crane’s weight doesn’t exceed the building’s load-bearing capacity.

Work Area Layout: 

Identify any potential obstructions in the workspace, such as pillars, machinery, or uneven floors. The crane’s movement shouldn’t be hindered by these obstacles.

Specific Industry Requirements: Consider factors specific to your industry. For instance, if you work in a food processing plant, you might need a crane made from corrosion-resistant materials to withstand frequent washdowns. Similarly, explosive environments might necessitate specialized cranes with explosion-proof features.

Hoist Selection:

The hoist is the lifting mechanism attached to the crane. Here’s what to consider:

Power Source:

 Choose between electric hoists, the most common and versatile option, or manual hoists (chain or ratchet) for lighter loads and situations with limited power access. Pneumatic hoists are another option for specific applications.

Hoist Line Material: 

The line material, typically wire rope or chain, should be chosen based on weight capacity and durability. Wire rope offers superior strength for heavy loads, while chain hoists are more compact and cost-effective for lighter loads.

Lift Speed: 

Select a hoist speed that optimizes your workflow. Consider the weight of the load and the frequency of lifting cycles. While faster speeds can increase productivity, they might not be necessary for all applications.

Additional Considerations:

Safety Features:

 Prioritize safety by ensuring your chosen crane and hoist have essential features like overload protection, limit switches to prevent overtravel, and emergency stop systems. Always adhere to Bureau of Indian Standards (BIS) regulations for crane and hoist operations in India.

Maintenance and After-Sales Service: A reliable after-sales service network is crucial for prompt repairs, maintenance support, and readily available spare parts. Choose a hoist crane manufacturer in India with a well-established service network across the country.

Cost and Budget: 

While cost is a factor, prioritize safety, reliability, and equipment performance over the initial price tag. Look for a balance between affordability and long-term value. Research average crane prices in India for your desired capacity and features to set realistic budget expectations.

User Experience and Training:

Operator comfort and ease of use play a significant role in overall productivity and safety. Look for cranes and hoists with ergonomic controls, clear operator interfaces, and features that minimize operator fatigue.

Invest in comprehensive operator training to ensure proper usage of the equipment, adherence to safety protocols, and identification of potential hazards.
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Safety and precautions

• An overhead crane should never be used without workers who are knowledgeable and well-trained. People can lose their life due to even the smallest of errors.
• To prevent a load moment that can cause the crane to topple over, the loading state of the crane must be taken into account.
• It is necessary to post “hoist danger” signs all around the work area. The employee must not stand or do tasks below the hoist area.
• When operating an overhead crane, employees should observe the appropriate safety precautions and personnel length measures.
• At least once a year, a professional inspection of the load-bearing structure should be carried out, and the results should be supplied for the crane file.
• Steer clear of swinging a crane, grab or hook when an above trolley or hoist is in motion.
• Check the crane for any loose objects that might come off while it’s operating.
• A fire extinguisher that is fully charged must be installed in the crane that has an operator cabin.
• For the best rotation and operation, a crane’s stability is greatly dependent upon the quality and levelness of the ground. The crane’s stability is determined, in part, by the radius to the load gravity, the load weight, and the angle of the boom.

Proper Safety And Maintenance

• Inspections of worn or cracked areas in the wielded area are necessary for safety reasons.
• Before using, it is necessary to inspect the hook roller brackets, welds, locking mechanisms, bearings, pins, shafts, gears, and detachable outrigger attachment.
• Prior to starting, check all of the brakes, including the trolley motor and bridge brakes.
• It is necessary to inspect the main chords and lacings for evidence of flaking or cracking paint.
• You will probably verify the functionality of the bridge and trolley motor brakes as well as the condition of all the below-the-hook devices.
• Verify that all indicators, including the crane’s load and boom angle indications, are properly calibrated.
• It is necessary to verify that the locking devices, motion lever, and brakes respond correctly. Aside from that, the load moment indicator (LMI) or rated capacity indicator (RCI) accuracy needs to be verified.
• There must be routine inspections of the crane. This covers loosened, missing nuts, bolts, or pins as well as worn, cracked, or deformed pieces.
• The hook block requires more attention than usual. It would be beneficial if you checked to make sure the load chain and wire rope are positioned correctly. Adjust those if they are not positioned correctly.
• When the crane is moving, the operator needs to pay close attention.
• Verify that the chain sprockets are functioning properly and that the wire rope is free from kinking, cutting, crushing, unstranding, or heat damage.

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Different Types of Hoists

• Manual Hoists

Manual hoists are hand- or lever-operated lifting devices, sometimes referred to as chain falls. These kinds of hoists rely on a load chain for support and a hand chain to regulate raising and lowering. To raise or lower the products, the operator either pulls on either end of the hand chain or cranks a lever attachment.
Using hand hoists for lifting tasks has many advantages. To begin with, they are less expensive than motorised hoists and are suitable for a variety of lifting applications. In addition, manual hoists work well in non-electric environments.

• Electric Hoists

Chains or wire ropes are used by electric hoists, which run on electricity to raise or lower things. When raising or lowering their goods, the operator simply presses a button as opposed to manually turning a lever or tugging a chain. Whether you select an electric chain hoist, electric wire rope hoist, or electric belt hoist, the uses for these hoists differ.

• Hydraulic Hoists

Hydraulic hoists operate without a motor system, using an oil-based piston mechanism as opposed to conventional lifts. With a smaller motor, the piston enables the hoist to lift much greater loads. Boats are lifted into and out of the water by hydraulic hoists in the majority of shipyards and marinas. Additionally, they are able to load and unload shipping containers into adjacent trucks and storage facilities from ships.

• Piston Hoists

The fluid pressure moves these kinds of hoists in a linear fashion. It moves the force to a second point by applying force to one location in an incompressible liquid. Two pistons linked by an oil-filled hose power the process.

• Gear Hoists

Typically, a gear hoist consists of a set of gears that cooperate to elevate a load: a driving gear and one or more drive gears. These hoists are frequently used in the industrial, material handling, and construction industries because of their superior mechanical performance and ability to precisely raise large weights.

• Rotary Vane Hoists

Vane hoists have a cylindrical housing with internal rotor-mounted vanes or blades. The load can be raised or lowered by the vacuum created by the rotor’s rotation. In industries like material handling, packing, and automation where careful lifting with low damage risks is necessary, rotary vane hoists are frequently utilised.

• Pneumatic Hoists

Compressed air is used by pneumatic hoists to make lifting and hauling easier. These hoists can operate continuously without stopping because they have a 100% duty cycle. Because of this, they are perfect for heavy-duty, high-speed lifting applications where other hoists would probably not last. Air hoists are ideally suited for exceptionally long lifts where an electric motor would overheat due to their special characteristics.

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Cranes and hoists, which were once basic devices used to raise and lower objects, have evolved into more sophisticated devices that streamline processes in the construction, mining, infrastructure, manufacturing, and automotive industries. Heavy loads must be raised or lowered in numerous processes in a wide range of sectors, particularly manufacturing, mining, and construction. Machines like hoists and cranes have considerably reduced the need for human labor, shortened processing time, and increased productivity. Given the many utilities, the hoist crane manufacturers in India are getting into the zone of producing better and safer options.

A crane is a device for lifting objects. To hoist and lower goods as well as move them horizontally, it has a winder (also known as a wire rope drum), wire ropes or chains, and sheaves. It has one or more simple machines to generate the mechanical power needed to move the loads because doing so would be physically impossible for a person. For loading and unloading freight, cranes are frequently utilized in the transportation sector.

Did you know that in Ancient Greece, cranes were first employed in building projects?

The majority of their strength came from workers, men, or other animals. Later, as their use grew, they developed into larger cranes that could lift heavier loads. With the expansion of the shipping sector, harbor cranes were developed for material loading and unloading as well as the construction of large ships. Most of the early cranes were made from wood because it was the material that was most frequently used at the time. Cast iron and steel cranes came much after – during the time of industrial revolution.

Today, electric hoists have revolutionized the safe and efficient transfer of heavy loads, drastically altering the lifting and material handling sector. Thanks to technical advancements that allow for higher capacities, improved precision, and improved safety precautions, the use of lifting has been safer, more efficient, and more trustworthy in recent years.

Like all machinery, cranes abide by the law of conservation of energy. As a result, the energy supplied to the load cannot be greater than the energy supplied to the machine. Chain reactions involving cranes are also possible; if one collapses, other cranes nearby may follow suit. Crane design is mostly based on three factors. First and foremost, it should be able to hoist the weight of the load; second, it must be stable; and third, it must not rupture.

Depending on its intended usage, cranes come in a variety of forms. Included in this group are mobile cranes, truck-mounted cranes, sidelift cranes, all-terrain cranes, crawler cranes, aerial cranes, fixed cranes, tower cranes, hammerhead cranes, overhead cranes, deck cranes, jib cranes, bulk-handling cranes, etc.

Technological advancements

The electric chain hoist integrates a number of mechanical and technological developments that are tailored to the changing ergonomic requirements of our environment and deliver benefits to both our workers and overall profitability. The most recent advancements in chain hoist technology successfully address possible risks to productivity and safety, such as shock loading, overloads, twisted chain links, chain wear, and ergonomic difficulties. In recent years, the following intelligent features have been introduced such as:

• Compact Design and Portability
• Remote Control and Wireless Technology
• Improved Chain and Pocket Wheel Designs
• Drive Technology
• Slack Chain Detection
• Anti-Sway Technology
• Load Monitoring Systems
• Digital Interfaces and Human-Machine Interaction

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There are two major sub-divisions of hoists –

Manual and Powered hoists

Ratchet (lever-actuated) or hand chain operated lifting apparatuses, often known as manual hoists or chain falls, are also known as chain falls. The hand chain, which controls the rising and lowering motion, and the load chain, which supports the load, are the two chains that make up a manual lifting hoist.
One of the many forms of lifting equipment available are powered hoists, which come in three varieties: electric, air/pneumatic, and hydraulic.
The hoist crane manufacturers in India can help yu select the right one depending on the requirement.

What you need to look for in a hoist

Lift Capacity

The weight that the hoist can lift is referred to as its lift capability. This is based on the line material’s tolerance, usage patterns, power sources, and the structure the hoist is suspended from. Choose a hoist whose lifting capacity exceeds the weight of your biggest load.

Line Material

The medium through which a force will be applied to lift an object is the line material. Chain and wire rope or cable are the most often used line materials. Rope and straps or webbing can be utilised for smaller, lighter loads.

Power Source

The energy from the power source is what ultimately drives the gears that raise or lower the line material. Hand chains or levers are used to operate the most basic chain hoists. The majority of large weight hoists are electrically operated. The combustion of fuel, such as petrol and diesel, can power portable hoists. Hoists with air or hydraulic power are frequently employed in settings where electrical unit sparking is a concern.

Suspension Type

Simple hoist types can be hooked or bolted onto stationary fixtures or moveable supports to be suspended or put in fixed places. Other variants include hardware that enables them to be connected to overhead trolleys; these hoists can move along a rail by being pulled or pushed, or they can use independent motors.

Lift Height

The lift measures the distance between the load hook’s highest and lowest positions. The term “reach” refers to the result of adding headroom and lift.

Lift Speed

The rate at which a weight can be lifted is known as lift speed. Various or variable speeds are available in some models. The weight and height of the load may have an impact on lift speed. Hoists with a higher capacity typically have slower lifting rates. Some models offer flexibility when working with a variety of loads thanks to their multiple speeds.

Headroom

The distance between the rail or tread that the hoist is mounted on and the hook that is fastened to the load is known as the headroom of a hoist. Similar to mobile models, this can be calculated as the separation between the mounting point for the hoist and the lifting hook.

Applications and Industries

Hoists are utilised whenever a load has to be lifted and moved; they are not only used in industrial settings. Hoists are used for a variety of tasks, such as lifting goods, building supplies, machinery and stock in warehouses.

Hoists are employed in, but are not limited to, the following sectors:

• Automotive,
• Logging,
• Marine Manufacturing,
• Aerospace
• Mining

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What is an overhead crane?

A crane is a sophisticated device used to raise, lower, and transfer large or heavy items. Cranes come with accessories that enable them multidirectional mobility. The hoist, trolley, and bridge actions work together to completely cover your production floor.

What is a Hoist?

A hoist is a device that excels at carrying out a specific task: raising and lowering a load on a vertical axis. Hoists are positioned atop the crane’s main horizontal beam, also known as the bridge girder. When the trolley is attached to the hoist, the hoist can move back and forth across the bridge girder. Wire rope hoists are the best option for loads of 5 tonnes or more, while chain hoists are good for lifting loads below 5 tonnes with little maintenance required. A single rope is used on the rope drum in single-reeved hoists, while two ropes are used on a single drum in double-reeved hoists to achieve real vertical lift. On a single-reeved hoist, minimal hook drift, or lateral movement of the hook, is possible with greater diameter rope drums.

What is a Trolley?

The crane’s trolley is the device used to move the hoist along the bridge girder. To position the hoist above a load, it is moved horizontally along the top or bottom of the bridge girder. Low headroom, regular headroom, and double girder trolleys are the three different categories of trolleys.

What is a bridge?

End trucks are used by cranes to move the bridge along the runway rail, including the hoist, trolley, and girder beams. The third leg of the crane’s multi-directional mobility is added by the bridge motion, which provides complete hook coverage over the width of your building.

Crane electrification: How does a crane run?

The wiring and support system known as a festoon is what powers a trolley and hoist across the bridge. The primary bridge panel, which powers all of the crane’s electronics, receives electricity from the runway busbar. The hoist panel and the bridge drives, which power the hoist, trolley, and bridge drive, are then reached by festoon cables. Most operators use a pendant or radio to control the crane’s movement for best productivity and safety.

How do you choose the right crane components? 

The equipment you choose should be compatible with your particular building architecture, from the overall crane package down to the individual components. Understanding the measurement systems used to create specific crane parts can help you make the most of the custom features and options available.

Span :

The breadth of the complete crane is determined by the distance between the centers of the runway beams.

Trolley Gauge :

The distance between the centers of one trolley rail and the other trolley rail in a double girder crane is known as the trolley gauge dimension.

Headroom :

When the hook is lifted to its highest point, the space between the saddle of the hook and the bottom of the trolley wheels is measured. When there is a limited lifting distance, low headroom hoists like the SX low headroom hoist offer the highest level of space efficiency. The C dimension is another name for the headroom.

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Let us assume that a boiler is being hoisted using a steel gantry that has been raised to its highest setting. A steam boiler from LGH with dimensions of 6.5’W x 12’L x 13’H and a shipping weight of 12,400 lbs will be lifted using a steel gantry with a maximum height beneath the beam of 15’10”. In this case, assuming a perfectly balanced centre of gravity, you may get away with using two 5-ton steel setup gantries to accommodate the length (CG). This indicates that we have just under three feet (34 inches) of vacant space above the unit for our rigging to fit within, based on the maximum height given above. It seems like a lot, yes? Starting from the beam down, let’s examine some of the choices for this lift’s headroom needs.

Beam Clamps

We can split the shipment weight in half to equal 6,200 lbs. and suppose that is the weight visible on each gantry given the weight and the same CG. A 2-ton clamp is adequate since, after dividing that by the two clamps needed, each clamp must be able to support 3,100 lbs. This would require a Riley 2-ton Superclamp model S1A with a 4,480 lb weight rating, taking up around 10 inches of headroom. There are now exactly two feet of headroom over your boiler.

Hand Chain Hoist

The most likely option, using the same numbers as previously and requiring your hoist to lift only 3,100 lbs, would be your 2-ton Coffing hand chain hoist, which requires an additional 15 inches of headroom. You now have 9 inches of headroom or 9 inches of lift available above the boiler. Keep in mind that this is one of the more labor-intensive solutions because it requires people to pull the chain.

Electric Chain Hoist

Although it is expensive, an electric chain hoist will significantly reduce labour and time requirements. With the clamp in place and 22.6″ of headroom needed to operate a 2-ton Harrington SNER020L hoist, there is only 1.5″ of free space above the boiler unit.

Air Chain Hoist

The air hoist’s convenience comes at the sacrifice of headroom, much like the electric hoist does. While the 2-ton JDN Profi (NS) Series 2TI model leaves a little more room, it consumes 19.6″ of headroom, leaving you with only 4.4″ of available headroom/lift for the boiler.

Low-Headroom or Ultra-low Headroom Trolley Hoists

If you need to lift the boiler more than 9 inches and precision is important, this solution can be appealing. However, it would be wise to install end stops to the beam to ensure safety. To prevent unintentional trolley movement, your beam should always be square and level. The needed headroom is reduced by the trolley’s integration into the hoist unit to 16.5″ for the low headroom type or 6.5″ for the ultra-low hoist. There is still a sizable 17.5″ or 27.5″ of headroom available. But there is a catch with these hoists. In addition to the trolley’s potential for unintended movement, the low headroom hoist weighs 107 pounds whereas the ultra-low hoist weighs 395 pounds when fully chained up, which may influence the decision.

After examining the alternatives, it is evident that the hand-chain hoist offers the highest level of portability while yet leaving enough room. The greatest possibilities for remaining headroom/lift space are those where the gantry stays absolutely plumb and level during the lift and when the weight of the trolley hoists is minimal. 

As you can see, the amount of headroom needed on any lift plan can pile up quite rapidly. To make sure you have enough room before starting a lift, it is crucial to understand how to determine your headroom.

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Examining the direction in which the weight must move can help to differentiate between the two. A hand chain hoist is an excellent choice for vertical and angular lifting, but they are not appropriate for pulling in a horizontal direction. Lever hoists have the potential to function both vertically and horizontally with no difference in setup or capacity; in this case, come-alongs and Griphoists are especially mentioned as manual options with greater degrees of precision.

Consider replacing a load in a space where there is little any headroom to accommodate a clamp/trolley, hoist, or skates in the final position. What do you do when the final placement must be made exactly where the old unit was and the location forbids anchoring a winch into the ground? This is a fantastic opportunity to use a lever hoist.

First, let’s briefly go over the distinction between a come-along and a griphoist before we get started. Most frequently, people’s first thought when considering a lever hoist is a chain come-along. Come-alongs work by rotating a gear with the help of a ratchet and pawl, which pulls the chain in a straight line. Come-a-longs carry loads with greater precision than a standard manual chain hoist even if they move slowly. Come-a-longs also enable the movement of weights weighing up to 18,000 pounds with less than 80 pounds of power applied to the lever.

It’s crucial to never utilise cheater bars or other improper techniques with a chain come-along because the levers are designed for maximum safety. 

Instead, Griphoists, also known as Tirfors, work with wire rope that has been carefully engineered to allow two grip-jaws inside the device to clamp down on the wire rope while alternately activating each jaw, much like a hand-over-hand pulling technique. The length of rope in your fleet or purchased from your local distributor is the only restriction on the amount of pull possible with a griphoist. However, you must be sure that the wire rope you are using is intended for use in a griphoist. An engineer should first evaluate the practicality of any anchoring places where the lever hoist can be mounted as a base in order to comply with the bolt-down requirement. It’s time to set up your hoist and start the move, provided there is a safe column or structure with a clear line of sight. The first step is to calculate the necessary force using the load’s weight and the coefficient of friction.

Without enlisting sheave blocks, which would improve the capacity by leveraging mechanical advantages, griphoists are only available in capacities up to 4 tonnes, while come-alongs are available in capacities up to 9 tonnes. You can choose between the two options knowing the precise force needed and what will work best for you. A lever hoist can be used to manage a situation like this that would have been impossible or much more difficult to perform otherwise.

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